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Thank You

for selecting a 

QUALITY

product by Lincoln Electric. We want you

to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely

before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information 

must

be followed 

exactly

to avoid 

serious personal injury

or 

loss of life

.

This statement appears where the 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 to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________

Model  Number ___________________________________________________________________________

Code  Number or Date Code_________________________________________________________________

Serial  Number____________________________________________________________________________

Date  Purchased___________________________________________________________________________

Where  Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing:  Complete the form on the back of the warranty statement included in the literature packet

accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration:  Go to our 

WEB SITE at www.lincolnelectric.com. 

Choose “Support” and then “Register

Your Product”. Please complete the form and submit your registration.

Содержание POWER MIG 256

Страница 1: ...TE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful For use with machine Code Numbers 11780 11781 For use with machine Code Numbers Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelect...

Страница 2: ...AKER 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 av...

Страница 3: ...or 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 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produce fu...

Страница 4: ...s 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 site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not welding make certain no part of the electrode ...

Страница 5: ...riés et non inflammables 4 Des gouttes de laitier en fusion sont émises de lʼarc de soudage Se protéger avec des vêtements de protection libres de lʼhuile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier 6 Elo...

Страница 6: ...y important when identifying the correct replacement parts CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use...

Страница 7: ... 3 Procedure for Changing Drive Roll B 3 Wire Reel Loading B 4 Mounting of 10 to 44 lb Spools B 4 To Start the Welder B 4 Feeding Electrode B 5 Idle Roll Pressure Setting B 5 Wire Drive Configuration B 6 Making a Weld B 7 Avoiding Wire Feeding Problems B 7 Fan Control B 7 Input Line Voltage Protection B 7 Wire Feed Overload Protection B 7 Welding Thermal Overload Protection B 8 Overcurrent Protect...

Страница 8: ...g Instructions for Magnum PRO 250L D 2 Gun Handle Disassembly D 3 ________________________________________________________________________ Troubleshooting Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 thru E 4 ________________________________________________________________________ Wiring Diagram and Dimension Print Section F _____________________________________________...

Страница 9: ...700 IPM 1 27 17 8 m minute WIRE SPEED RANGE Standard Voltage Phase Frequency Input Current 200 Amp Rated Output Input Current 250 Amp Rated Output 208 230 1 60 Hz 47 44 Amps 56 52 Amps 230 460 575 1 60 Hz 41 20 16 Amps 47 24 19 Amps Duty Cycle Amps Volts at Rated Amperes 40 250 Amps 26 Volts 60 200 Amps 28 Volts 100 145 Amps 26 Volts Welding Current Range Continuous Maximum Open Circuit Voltage We...

Страница 10: ... THE POWER MIG 256 Cut banding 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 the Gas Bottle Platform holding the machine to the skid Roll the machine off the skid assembly LOCATION Locate the welder in a dry location where there is free circulation of c...

Страница 11: ...ity for GMAW If negative polarity is required interchange the connection of the two cables located in the wire drive compartment near the front panel The electrode cable which is attached to the wire drive is to be con nected to the negative labeled terminal and the work lead which is attached to the work clamp is to be connected to the positive labeled terminal GUN AND CABLE INSTALLATION The Magn...

Страница 12: ...ighten the union nuts securely with a wrench 6 Before opening the cylinder valve turn the regulator adjusting knob counterclockwise until the adjusting spring pressure is released A 4 A 4 INSTALLATION 7 Standing to one side open the cylinder valve slowly a fraction of a turn When the cylinder pressure gauge pointer stops moving open the valve fully Never stand directly in front of or behind the fl...

Страница 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 explosion Keep flammable material away Do not weld on closed contain ers ARC RAYS can burn eyes and skin Wear eye ear and body protec tion Observe all safety information throughout this manual WARNING...

Страница 14: ...WELDING CAPABILITY The POWER MIG 256 is rated at 250 amps 26 volts at a 40 duty cycle based on a ten minute cycle time It is capable of higher duty cycles at lower output currents and capable of up to 300 Amps at lower duty cycles LIMITATIONS POWER MIG 256 WILL NOT operate satisfactorily if powered with a portable or in plant generating system DESCRIPTION OF CONTROLS See Figure B 1 1 Power ON OFF ...

Страница 15: ... Drive roll size is stenciled on each side of the drive roll If feeding problems occur check to make sure that the wire size and the drive roll size matches See Procedure for Changing Drive Roll in this section This information also appears on the Procedure Decal on the door inside the wire compartment WIRE SIZE CONVERSION PARTS The POWER MIG 256 is rated to feed 025 through 045 0 6 1 1 mm solid o...

Страница 16: ...OT THE WELDING ELECTRODE 10 To remove Readi Reel from Adapter depress retaining spring tab with thumb while pulling the Readi Reel cage from the molded adapter with both hands Do not remove adapter from spindle CAUTION 2 IN O D SPINDLE ADAPTER RETAINING SPRING BRAKE HOLDING PIN GROOVES READI REEL INSIDE CAGE WIRES RELEASE BAR RETAINING COLLAR To Mount 10 to 44 Lb 4 5 20 kg Spools 12 300 mm Diamete...

Страница 17: ... the first six inches If the electrode is not properly straightened it may not feed properly through the wire drive system 3 Release the pressure on the idle roll by swinging the adjustable pressure arm down toward the back of the machine Lift the cast idle roll assembly and allow it to sit in an upright position Leave the outer wire guide plate installed Manually feed the wire through the incomin...

Страница 18: ...2 Remove the welding wire from the wire drive 3 Remove the thumb screw from the wire drive 4 Remove the welding gun from the wire drive Figure B 5 POWER MIG 256 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 screw 6 Remove the outer wire guide and push the gun bushing out of the wire drive Be...

Страница 19: ...11 When no more welding is to be done close valve on gas cylinder if used momentarily operate gun trig ger to release gas pressure and turn off POWER MIG 256 AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing the following gun handling procedures Do not kink or pull cable around sharp corners Keep the gun cable as straight as possible when weld ing or loading electrod...

Страница 20: ...tats automatically reset when the temperature reaches a safe operating level and welding and feeding are allowed again when gun is retriggered OVERCURRENT PROTECTION The machine will automatically reduce the output if the load on the machine exceeds 300 to 320 amperes This protects the welding power SCRʼs from excessive short circuit currents and from exceeding their temperature rating before the ...

Страница 21: ...y is separately available for use with the POWER MIG 256 Each is rated 200 amps 60 duty cycle or 250 amps 40 duty 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 1 Optional liners for different wire diameters are sold separately see table D 1 Maintenance Section MAGNUM ...

Страница 22: ...yed value due to tension setting liner condition or gun variation CONNECTING THE SPOOL GUN TO THE POWER MIG 256 See Figure C 1 1 Connect the Spool Gun control cable to the mating 7 pin receptacle in the Power MIG wire drive compartment K487 25 Magnum SG Spool Gun requires K2445 1 cable 7 pin to 6 pin adapter 2 Connect the Spool Gun electrode lead to the positive stud with the Spool Gun electrode l...

Страница 23: ...electrically HOT Be sure unused gun is positioned so electrode or tip will not contact metal case or other metal common to work 1 Pulling the trigger for the built in feeder gun Disables spool gun operation Closing feeder gun trigger starts feeder gun welding and makes both electrodes electrically HOT 2 Pulling SPOOL GUN Trigger Disables built in feeder gun operation Closing spool gun trigger star...

Страница 24: ...ne and feed prob lems are experienced try liner replacement and refer to trouble 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 equipment Do not touch electrically hot parts GENERAL MAINTENANCE In extremely dusty locations dirt may clog the air pas sa...

Страница 25: ...n meet the liner cutoff length requirement Liners are shipped with the jacket of the liner extended the proper amount 1 Remove the gas nozzle and nozzle insulator if used to locate the set screw in the gas diffuser which is used to hold the old liner in place 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 f...

Страница 26: ...e turn the collars approxi mately 60 degrees counterclockwise the same direction as removing a right hand thread until the collar reaches a stop Then pull the collar off the gun handle If the collars are difficult to turn position the gun handle against a corner place a screwdriver against the tab on the col lar and give the screwdriver a sharp blow to turn the collar past an internal locking rib ...

Страница 27: ...s the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Ser...

Страница 28: ...ed with built in feeder 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 assembly is removed from machine then the problem is within the POWER MIG 256 1 Check input voltage Make sure input voltage matches name plate rating and reconnect panel configuration 2 Make sure settings ...

Страница 29: ...sion 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 7 Check wire spindle for ease of rotation and adjust break ten sion knob if necessary 8 Check that the gun is pushed all the way into gun mount and properly seated RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have b...

Страница 30: ...ly 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 Check or replace 4 If gas solenoid does not operate when gun trigger is pulled the problem is within the POWER MIG 256 5 Make sure the gun is pushed all the way into gun mount and is properly seated ...

Страница 31: ...ECT PANEL G 207 LINE SWITCH S1 H4 TO SINGLE PHASE SUPPLY LINE X9 X5 X5 X6 X6 X7 X7 X1 X9 X8 TO WORK G2 352 353 FAN MOTOR TO WORK J3 TO WORK 207 325B OUTPUT CHOKE THERMOSTAT 320 B R U J11 CONTROL BOARD 2 1 5 8 4 1 8 1 9 16 1 3 4 6 8 1 14 7 1 12 7 6 10 6 5 1 CAVITY 1 NON LEAD SIDE OF CONNECTOR 2 3 4 NUMBERING SEQUENCE J11 1 2 3 8 7 6 5 4 W B B R U W B J12 J12 311 GAS SOLENOID 3 392 4 CIRCUIT BREAKER...

Страница 32: ...6 X5 515 206B B 2 3 4 7 8 9 10 3 5 206 205 320 8 6 14 15 16 6 5 W 206S 207 353 X8 325B X9 352 4 10 12 13 7 12 354 G2 204 G1 X7 390 325 555 1 J2 6 7 8 9 J1 10 1 515B 324 208 12 13 1 J3 253 251 552 551 256 209 GND 352 353 515B 555 206B G2 X2 D1 209 X8 D2 BAFFLE MOUNTED RECTIFIER DIODE BRIDGE 208 204 X3 X4 207 X9 X5 X5 X6 X6 X7 X7 X1 X9 X8 TO WORK G2 352 353 FAN MOTOR TO WORK J3 TO WORK 207 ARC VOLTA...

Страница 33: ...F 3 F 3 DIMENSION PRINT M19231 1 A 02 19 15 39 92 12 00 38 58 32 56 29 73 30 43 20 12 POWER MIG 256 ...

Страница 34: ...NOTES ...

Страница 35: ... 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 de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrod...

Страница 36: ... gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öffnen Maschine anhalten Não opere co...

Страница 37: ...s 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 Products ...

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