EASY MIG 180 - Welding machine LINCOLN ELECTRIC - Free user manual and instructions

USER MANUAL EASY MIG 180 LINCOLN ELECTRIC

Operator’s Manual WIRE FEEDER WELDER (125, 140, 180 MODELS) Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator IMT891-D | Issue D ate Jun-11 © Lincoln Global, Inc. All Rights Reserved.For use with machines having Code Numbers: 11173 thru 11506, 11550, 11658 Save for future reference Date PurchasedCode: (ex: 10859)Serial: (ex: U1060512345)THANK YOU FOR SELECTING

A QUALITY PRODUCT BY

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.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful. 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. KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data Sheet (SDS) and the warning label that appears on all containers of welding materials. USE ENOUGH VENTILATION or exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and 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 de velop 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 helmet properly fitted and with proper grade of filter plate (See ANSI Z49.1). PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots. PROTECT others from splatter, flash, and glare with protective screens or barriers. IN SOME AREAS, protection from noise may be appropriate. BE SURE protective equipment is in good condition. Also, wear safety glasses in work area AT ALL TIMES. SPECIAL SITUATIONS DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous. DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken. They can release highly toxic fumes or gases. Additional precautionary measures PROTECT compressed gas cylinders from excessive heat, mechanical shocks, 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 Safety 01 of 04 - 5/16/2018SECTION A: WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaust

exposes you to chemicals known to the State of California to cause cancer and birth defects, or other reproductive harm.

• Always start and operate the engine in a well-ventilated area.

• If in an exposed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system.

• Do not idle the engine except as necessary. For more information go to www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or

cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm

YOURSELF AND OTHERS FROM POSSIBLE SERIOUS

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,

EQUIPMENT. 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-ventilated areas or vent the engineexhaust fumes outdoors. 1.c. Do not add the fuel near an open flame weldingarc or when the engine is running. Stop theengine and allow it to cool before refueling toprevent spilled fuel from vaporizing on contactwith hot engine parts and 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 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 orrepairing equipment. 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 AND

BE DANGEROUS 2.a. Electric current flowing through any conductorcauses 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 physicianbefore welding. 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. SAFETY Safety 02 of 04 - 5/16/2018ELECTRIC SHOCK CAN KILL. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or 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 area of 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:

• AC Welder with Reduced Voltage Control. 3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”. 3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be 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 and welding machine in good, safe operating condition. Replace damaged insulation. 3.g. Never dip the electrode in water for 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 It ems 6.c. and 8. ARC RAYS CAN BURN. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to 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.

CAN BE DANGEROUS. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes 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 hardfacing (see instructions on container or SDS) 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 unless exposure assessments indicate otherwise. In confined spaces or in some circumstances, outdoors, a respirator may also be required. Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by

various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits. 5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products. 5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe. 5.e. Read and understand the manufacturer’s instructions for this equipment and the consumables to be used, including the Safety Data Sheet (SDS) and follow your employer’s safety practices. SDS forms are available from your welding distributor or from the manufacturer. 5.f. Also see item 1.b. SAFETY Safety 03 of 04 - 5/16/2018WELDING AND CUTTING

FIRE OR EXPLOSION. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the 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. 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 circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. 6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above). 6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode. 6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area. 6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through 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 MAY EXPLODE IF

DAMAGED. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition. 7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support. 7.c. Cylinders should be located:

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

13.7 in 10.15 in 17.9 in 64 Ibs

If connected to a circuit protected by fuses use Time Delay Fuse marked “D”. :=B;6A@ !#('J&!#&"!,

13.7 in 10.15 in 17.9 in 54 Ibs

If connected to a circuit protected by fuses use Time Delay Fuse marked “D”. "#%'"%O&N !(!&''"!

13.7 in 10.15 in 17.9 in 48 Ibs

If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.

Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air passages and cause overheating.

WIRE FEEDER WELDER(125, 140, 180 MODELS) cannot be stacked.

Each machine must be placed on a secure, level sur- face, directly or on recommended cart. The machine may topple over if this procedure is not followed. %2.1 2;A6?2 6;@A.99.A6<; @20A6<; /23<?2 @A.?A6;4 6;@A.99.A6<;

%2>B6?2:2;A@<? .E6:B:"BA=BA 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.A-3 INSTALLATION WIRE FEEDER WELDERS (125, 140, 180 MODELS) A-3 INCLuDED COMPONENTS

• Black Flux-cored Gasless GunNozzle (Installed on Welding Gun)

These small portable wire feed welders are capable of MIG welding on steel, stainless steel, and aluminum. They are also capable of flux-cored welding on mild steel. MIG welding stands for Metal Inert Gas welding and requires a separate bottle of shielding gas to protect the weld until it cools. Appropriate shielding gas based on the type of material you are welding can be purchased separately from your local welding gas dis- tributor. MIG welding is ideal for welding on thinner and clean materials when a very clean excellent cos- metic looking weld is required. An example would be automotive body panels. Self Sheilding Flux-cored Welding does not require separate shielding gas to protect the weld since the welding wire has special additives known as flux to protect the weld until it cools. Flux-cored welding is ideal for medium to thicker material and if welding on painted or rusty steel. Flux-cored welding is also ideal 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 welding 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 can be purchased separately. This machine can weld aluminum using .035 diameter 4043 aluminum welding wire. Since aluminum weld- ing wire is soft an optional aluminum spool gun is rec- ommended for best results. A welding Procedure Decal is located inside machine door to help provide suggested settings for welding. %2.1 2;A6?2 <=2?.A6<; @20A6<; /23<?2 <=2?.A6;4A52

"!'%"&!&''!& '56@:.056;25.@A523<99<D6;40<;A?<9@&2264B?2#"*%&*' – Turns power on and off to themachine.% )"' "!'%" J This knob sets theoutput voltage of the machine. Along with wire feedspeed (WFS) this control sets a weld procedure.Refer to the procedure decal on the inside wiredrive compartment door to set a correct weldingprocedure based on type of material and thicknessbeing welded.*%&#"!'%"*&JThe knobsets the speed that the machine feeds wire. Alongwith arc voltage this control sets a weld procedure.Refer to the procedure decal on the inside wiredrive compartment door to set a correct weldingprocedure based on type of material and thicknessbeing welded.&2264B?2(! '%% J Depress the trigger to activatesthe wire drive to feed wire and energizes the outputof the machine. Depress the trigger to weld andrelease the trigger to stop welding.*! (! J Delivers wire and welding cur-rent to the weld.a. Gun Liner – wire travels through the liner fromthe wire drive. The gun liner will feed .025 to .035wire. The 180A machine can weld with .045 wireif an optional .045 liner is installed in the gun.b. Contact Tip – provides electrical contact to thewire.c. Nozzle – When flux-cored welding the black noz-zle protects the mounting threads on the gun.When MIG welding the brass nozzle funnels theshielding gas to the weld. *"% # J Clamps to the workpiece being welded and completes the electricalwelding circuit.(! '%% "!!'"% %#' JPlug the 4 pin gun trigger connector into this recep-tacle.

See Figure B.3 *! (! "!!'"% (&! '( &%*J Provides electrical power to the welding gun. The thumbscrew holds the welding gun into the connector block. (Front of Machine, Side Door and Wire Drive Cover have been removed for clarity of Items 8 and 9). "('#(' '% !& JThese connections allow to change the welding polarity of the machine depending on whether you are MIG welding or flux- cored welding. See Figure B.4 *%&#""&#!!%JHolds a 4 inch diameter spool. Use the 2 inch spindle adapter included with the machine to use 8 inch diameter spools. The thumbscrew sets the brake friction to prevent the spool from over rotating when the trigger is released. See Figure B.5 *% %) " #"!!'& J Feeds wire from the wire spool through the drive and through the welding gun to the weld. .?6C2 %<99 J Drives the wire through the drive system. The drive roll has a groove to match the specific wire type and diameter. Refer to Table B.1 for available drive rolls. /6;2?"BA4<6;4B612J The liner guides the wire between the bearing on the Pivot Arm Assembly and Drive Roll and through the outgo- ing guide. 0?6C2 %<99 '2;@6<; '5B:/@0?2D J Turning clockwise increases the force on the drive roll and turning counterclockwise decreases the force.

*6?26.:2A2? 'F=2 .025 MIG wire .030 MIG wire .035 MIG wire .030 flux-cored .035 flux-cored .045 flux-cored ?6C2%<99 .025/.030 Smooth Drive Roll .035 Smooth Drive Roll .030/.045 Knurled Drive Roll .030/.045 Knurled Drive Roll ?6C2%<99#.?A !B:/2? KP2529-1 KP2529-2 KP2529-3 KP2529-3 See Figure B.6 %('%%J If the rated input current of the machine is exceeded this circuit breaker will trip. Press to reset. &!'JShielding gas connects to this inlet (This is optional on 125 Amp Unit.)

2. Slide the connector end of the gun and cable

through the hole in the machine front and into the gun connector bushing on the wire drive.

3. Make sure the gun connector end is seated fully

into the wire drive and tighten the molded hand screw to secure the gun connector.

4. Plug the gun trigger lead connector into the 4 pin

gun trigger receptacle on the machine front.

5. Wire Drive Polarity. Flux cored welding requires

negative (-) polarity. Connect the short power cable from the wire drive to the negative (-) output terminal and tighten threaded knob.

6. Work Lead Connection. Slide the lugged end of

the work cable through the hole in the machine front and place on the positive (+) output terminal and tighten threaded knob.

1. Locate the blue labeled 4" diameter spool of .035

NR-211MP flux-cored wire and place onto wire spool spindle. Orient the spool so that the wire feeds off the top of the spool.

2. Secure spool in place by tightening the wing nut

against the against the spacer that holds the wire spool on the spindle.

3. Open the pivot arm assembly by rotating the ten-

sion arm assembly down and lift pivot arm assem- bly up.

4. Remove drive roll

by turning the twist lock that holds the drive roll on. Install the .030/.045 knurled drive roll.

5. Carefully unwind and straighten the first six inches of

welding wire from the spool. Do not let the end of the wire go to prevent the wire from unspooling. WORK CLAMP (4 PIN)TRIGGER RECEPTACLEPLUGGED INCONNECTOREND ATTACHALL COMPONENTS SHOWN CONNECTED(FRONT AND SIDE DOOR IS REMOVED FOR CLARITY) SHORT POWER

6. Feed the wire through the inlet liner, over the

drive roll groove, thru the outgoing guide and wire drive outlet on the gun side.

7. Close the Pivot Arm Assembly and secure by piv-

oting the Tension Arm Assembly back to the up position. (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 trigger to feed the wire through the gun liner until the wire comes out of the threaded end of the gun several inches. (See figure B.11)

10. When trigger is released spool of wire should not

unwind. Adjust wire spool brake accordingly. ")! #%'& ! '% "!''!(&!(%,"%

12. Install the black flux cored welding nozzle to the

13. Trim the wire stickout to 3/8” from the contact tip.

Close the case side door. The machine is now ready to weld.

15. Read "Learn to Weld" (LTW1) that is included

with the machine or watch the "How to Weld" DVD included with the machine.

16. Based on the thickness of the material you are

going to weld and the type and diameter of the welding wire set the voltage and the wire feed speed per the procedure decal attached to the inside of the wire drive compartment door. .035"(0.9mm) NR-211-MP WIRE SPOOL REMOVED NOZZLE REMOVED CONT ACT TIP

LAY CABLE AND GUN STRAIGHTEN

TRIM WIRE STICKOUT 3/8"(9.5mm) from the Contact Tip

8. Gas Regulator & Gas Line

shielding gas (or 100%

regulator adapter which is sold separately.

• 125 Amp Units can be upgraded for MIG welding using KIT K2526-1 (See Accessory Section).

MIG welding requires an appropriate bottle of shielding gas. For mild steel either a cylinder bottle of Ar/CO

3. Attach the flow regulator to the cylinder valve and

tighten the union nut securely with a wrench. !"' If connecting to 100%

regulator adapter is required. Purchase separately S19298

adapter be sure to install plastic washer included in the fitting on the bottle side.(See Figure B.13 )

4. Refer to Figure B.13. Attach one end of inlet gas hose

to the outlet fitting of the flow regulator and tighten the union nut securely with a wrench. Connect the 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.

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 earth ground. Refer to Figure B.13.

2. With the cylinder securely installed, remove the

cylinder cap. Stand to one side away from the out- let and open the cylinder valve very slightly for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet. &(% '" # ,"(% *, %" ' )) "('' *! K%!L ' ))!2C2? @A.;116?20A9F 6;3?<;A <3<? /256;1 A52 39<D ?24B9.A<? D52; <=2;6;4 A52 0F96;12? C.9C29D.F@@A.;1A<<;2@612

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

2. Set gas flow rate for 30 to 40 cubic feet per hour (14

to 18 I/min.) under normal conditions, increase to as high as 40 to 50 CFH (18 to 23.5 I/min.) under drafty (slightly windy) conditions.

3. Keep the cylinder valve closed, except when using

the machine. "#%'"%O&N !(b-9 OPERATION b-9 WIRE FEEDER WELDERS (125, 140, 180 MODELS) 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 hole of the machine front and into the gun connector bushing on the wire drive.

3. Make sure the gun connector end is seated fully

into the wire drive and tighten the thumbscrew to secure the gun.

4. Plug the gun trigger lead connector into the 4 pin

gun trigger receptacle on the machine front.

5. Wire Drive Polarity. MIG welding requires Positive

(+) polarity. Connect the short power cable from the wire drive to the positive (+) output terminal and tighten the thumbscrew.

6. Work Lead Connection. Slide the lugged end of the

work cable through the hole in the machine front and place on the negative (-) output terminal and tighten thumbscrew.

1. Locate the green labeled 4" diameter spool of .025

L-56 solid MIG wire and place onto wire spool spin- dle. Orient the spool so that the wire feeds off the top of the spool.

2. Secure spool in place by tightening the wing nut

against the against the spacer that holds the wire spool on the spindle.

3. Open the pivot arm assembly by rotating the ten-

sion arm assembly down and lift pivot arm assem- bly up.

4. Remove drive roll

by turning the twist lock that holds the drive roll on. Install the .025-.035 smooth grooved drive roll.

5. Carefully unwind and straighten the first six inches

of welding wire from the spool. Do not let the end of the wire go to prevent the wire from unspooling.

(FITS ON STUD INSIDE

6. Feed the wire through the inlet liner, over the drive

roll groove, thru the outgoing guide and wire drive outlet on the gun side.

7. Close the Pivot Arm Assembly and secure by piv-

oting the Tension Arm Assembly back to the up position. (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 to on and depress the

gun trigger to feed the wire through the gun liner until the wire comes out of the threaded end of the gun several inches. (See Figure B.18)

10. When trigger is released spool of wire should not

unwind. Adjust wire spool brake accordingly. ")! #%'& ! '% "!''!(&!(%,"%

12. Install the brass gas MIG welding nozzle to the

13. Trim the wire stickout to 3/8 from the nozzle end.

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

15. Read "Learn to Weld" (LTW1) that is included with

the machine or watch the "How to Weld" DVD included with the machine.

16. Based on the thickness of the material you are

going to weld and the type and diameter of the welding wire set the voltage and the wire feed speed per the procedure decal attached to the inside of the wire drive compartment door. TENSION ARM ASSEMBLYLOCKED IN UP POSITIONPIVOT ARM ASSEMBLYWITH BEARING PRESSINGAGAINST DRIVE ROLLDIRECTIONOF WIREDRIVE ROLLLINEROUTGOING GUIDEBEARINGSLIDE WIRE INTO GUN CONNECTOR SIDE WIRE SPOOL.025" (0.6mm)

WIRE SPOOL .025" (0.6mm)

WIRE SPOOL .025" (0.6mm)

1. Follow the MIG welding steps in the previous sec-

2. Connect a bottle of 100% Argon shielding Gas per

per instructions included with gun.

6. Turn machine on and make weld per recommended

settings on Procedure Decal inside machine door. WIRE FEEDER WELDERS (125, 140, 180 MODELS) SETTING uP AND MAKING A ALuMINuM WELD uSING SPOOL GuN WARNING

&=<A'6:2?6A Timer kit, when turned on, allows you to set a fixed weld time so that when the gun trigger is pulled the machine will weld for a fixed time period up to 10 sec- onds. Ideal for making consistent spot welds when welding on thin sheet metal ;;2?@562916A<?):<129@ Includes everything needed to weld with .045 diame- ter Innershield wire. Includes an .035/.045 Magnum™ 100L gun liner, .045 Contact Tip, gasless nozzle, knurled drive roll, .035-.045 inner wire guide, and a 10 lb. (4.5kg) spool of .045"(0.9mm) Innershield® NR®-212 wire. .4;B:&&=<<9B; Designed to easily feed small 4" diameter (1lb. spools of) .030 or .035 aluminum wire. Includes gun, adapter kit, three extra .035 contact tips, gas nozzle, and spool of Superglaze 4043 .035" diameter welding wire. Packaged in a convenient carry case. &:.99.;C.@<C2? Protect your machine 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 welding gun. For additional Optional and Miscellaneous Parts (See Parts Pages) "#%'"%O&N !(C-2 ACCESSORIES C-2 WIRE FEEDER WELDERS (125, 140, 180 MODELS) 3-3/4"

16" 3-11/16" 8-1/16" 3-13/32" 9/32" DRILL 3 PLACES 1/4"-20 X 1/2" Hex Head Cap Screw (2 Required) 1/4"-20 X 1" Thread Forming Screw (1 Required) 1/4"-20 X 1/2" Hex Head Cap Screw (2 Required) For mounting welding 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. 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 platform, lower tray for added storage capacity and adjustable height handle.C-3 ACCESSORIES C-3 WIRE FEEDER WELDERS (125, 140, 180 MODELS) 2-15/16"3-3/16"7-9/16"1-1/2"13-1/2"1-1/4"9/32" DRILL 3 PLACES1/4"-20 Flange Nut (2 Required) 1/4"-20 X 1" Thread Forming Screw (1 Required)1/4"-20 X 1/2" Hex Head Cap Screw (2 Required) For mounting welding machines to K2275-1 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 tray for added storage capacity, a sturdy fixed handle and convenient cable wrap hanger. OPERATOR’S MANuAL

#"*%&"(%" #%' !' No user serviceable parts inside! Do not attempt to perform service in the power source (fixed) side of the WIRE FEEDER WELDERS (125,140, 180 MODELS). Take 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 pas- sages causing the welder to run hot with premature tripping of thermal protection. If so, blow dirt out of the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build-up on internal parts.

1. When necessary, vacuum accumulated dirt from

gearbox and wire feed section.

2. Occasionally inspect the incoming guide tube and

clean inside diameter if necessary.

3. Motor and gearbox have lifetime lubrication and

require no maintenance.

Has lifetime lubrication — requires no maintenance.

"% !( I(! B;./9292.;6;4 Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using low pressure air, gently blow out the cable liner from the gas diffuser end. E02@@6C2=?2@@B?2.AA52@A.?A:.F0.B@2A5216?A A<3<?:.=9B4 Flex the cable over its entire length and again blow out the cable. Repeat this procedure until no further dirt comes out. <;A.0A'6=@!<GG92@.;1B;'B/2@

1. Dirt can accumulate in the contact tip hole and

restrict wire feeding. After each spool of wire is used, remove the contact tip and clean it by push- ing a short piece of wire through the tip repeatedly. Use the wire as a reamer to remove dirt that may be adhering to the wall of the hole through the tip.

2. Replace worn contact tips as required. A variable

or “hunting” arc is a typical symptom of a worn con- tact tip. To install a new tip, choose the correct size contact tip for the electrode being used (wire size is stenciled on the side of the contact tip) and screw it snugly into the gas diffuser.

3. Remove spatter from inside of gas nozzle and from

tip after each 10 minutes of arc time or as required.

4. Be sure the gas nozzle is fully screwed onto the

diffuser for gas shielded processes. For the Innershield

process, the gasless nozzle 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 as far as possible. Then screw the gun tube into the cable connector until it bottoms. Then unscrew (no more than one turn) the gun tube until its axis is perpendicular to the flat sides of the cable connec- tor and pointed in the direction of the trigger. Tighten the locking nut so as to maintain the proper relationship between the gun tube and the cable connector. Replace the gun handle, trigger and dif- fuser. Replace the gas nozzle or gasless nozzle. ('"!1-1/4”(31.8 mm)Liner Trim LengthGas DiffuserGas Nozzle orGasless Nozzle

")%"#%"''"! "BA=BA"C2?9<.1 The WIRE FEEDER WELDERS (125,140, 180 MOD- ELS) is equipped with a circuit breaker and a thermo- stat which protects the machine from damage if maxi- mum output is exceeded. The circuit breaker button will extend out when tripped. The circuit breaker must be manually reset. '52?:.9#?<A20A6<; The WIRE FEEDER WELDERS (125,140, 180 MOD- ELS) has a rated output duty cycle as defined in the Technical Specification page. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools to a reasonable operating tem- perature. This is an automatic function of the WIRE FEEDER WELDERS (125,140, 180 MODELS) and does not require user intervention. The fan continues to run during cooling. 920A?<;60*6?2?6C2 <A<?#?<A20A6<; The WIRE FEEDER WELDERS (125,140, 180 MOD- ELS) has built-in protection for wire drive motor overload. Set Screw Brass CableConnectorLiner Assembly (Liner bushing to be sealed tightagainst brass cable connector)

NOTICE: The variation in cable lengths 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 tube by

unscrewing counter-clockwise.

4. Lay the gun and cable out straight on a flat surface.

Loosen the set screw located in the brass connec- tor at the wire feeder end of the cable. Pull the liner out of the cable.

5. Insert a new untrimmed liner into the connector end

of the cable. Be sure the liner bushing is stenciled appropriately for the wire size being used.

6. Fully seat the liner bushing into the connector.

Tighten the set screw on the brass cable connector. At this time, the gas diffuser 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 the length shown in the Figure D.2. Remove any burrs from the end of the liner.

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

and securely tighten.

The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counter-clockwise until the collar reaches a stop. Then pull the collar off the gun handle. If the collars are diffi- cult to turn, position the gun handle against a corner, place a screwdriver against the tab on the collar and give the screwdriver a sharp blow to turn the collar past an internal locking rib. See Figure D-3.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your <0.96;0<9;BA5<?6G216291&2?C602.0696AF for technical troubleshooting assistance before you proceed.

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMP- TOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Step 2. POSSIBLE CAUSE. The second column labeled “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 Authorized Field Service Facility. "*'"(&'%"(&""'!( Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

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 your <0.96;0<9;BA5<?6G216291&2?C602.0696AF for technical troubleshooting assistance before you proceed.

Major physical or electrical damage is evident. No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate. No wire feed, weld output or gas flow when gun trigger is pulled. Fan operates normally.

“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

1. The thermostat may be tripped

due to overheating. Let machine cool. Weld at lower duty cycle.

2. Check for obstructions in air

flow. Check Gun Trigger connec- tions. See Installation section.

3. Gun trigger may be faulty.

If all recommended possible areas of misadjustment have been checked and the problem persists, <;A.0A F<B? 9<0.9 6;0<9; BA5<?6G21 6291 &2?C602 .0696AF "('#('#%" &

No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (33V) – weld output.

1. If the wire drive motor is running

make sure that the correct drive rolls are installed in the machine.

If all recommended possible areas of misadjustment have been checked and the problem persists, <;A.0A F<B? 9<0.9 6;0<9; BA5<?6G21 6291 &2?C602 .0696AF

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 your <0.96;0<9;BA5<?6G216291&2?C602.0696AF for technical troubleshooting assistance before you proceed.

Low or no gas flow when gun trigger is pulled. Wire feed, weld output and fan operate normally.

1. Check gas supply, flow regulator

2. Check gun connection to

machine for obstruction or leaky seals.

If all recommended possible areas of misadjustment have been checked and the problem persists, <;A.0A F<B? 9<0.9 6;0<9; BA5<?6G21 6291 &2?C602 .0696AF

Arc is unstable – Poor starting

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.)

6. Check gun for damage or

tation and alignment.

If all recommended possible areas of misadjustment have been checked and the problem persists, <;A.0A F<B? 9<0.9 6;0<9; BA5<?6G21 6291 &2?C602 .0696AF *!#%" &F-1 DIAGRAMS F-1 WIRE FEEDER WELDERS (125, 140, 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. OPERATOR’S MANuALF-2 DIMENSION PRINT F-2 WIRE FEEDER WELDERS (125, 140, 180 MODELS) M21111-1

FIGURA B.1FIGURA B.2

FIGURE B.1FIGURE B.2

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground.

• Keep flammable materials away.

• Wear eye, ear and body protection.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

• Turn power off before servicing.

• Do not operate with panel open or guards off.

• Não opere com os paineis abertos ou guardas removidas.CUSTOMER ASSISTANCE POLICY 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 advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’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 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.