Easy MIG 140 - Welding machine LINCOLN ELECTRIC - Free user manual and instructions

USER MANUAL Easy MIG 140 LINCOLN ELECTRIC

Operator’s Manual WIRE FEEDER WELDERS (125, 140 MODELS) Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator IM10049-B | Issue D ate Oct- 19 © Lincoln Global, Inc. All Rights Reserved.For use with machines having Code Numbers: 11631, 11632, 11633, 11634, 11635, 11636, 11637, 11638, 11639, 12100, 12101, 12102, 12103, 12104, 12105, 12106, 12107, 12191, 12192 Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345)

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.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame. 7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder. 7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. 7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use. 7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association, 14501 George Carter Way Chantilly, VA 20151. FOR ELECTRICALLY POWERED EQUIPMENT. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. Refer to http://www.lincolnelectric.com/safety for additional safety information. SAFETY Safety 04 of 04 - 5/16/20186

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

Requirements For Maximum Output 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.

INPUT – SINGLE PHASE ONLY

RATED OUTPUT OUTPUT Standard Voltage/Frequency 120 V / 60 Hz Duty Cycle 20% Duty Cycle Current 90 Amps Voltage at Rated Amperes

Power Cord 15 Amp, 125 V, Three Prong Plug (NEMA Type 5-15P) Extension Cord 3 Conductor # 12 AWG (4mm

RATED OUTPUT OUTPUT Standard Voltage/Frequency 120 V / 60 Hz Duty Cycle 20% Duty Cycle Current 90 Amps Voltage at Rated Amperes

Power Cord 15 Amp, 125 V, Three Prong Plug (NEMA Type 5-15P) Extension Cord 3 Conductor # 12 AWG (4mm

• .025” -.035”(0.6mm-0.8mm) Dual Groove Drive Roll (Factory installed .035”(0.9mm) groove ready for flux- cored process)

• Black Gun Nozzle (Installed on Welding Gun)

• (3) .035”(0.9mm) Contact Tips (1 installed on the welding gun)

"INSTRUCTION MANUAL" DVD 2" SPINDLE ADAPTER (FOR 8" REEL OF WIRE)

• (3) .035”(0.9mm) Contact Tips (1 installed on the welding gun).

• .025” -.035”(0.6mm-0.8mm) Dual Groove Drive Roll (Factory installed .035”(0.9mm) groove ready for flux-cored process).

• Black Gun Nozzle (Installed on Welding Gun)

.025 GROOVE .035 GROOVEB-1 OPERATION WIRE FEEDER WELDERS (125, 140) Read entire operation section before operating the WIRE FEEDER WELDERS. ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground.

• Always wear dry insulating gloves. FUMES AND GASES can be danger- ous.

• 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 containers. ARC RAYS can burn eyes and skin.

• Wear eye, ear and body protection. Observe all safety information throughout this manual.

This machine has the following controls: See Figure B.1

1. POWER SWITCH – Turns power on and off to the machine.

2. ARC VOLTAGE CONTROL – This knob sets the output voltage

of the machine. Along with wire feed speed (WFS), this con- trol sets a weld procedure. Refer to the procedure decal on the wire drive compartment door to set a welding procedure based on the type of material and thickness being welded.

3. WIRE FEED SPEED CONTROL (WFS) – This knob sets the

speed that the machine feeds wire. Along with arc voltage, this control sets a weld procedure. Refer to the procedure decal on the wire drive compartment door to set a welding procedure based on the type of material and thickness being welded. See Figure B.2

4. GUN TRIGGER – Pressing the trigger activates the wire drive

and energizes the output of the machine. Press the trigger to weld and release the trigger to stop welding.

5. WELDING GUN – Delivers wire and welding current to the

work piece. 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. b. Contact Tip – provides electrical contact to the wire. c. Nozzle – When flux-cored welding, the black nozzle pro- tects the mounting threads on the gun. When MIG welding, the brass nozzle funnels the shielding gas to the weld.

6. WORK CLAMP & CABLE – Clamps to the work piece being

welded and completes the electrical welding circuit.

7. GUN TRIGGER CONNECTOR RECEPTACLE – Plug the 4 pin

gun trigger connector into this receptacle.

Provides electrical power to the welding gun. The thumbscrew holds the welding gun into the connector block. (Front Cover and Side Door have been removed for clarity of Items 8 and 9).

9. OUTPUT TERMINALS - Connections to these terminals deter-

mines the welding polarity, depending on whether the process being used is flux-cored welding or MIG welding. See Figure B.4

10. WIRE SPOOL SPINDLE AND BRAKE – Holds a 4”(102mm)

diameter spool. Use the 2”(51mm) spindle adapter included with the machine for 8” (203mm) diameter spools. The wing nut sets the brake friction to prevent the spool from over rotating when the trigger is released. Tightening the wing nut will prevent the spool from rotating when the trigger is released. See Figure B.5

11. WIRE DRIVE & COMPONENTS – Feeds wire from the wire

spool through the drive and through the welding gun to the work piece. a. Drive Roll – Drives the wire through the drive system. The drive roll has grooves to match the specific wire type and diameter. Refer to Table B.1 for available drive rolls. b. Incoming & Outgoing Guide – The wire is fed through both guides. The Pivot Arm Assembly, Tension Arm Assembly and Drive Roll keep pressure on the wire in the groove. c. Tension Arm Assembly – Turning clockwise increases the forward force on the wire and turning counterclockwise decreases the force.

See Figure B.5a Magnum 100SG / Magnum 100L Switch - The spool gun switch is available on 140 Amp machines only. The Magnum 100SG Spool Gun can be purchased at authorized retailers. The part number is K2532-1. MAGNUM 100SG SWITCH MAGNUM 100L

12. CIRCUIT BREAKER – If the rated input current of the machine is

exceeded this circuit breaker will trip. Press to reset.

13. GAS INLET –Shielding gas connects to this inlet

(This is not available 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 bush- ing. Tighten thumb screw to connector bushing.

3. Make sure the gun connector end is seated fully into the

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

receptacle on the machine front.

5. Wire Drive Polarity. NR-211 MP requires negative (-) polarity.

Connect the short power cable from the wire drive to the negative (-) output terminal and tighten wing nut.

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

cable through the hole in the machine front and route cable through strain relief as shown in figure B.7. Place lug on the positive (+) output terminal and tighten wing nut.

1. Locate the sample spool of .035”(0.9mm) 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 by tightening the wing nut against the spacer

that holds the wire spool on the spindle. Do not over tighten the spool.

3. Open the pivot arm assembly by rotating the tension arm

assembly down and lift pivot arm assembly up.

4. Remove drive roll

by un-screwing the black knob that holds the drive roll on. Install the Dual Groove drive roll with the .035”(0.9mm) mark facing outward which will allow feeding of .035” (0.9mm) NR-211MP flux-cored wire

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.

(FRONT AND SIDE DOOR IS REMOVED

PI V OT AR M ASSEMBLY

6. Feed the wire through the incoming guide, 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 rotating the

Tension Arm Assembly back to the up position. (See Tension information on decal.) (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 fig- ure B.11)

10. When trigger is released spool of wire should not unwind.

Adjust wire spool brake accordingly.

• When the gun trigger is depressed, drive rolls, spool of wire and electrode are ELEC- TRICALLY LIVE (HOT).

• Keep away from moving parts and pinch points.

• Keep all doors, covers, panels and guards securely in place.

(0.9mm) contact tip.

12. Install the black welding nozzle to the gun.

13. Trim the wire stickout to 3/8”

(9.5mm) from the contact tip. (See Figure B.12)

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

15. "Learn to Weld" Video is on the DVD.

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.

REMOVED NOZZLE REMOVED CONT

TENSION ARM ASSE MBL

shielding gas (or 100%

regulator adapter which is soldseparately).

• 125 Amp Units can not be upgraded for MIG welding.

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

can be used; refer to the following instructions to properly connect shielding gas to the machine. CYLINDER may explode if damaged. Keep cylinder upright and chained to support

• Keep cylinder away from areas where it may be damaged.

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

• Keep cylinder away from welding or other live electrical circuits. 75/25

3. Attach the flow regulator to the cylinder valve and tighten the

union nut securely with a wrench. NOTE: 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 certain 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 earth ground. Refer to Figure B.13.

2. With the cylinder securely installed, remove the cylinder

cap. Stand to one side away from the outlet 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. BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUT- LET WHEN “CRACKING” THE VALVE. Never stand directly in front of or behind the flow regulator when opening the cylin- der valve. Always stand to one side. SHIELDING GAS

, open the cylinder very slowly. For argon-mixed gas, open cylinder valve slowly a fraction of a turn. When the cylin- der 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

L/min) under normal conditions. Increase to as high as 40 to 50 CFH (18 to 23.5 L/min) for out of position welding.

3. Keep the cylinder valve closed, except when using the

machine. WARNING WARNING WARNINGB-9 OPERATION WIRE FEEDER WELDERS (125, 140) 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. Tighten thumbscrew to connector bushing.

3. Make sure the gun connector end is seated fully into the wire

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 posi- tive (+) output terminal and tighten wingnut.

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

cable through the hole in the machine front and route cable through the strain relief as shown in figure B.14. Place lug on the negative (-) output terminal and tighten wing nut.

1. Locate the sample spool of .025”(0.6mm) L-56 solid MIG 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

spacer that holds the wire spool on the spindle.

3. Open the pivot arm assembly by rotating the tension arm

assembly down and lift pivot arm assembly up.

4. Remove drive roll

by un-screwing the black knob that holds the drive roll on. Install the Dual Track drive roll with the .025”(0.6mm) mark facing outward which will allow feeding of .025” (0.6mm) L-56 Solid MIG wire

5. Carefully unwind and straighten the first six inches of welding

wire from the spool. Hold onto the wire until the the Pivot Arm assembly and Tension Arm are locked in place. This will pre- vent the wire from unspooling. GUN AND CABLEWORK CLAMP(4 PIN)LEAD CONNECTORTERMINAL END (FITS ON STUD INSIDESEE FIGURE BELOW)SLIDECONNECTOREND HERE

PI VOT A RM ASS EMBLY

6. Feed the wire through the incoming guide, 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 rotating the

Tension Arm Assembly back to the up position. (See Tension information on decal.) (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 switch to on and press the gun trig-

ger to feed 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, the spool of wire should not

unwind. Adjust wire spool brake accordingly.

• When the gun trigger is depressed drive rolls, spool of wire and electrode are ELECTRICALLY LIVE (HOT).

• Keep away from moving parts and pinch points.

• Keep all doors, covers, panels and guards securely in place.

12. Install the brass MIG welding nozzle to the gun.

13. Trim the wire stickout to 3/8”(9.5mm) from the nozzle end.

14. Close the wire drive compartment door. The machine is now

15. "Learn to Weld" Video is on the DVD.

16. Based on the thickness of the material you are going to weld

and the type and diameter of the welding wire, set the volt- age and the wire feed speed per the procedure decal attached to the inside of the wire drive compartment door.

1. Loosen the THUMB SCREW and disconnect Magnum 100L

2. Insert K2532-1 Magnum 100SG spool gun into the brass block

and tighten the THUMB SCREW.

3. Depress Gun selector SWITCH to Spool Gun position. (See

Figure B.20 and B.21)

4. Connect a bottle of 100% Argon shielding Gas per previous

5. Follow the MIG welding steps in the previous section.

6. Turn machine on and make weld per recommended settings

on Procedure Decal inside machine door. SETTING UP AND MAKING A ALUMINUM WELD USING SPOOL GUN (Aluminum Welding can only be used on 140 Amp machines.) FIGURE B.21 (Location of Selector Switch and Thumb Screw) MAGNUM 100SG SWITCH

OPERATOR’S MANUALC-1

ACCESSORIES WIRE FEEDER WELDERS (125, 140) K2532-1 - Magnum 100SG Spool Gun (Only available on 140 Models K2480-1, K2514-1, K2658-1 and K2697-1). 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. K2377-1 - Small Canvas Cover Protect your machine when not in use. Made from attractive red canvas that is flame retardant, mildew resistant and water repel- lent. Includes a convenient side pocket to hold welding gun. For additional Optional and Miscellaneous Parts (See Parts Pages)C-2 ACCESSORIES WIRE FEEDER WELDERS (125, 140) 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.

16" 3-11/16" 3-13/32" 9/32" DRILL 2 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 (2 places) into the cart top as shown and attach the welding machine to the cart with the proper hardware shown.

OPERATOR’S MANUALC-3

ACCESSORIES WIRE FEEDER WELDERS (125, 140) 1/4"-20 Flange Nut (2 Required) 1/4"-20 X 1/2" Hex Head Cap Screw (2 Required) K2275-3 - 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.D-1 MAINTENANCE WIRE FEEDER WELDERS (125, 140) SAFETY PRECAUTIONS ELECTRIC SHOCK can kill.

• Disconnect input power by removing plug from receptacle before working inside WIRE FEEDER WELDERS (125 and 140 MODELS). Use only grounded receptacle. Do not touch electrically “hot” parts inside WIRE FEEDER WELDERS (125 and 140 MODELS).

• Have qualified personnel do the maintenance and trouble shooting work.

POWER SOURCE COMPARTMENT

No user serviceable parts inside! Do not attempt to perform ser- vice in the power source (fixed) side of the WIRE FEEDER WELDERS (125 and 140 MODELS). Take the unit to an authorized Lincoln Service Center if you experience problems. NO mainte- nance is required. In extremely dusty locations, dirt may clog the air passages 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.

WIRE FEED COMPARTMENT

1. When necessary, vacuum accumulated dirt from gearbox and

2. Occasionally inspect the incoming guide tube and clean

inside diameter if necessary.

3. Motor and gearbox have lifetime lubrication and require no

Requires no maintenance. Do not lubricate shaft.

Gun Cable Cleaning 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. Excessive pressure at the start may cause the dirt to form a plug.

Flex the cable over its entire length and again blow out the cable. Repeat this procedure until no further dirt comes out. Contact Tips, Nozzles, and Gun Tubes

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 pushing 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 “hunt-

ing” arc is a typical symptom of a worn contact tip. To install a new tip, choose the correct size contact tip for the elec- trode 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 be screwed onto the diffuser.

5. To remove gun tube from gun, remove gas nozzle or gasless

nozzle and remove diffuser from gun tube. Remove both col- lars from each end of the gun handle and separate the han- dle 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 connector 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, trig- ger and diffuser. Replace the gas nozzle or gasless nozzle. CAUTION WARNING

OPERATOR’S MANUALD-2

MAINTENANCE WIRE FEEDER WELDERS (125, 140) 1-1/4”(31.8 mm) Liner Trim Length Gas Diffuser Gas Nozzle or Gasless Nozzle OVERLOAD PROTECTION Output Overload The WIRE FEEDER WELDERS (125 and 140 MODELS) are equipped with a circuit breaker and a thermostat which protects the machine from damage if maximum output is exceeded. The circuit breaker button will extend out when tripped. The circuit breaker must be manually reset. Thermal Protection The WIRE FEEDER WELDERS (125 and 140 MODELS) have 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 temperature. This is an automatic function of the WIRE FEEDER WELDERS (125 and 140 MODELS) and does not require user intervention. The fan continues to run during cooling. Electronic Wire Drive Motor Protection The WIRE FEEDER WELDERS (125 and 140 MODELS) have built-in protection for wire drive motor overload. Set Screw Brass Cable Connector Liner Assembly (Liner bushing to be sealed tight against brass cable connector) FIGURE D.2 Liner trim length CHANGING LINER NOTICE: The variation in cable lengths prevents the interchange- ability of liners. Once a liner has been cut for a particular gun, it should not be installed in another gun unless it can meet the liner cutoff length requirement. Refer to Figure D.2.

1. Remove the gas nozzle from the gun by unscrewing counter-

2. Remove the existing contact tip from the gun by unscrewing

3. Remove the gas diffuser from the gun tube by unscrewing

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

the set screw located in the brass connector at the wire feed- er 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 dif- fuser 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

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 collars reach a stop. Then pull the collars off the gun handle. If the col- lars are difficult 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 lock- ing rib. See Figure D.3.

E-1 TROUBLE SHOOTING WIRE FEEDER WELDERS (125, 140) If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility 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 (SYMPTOMS)”. 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 symp- tom. 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.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs per- formed 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 through- out this manual.

WARNINGObserve 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 Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION E-2 TROUBLE SHOOTING WIRE FEEDER WELDERS (125, 140) PROBLEMS (SYMPTOMS) Major physical or electrical damage is evi- dent. 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. 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

2. Make certain that power switch is in

3. Make sure circuit breaker is reset.

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 connections. See Installation section.

3. Gun trigger may be faulty.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility. OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has cor- rect open circuit voltage (33V) – weld out- put. POSSIBLE CAUSE

1. If the wire drive motor is running make

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

2. Check for clogged cable liner or con-

3. Check for proper size cable liner and

• Check Magnum 100SG/Magnum 100L switch is properly switched to activate proper gun. RECOMMENDED

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility. FEEDING PROBLEMSObserve 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 Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION E-3 TROUBLE SHOOTING WIRE FEEDER WELDERS (125, 140) PROBLEMS (SYMPTOMS) Low or no gas flow when gun trigger is pulled. Wire feed, weld output and fan operate normally. POSSIBLE CAUSE

1. Check gas supply, flow regulator and

2. Check gun connection to machine for

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.

PROBLEMS (SYMPTOMS) Arc is unstable – Poor starting POSSIBLE CAUSE

1. Check for correct input voltage to

3. Check gun tip for wear or damage and

proper size – Replace.

4. Check for proper gas and flow rate for

process. (For MIG only.)

6. Check gun for damage or breaks.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility. WELDING PROBLEMS

OPERATOR’S MANUALWIRING DIAGRAM FOR CODE 11631, 11632, 11633, 11638, 11639

N.C. 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. F-1 DIAGRAMS

WIRE FEEDER WELDERS (125, 140)F-2

DIAGRAMS WIRE FEEDER WELDERS (125, 140) 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.

A.02 WARNINGHIGH VOLTAGEcan killOnly qualified persons should install,use or service this machine.Do not operate with covers removed.Disconnect input power by unpluggingpower cord before servicing.Do not touch electrically live partsLATCHELECTRICAL SYMBOLS PER E1537

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.F-4 DIAGRAMS WIRE FEEDER WELDERS (125, 140) M24970 A.02 WARNINGHIGH VOLTAGEcan killOnly qualified persons should install,use or service this machine.Do not operate with covers removed.Disconnect input power by unpluggingpower cord before servicing.Do not touch electrically live partsLATCHELECTRICAL SYMBOLS PER E1537

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.

FIGURA B.1 FIGURA B.2

PROBLEMAS (SÍNTOMAS) Low or no gas flow when gun trigger is pulled. Wire feed, weld output and fan operate normally. CAUSA POSIBLE

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Printed 05/28/2015 at 12:00:14. Produced by Enigma.No Image Miscellaneous Items

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2A 9SL12395-22 NAMEPLATE 1

4A 9ST9695-5 LOCKWASHER 2

9ST9695-5 LOCKWASHER 1

9ST10940-10 3/8-32HJN 1

Printed 05/28/2015 at 12:00:14. Produced by Enigma.P-653-C.jpg Case Front Assembly

Printed 05/28/2015 at 12:00:14. Produced by Enigma.KEY PART NUMBER DESCRIPTION QTY 9SL15790 Center Panel Assembly 1

1 9SL15805 CENTER PANEL 1

9SL15789 WIRE DRIVE/OUTPUT STUD ASBLY 1

2A 9SL15782 WIRE DRIVE MOUNT 1

9 9ST9968-5 WING NUT 1

19 9ST9968-6 WING NUT 2

20 9ST10800-59 SWITCH 1

Center Panel Assembly & Control P.C. Board

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Case Back & Bottom Asbly

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1E 9SL12602 HANDLE 1

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Printed 05/28/2015 at 12:00:14. Produced by Enigma.Magnum Pro 100L - K3080-1KEY PART NUMBER DESCRIPTION QTY

2 9SG2209 GUN HANDLE SET 1