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

Brand	Lincoln Electric
Model	Easy MIG 140
Product type	Portable MIG/FCAW welding machine
Intended use	MIG (GMAW) welding on steel, stainless steel, aluminum; flux-cored wire (FCAW) welding on mild steel
Power supply	Single-phase, 120 V, 60 Hz, 20 A (max 25 A for maximum output)
Welding current range	30–140 A
Maximum open-circuit voltage	33 V
Duty cycle (at 90 A)	20%
Wire feed speed	1.3–12.7 m/min (50–500 in/min)
Accepted wire diameters	MIG wire: 0.6–0.9 mm; flux-cored wire: 0.8–0.9 mm
Dimensions (H x W x D)	347 x 258 x 454 mm
Weight	22.5 kg
Included accessories	Magnum 100L gun, ground clamp, gas regulator, gas hose, dual groove drive roll, contact tips, spindle adapter, training DVD
Key features	MIG and FCAW welding, voltage and wire speed adjustment, switchable polarity, thermal protection and circuit breaker, cooling fan
Routine maintenance	Cleaning gun liner with air blowing, replacing contact tips and nozzles, cleaning wire compartment
Safety	Protection against electric shock, arc radiation, toxic fumes; safety devices: circuit breaker, thermostat, protective covers
Replacement parts available	Contact tips, nozzles, liners, drive rolls, optional spool guns (Magnum 100SG)
Repairability	Repairs reserved for qualified Lincoln Electric personnel; wiring diagrams provided for specific codes
General information	124-page user manual available for download; operator manual included

Frequently Asked Questions - Easy MIG 140 LINCOLN ELECTRIC

How to install flux-cored wire in the Easy MIG 140 machine?

Place the wire spool on the spindle, orient the wire upward. Open the swing arm and install the drive roll with the 0.035" groove visible. Insert the wire into the inlet guide, the roll groove, the outlet guide, then close the tension arm. Remove the nozzle and contact tip, then press the trigger to advance the wire until it protrudes about 10 cm. Install the contact tip and black nozzle, then cut the wire to 9.5 mm from the tip.

What polarity to use for MIG welding with the Easy MIG 140?

For MIG welding, connect the short output cable to the positive (+) output terminal and the work clamp to the negative (-) terminal. For FCAW welding with NR-211MP flux-cored wire, reverse the polarity: output cable to negative (-) terminal and work clamp to positive (+) terminal.

What shielding gas to use for MIG welding mild steel?

For mild steel, use an argon/CO2 mix (75/25) or pure CO2. The recommended flow rate is 30 to 40 cubic feet per hour (14 to 18 L/min) in flat position, and up to 40-50 CFH (18-23.5 L/min) in vertical or overhead position. Be sure to close the cylinder after use.

How to change the contact tip of the gun?

Unscrew the nozzle, then unscrew the used contact tip. Clean the diffuser threads. Screw on the new contact tip of the appropriate size (engraved on the side) and tighten firmly. Replace the nozzle. Check that the wire passes freely.

What to do if the machine does not feed wire?

Check that the power switch is on and the circuit breaker has not tripped. Make sure the gun trigger is properly connected. Check that the drive roll is suitable for the wire diameter and that the cable liner is not blocked. Clean the liner with air blow if necessary. For the 140 A version, check that the gun selector (Magnum 100L/100SG) is in the correct position.

Can you weld aluminum with the Easy MIG 140?

Yes, only on 140 A models. Use a Magnum 100SG spool gun (sold separately) with 4043 aluminum wire of diameter 0.035" (0.9 mm). Connect a bottle of pure argon (100%) and set the flow rate. Select spool gun mode on the switch. Follow the voltage and speed settings indicated on the procedure label.

What is the duty cycle of the Easy MIG 140?

The rated duty cycle is 20% at 90 A. This means you can weld for 2 minutes in a 10-minute period before thermal protection activates. If the cycle is exceeded, a thermostat automatically cuts the output; let the machine cool (the fan continues to run).

How to adjust voltage and wire speed?

Use the arc voltage and wire feed speed (WFS) control knobs. Refer to the procedure label attached inside the drive roll compartment door to select settings based on material type and thickness. In general, higher voltage produces a longer arc, higher speed increases metal deposition.

What safety precautions to observe before welding?

Always wear a welding helmet with appropriate filter lens, dry leather gloves, fire-resistant clothing (wool, fire-resistant cotton) and safety glasses. Ensure the work area is free of flammable materials. Use adequate ventilation to avoid fume inhalation. For pacemaker wearers, consult a doctor before use.

How to maintain the gun cable liner?

After approximately 136 kg of solid wire or 23 kg of flux-cored wire, clean the liner. Remove the contact tip, stretch the cable straight, then blow compressed air at low pressure from the diffuser end. Bend the cable and repeat blowing until all dirt is removed. Do not use excessive pressure which could compact the dirt.

USER MANUAL Easy MIG 140 LINCOLN ELECTRIC

Line drawing of a Lincoln Electric welding machine (no text or symbols on the device itself)

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

Register your machine:

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLNELECTRIC.

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.

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.

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

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.

Illustration of a person in protective gear using a welding torch to prevent impact (no text or symbols)

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.

Silhouette of a person wearing a welding helmet and holding a tool, no text or symbols present

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.

SECTION 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 www.P65warnings.ca.gov

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of "Safety in Welding & Cutting - ANSI Standard Z49.1" from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of "Arc Welding Safety" booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWERED EQUIPMENT.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact

with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.

ELECTRIC 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:

• Semiautomatic DC Constant Voltage (Wire) Welder.
  • DC Manual (Stick) Welder.
  • 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.

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.

1. 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.

WELDING AND CUTTING SPARKS CAN CAUSE 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-I, "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.

TABLE OF CONTENTS

General Decription...... Page 7

Installation .... Section A

Technical Specifications ......A-1

Identify and Locate Components for 125 Amp Unit .A-2

Identify and Locate Components for 140 Amp Unit .A-3

Operation .... Section B

Safety and Product Description ....B-1

Controls and Settings B-2, B-3

Dual Track Drive Roll and Wire Guide Table .....B-4

Setting Up and Making a Flux-Cored Weld with a 125Amp or 140Amp machines ....B-4 thru B-6

Setting Up and Making a MIG Weld and Install Shielding

Gas for a 140Amp machine ....B-7 thru B-10

Setting Up and Making a Aluminum Weld .....B-11

Accessories ....Section C

Optional Accessories C-1

Utility Carts....C-2, C-3

Maintenance .... Section D

Safety Precautions .....D-1

Wire Feed Compartment, Fan Motor, Wire Reel

Maintenance ....D-1

Gun And Cable Maintenance ....D-2

Overload Protection .....D-2

Component Replacement Procedures .....D-2

Troubleshooting .... Section E

Safety Precautions ....E-1

How to Use Troubleshooting Guide ....E-1

Troubleshooting Guide ....E-2 thru E-3

Wiring Diagram and Dimension Print ..... Section F

Parts Pages . . . . . . . parts.lincolnelectric.com

PRODUCT DESCRIPTION (PRODUCT CAPABILITIES)

The portable 125Amp Wire Feeder Model is capable of flux-cored welding on mild steel. The portable 140Amp Wire Feeder Model is capable of MIG welding on steel, stainless steel, and aluminum, in addition to flux-core welding on mild steel.

MIG welding stands for Metal Inert Gas welding and requires a separate bottle of shielding gas to protect the weld. The Shielding gas used is determined by the type of material you are welding on. Shielding gases can be purchased separately from your local welding gas distributor. MIG welding is ideal for welding on thin and clean materials when an excellent cosmetic weld is required. An example is automotive body panels.

FCAW-S stands for Self shielding Flux-cored Arc Welding and does not require a shielding gas to protect the weld since the welding wire has special additives known as flux to protect the weld from impurities. Flux-cored welding is ideal for medium to thicker material and for welding on painted or rusty steel. Flux-cored welding is also ideal for 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 140Amp machine includes the necessary items to weld with either the flux-cored welding or MIG welding process on steel. To weld on stainless steel, an optional stainless steel welding wire can be purchased separately. The 140Amp machine is spool gun ready and the machine can weld aluminum using .035"(0.9mm) diameter 4043 aluminum welding wire. Since aluminum welding wire is soft, an optional spool gun is recommended for best results. A welding Procedure Decal on the wire drive compartment door provides suggested settings for welding.

COMMON WELDING ABBREVIATIONS

GMAW (MIG)

• Gas Metal Arc Welding

FCAW (Innershield or Outershield)

- Flux Core Arc Welding

TECHNICAL SPECIFICATIONS

125 Amp units (K2479-1, K2513-1, K2696-1, K2699-1, K2785-1)

INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency120 V / 60 Hz	Input Current20 Amps @ rated output

RATED OUTPUT
Duty Cycle20% Duty Cycle	Current90 Amps	Voltage at Rated Amperes19

OUTPUT
Welding Current Range30-125 Amps	Maximum-Open Circuit Voltage33 V	Wire Speed Range50 - 500 in/min.(1.3 - 12.7 m/min.)

RECOMMENDED INPUT CABLE AND FUSE SIZES
Input Voltage / Frequency120V 60Hz	Fuse or Breaker Size ^1,2 20 Amp		Input Amps20
Power Cord15 Amp, 125 V,Three Prong Plug(NEMA Type 5-15P)		Extension Cord3 Conductor # 12 AWG(4mm ^2 ) or Largerup to 50 ft.(15.2m)

PHYSICAL DIMENSIONS
Height13.7 in.347 mm	Width10.15 in.258 mm	Depth17.9 in.454 mm	Weight49.5 lbs.22.5 kg.

140 Amp units (K2480-1, K2514-1, K2658-1, K2697-1)

INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency120 V / 60 Hz	Input Current20 Amps @ rated output

RATED OUTPUT
Duty Cycle20% Duty Cycle	Current90 Amps	Voltage at Rated Amperes19.5

OUTPUT
Welding Current Range30-140 Amps	Maximum-Open Circuit Voltage33 V	Wire Speed Range50 - 500 in/min.(1.3 - 12.7 m/min.)

RECOMMENDED INPUT CABLE AND FUSE SIZES
Input Voltage / Frequency120V 60Hz	Fuse or Breaker Size ^1,2 20 Amp		Input Amps20
Power Cord15 Amp, 125 V,Three Prong Plug(NEMA Type 5-15P)		Extension Cord3 Conductor # 12 AWG(4mm ^2 ) or Largerup to 50 ft.(15.2m)

PHYSICAL DIMENSIONS
Height13.7 in.347 mm	Width10.15 in.258 mm	Depth17.9 in.454 mm	Weight49.5 lbs.22.5 kg.

IDENTIFY AND LOCATE COMPONENTS for 125 AMP UNIT

- Wire Feeder Welder

Line drawing of an industrial electronic device with cooling fans and buttons (no text or symbols)

• Work Cable & Clamp

Simple line drawing of a tool or device with a curved handle and a circular head (no text or symbols)

• Magnum 100L Welding Gun

Line drawing of a welding torch with curved bracing (no text or symbols)

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

- Spool of .035" (0.9mm) diameter NR-211MP Innershield Flux-cored Wire

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

.025 GROOVE .035 GROOVE

- Black Gun Nozzle (Installed on Welding Gun)

- 2"(51mm) Spindle Adapter (For 8" (203mm) reel of wire)

- Instruction Manual

- How to Weld "DVD"

2" SPINDLE ADAPTER (FOR 8" REEL OF WIRE)

"INSTRUCTION MANUAL"

IDENTIFY AND LOCATE COMPONENTS for 140 AMP UNIT

- Wire Feeder Welder

Line drawing of an electrical device with buttons and a label (no readable text or symbols beyond branding)

• Work Cable & Clamp

Simple line drawing of a mechanical tool or bracket with a handle and base (no text or symbols)

• Magnum 100L Welding Gun

• (3) .035"(0.9mm) Contact Tips (1 installed on the welding gun).
• (3) .025"(0.6mm) Contact Tips

• Spool of .035" (0.9mm) diameter NR-211MP Innershield Flux-cored Wire
• Spool of .025"(0.6mm) diameter Super Arc L-56 MIG Wire

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

.025 GROOVE .035 GROOVE

- Black Gun Nozzle (Installed on Welding Gun)

• Brass MIG Gun Nozzle for MIG welding

• 2"(51mm) Spindle Adapter for 8"(203mm) reel of wire.
• Regulator
  Gas Hose
• Instruction Manual
  • How to Weld "DVD"

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

Read entire operation section before operating the WIRE FEEDER WELDERS.

WARNING

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 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 containers.

ARC RAYS can burn eyes and skin.

- Wear eye, ear and body protection.

Observe all safety information throughout this manual.

CONTROLS AND SETTINGS

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 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.
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

1. 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.
2. 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 protects the mounting threads on the gun. When MIG welding, the brass nozzle funnels the shielding gas to the weld.

1. WORK CLAMP & CABLE – Clamps to the work piece being welded and completes the electrical welding circuit.
2. GUN TRIGGER CONNECTOR RECEPTACLE – Plug the 4 pin gun trigger connector into this receptacle.

FIGURE B.1

1 2 3 LINCOLN ELECTRIC

FIGURE B.2

5c 5b 5a 5 4 7 6

See Figure B.3

1. WELDING GUN CONNECTOR BUSHING & THUMBSCREW – 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).
2. OUTPUT TERMINALS - Connections to these terminals determines the welding polarity, depending on whether the process being used is flux-cored welding or MIG welding.

FIGURE B.3

Technical diagram of a mechanical assembly with numbered components labeled 8 and 9

See Figure B.4

1. 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.

FIGURE B.4

2" SPINDLE ADAPTER (FOR 8" REEL OF WIRE) (4" REEL OF WIRE)

See Figure B.5

1. 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.

FIGURE B.5

PIVOT ARM ASSEMBLY BEARING OUTGOING GUIDE TENSION ARM ASSEMBL. WIRE SPOOL .035" (0.9mm) NR-211-MP INCOMING GUIDE DRIVE ROLL

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.

FIGURE B.5a

SWITCH MAGNUM 100SG MAGNUM 100L

TABLE B.1 DRIVE ROLLS

		125/140 Amp
		Wire Diameter & Type	Smooth Drive Roll (Dual Grooves)
.035 GROOVE*	iROOVE	.025"(0.6mm) MIG wire	Use .025"(0.6mm) Drive Roll Groove
		.030"(0.8mm) MIG wire	Use .035"(0.9mm) Drive Roll Groove
		.035"(0.9mm) MIG wire
		.030"(0.8mm) flux-cored
		.035"(0.9mm) flux-cored

See Figure B.6

1. CIRCUIT BREAKER – If the rated input current of the machine is exceeded this circuit breaker will trip. Press to reset.
2. GAS INLET –Shielding gas connects to this inlet (This is not available on 125 Amp Unit.)

FIGURE B.6

Diagram of a gas cylinder connected to an analog device with labeled parts 12 and 13, showing wiring and components.

SETTING UP AND MAKING A FLUX-CORED WELD WITH 125AMP OR 140AMP MACHINES

A. ITEMS NEEDED FOR FLUX CORED WELDING

1. .035"(0.9mm) Contact Tip

1. Dual Groove Drive Roll.

2. .035"(0.9mm) NR-211MP Flux-Cored Wire

1. Welding Gun

Line drawing of a welding torch with clasp and handle (no text or symbols)

1. Work Cable & Clamp

1. Black Flux Cored gun nozzle

B. CONNECT LEADS AND CABLES ON THE MACHINE

FIGURE B.7

(See Figure B.7)

1. Open the case side door
2. Slide the connector end of the gun and cable through the hole in the machine front and into the gun connector bushing. Tighten thumb screw to connector bushing.

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

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.

SLIDE CONNECTOR END HERE [4 PIN] LEAD CONNECTOR GUN AND CABLE OPEN LATCH DOOR TERMINAL END (RITS ON STUD INSIDE SEE FIGURE BELOW) WORK CLAMP ALL COMPONENTS SHOWN CONNECTED (FRONT AND SIDE DOOR IS REMOVEDFOR CLARITY) TIGHTEN THUMB SCREW TO CONNECTOR BUSHING [4 PIN] TRIGGER RECEPTACLE PLUGGED IN SHORT POWER CABLE NEGATIVE "A" OUTPUT TERMINAL STRAIN RELIEF WORK CLAMP WORK LEAD CONNECTION POSITIVE "A" OUTPUT TERMINAL

C. LOAD WIRE SPOOL

(See Figure B.8)

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.

FIGURE B.8

PIVOT ARM ASSEMBLY BEARING OUTGOING GUIDE TENSION ARM ASSEMBLY WIRE SPOL 035° (0.9mm) NR-211-MP INCOMING GUIDE DRIVE ROLL

(See Figure B.9)

1. Feed the wire through the incoming guide, over the drive roll groove, thru the outgoing guide and wire drive outlet on the gun side.
2. 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)

1. Remove the nozzle from the gun and contact tip and straighten the gun out flat.
2. 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)
3. When trigger is released spool of wire should not unwind. Adjust wire spool brake accordingly.

WARNING

MOVING PARTS AND ELECTRICAL CONTACT CAN CAUSE INJURY OR BE FATAL.

- 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.

DO NOT REMOVE OR CONCEAL WARNING LABELS.

1. Install the .035"(0.9mm) contact tip.
2. Install the black welding nozzle to the gun.
3. Trim the wire stickout to 3/8" (9.5mm) from the contact tip. (See Figure B.12)
4. Close the case side door. The machine is now ready to weld.
5. "Learn to Weld" Video is on the DVD.
6. 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.

FIGURE B.9

Pivot Arm Assembly WITH BEARING PRESSING AGAINST DRIVE ROLL TENSION ARM ASSE MIBLY LOCKED IN UP POSITION BEARING INCOMING GUIDE DRIVE ROLL OUTGOING GUIDE WIRE SPOOL .035" (0.5mm) NR-211-MP DIRECTION OF WIRE SLIDE WIRE INTO GUN CONNECTOR SIDE

FIGURE B.10

REMOVED NOZZLE REMOVED CONTACT TIP LAYCABLE AND GUN STRAIGHTEN IN THIS POSITION 635°10.5mm NP-2-LMP WIRE SPOL

FIGURE B.11

INPUT CORD ON/OFF SWITCH FEED WIRE APPROVIVATELY 4.00" FROM THE GUNTUBE END DEPRESSTRIGGER TOACTIVATE WIRE, VIRCH FEEDS THE WIRE THRU THE LINER. WIRE SPOOL ROTATION WIRE SPOOL BRAKE WORK CLAMP AND CABLE

FIGURE B.12

TRIM WIRE STICKOUT 3/8"(9.5mm) from the Contact Tip INSTALL .035 CONTACT TIF INSTALL BLACK NOZZLE

SETTING UP AND MAKING A MIG WELD 140AMP MACHINE\*

A. ITEMS NEEDED FOR MIG WELDING

1. .025"(0.6mm) Contact Tip

1. .025"(0.6mm) Dual Groove drive roll is used with L-56 Solid Mig wire.

1. .025"(0.6mm) SuperArc L-56 Solid MIG Wire

L-56 MIG WIRE

1. Brass gun nozzle

1. Welding Gun

Line drawing of a welding torch with curved handle and flange (no text or symbols)

1. Work Cable & Clamp

Simple line drawing of a pliers or clamp with a curved handle and circular head (no text or symbols)

1. Gas Regulator & Gas Line

Technical line drawing of two mechanical components: a coiled pipe and a multi-cylinder valve assembly (no text or symbols)

1. Bottle of 75/25 Ar/CO 2 shielding gas (or 100% CO 2 shielding gas) (note this requires a CO _2 regulator adapter which is sold separately).

MALE END CO₂ 100% (REQUIRES ADAPTER) SOLD SEPARATELY)

FEMALE END 75/25 MIXES

* 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_2 or 100% CO_2 can be used; refer to the following instructions to properly connect shielding gas to the machine.

WARNING

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.

WARNING

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.

WARNING

BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN "CRACKING" THE VALVE. Never stand directly in front of or behind the flow regulator when opening the cylinder valve. Always stand to one side.

FIGURE B.13

MALE END CO₂ 100% REGULATOR ADAPTER PLASTIC WASHER S19296 FEMALE END 75/25 MIXES

1. Attach the flow regulator to the cylinder valve and tighten the union nut securely with a wrench.
   NOTE: If connecting to 100% CO₂ cylinder, a CO₂ regulator adapter is required. Purchase separately S19298 CO₂ adapter, be sure to install plastic washer included in the fitting on the bottle side.(See Figure B.13)
2. 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.

SHIELDING GAS

1. For CO_2 , 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 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.

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 drive.
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 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.

FIGURE B.14

LOCATE COMPONENTS TO CONNECT TO THE FRONT OF MACHINE OPEN LATCH DOOR SLIDE CONNECTOR END HERE TERMINAL END (FITS ON STUD INSIDE SEE FIGURE BELOW) (4 PIN) LEAD CONNECTOR GUN AND CABLE WORK CLAMP ALL COMPONENTS SHOWN CONNECTED (FRONT AND SIDE DOOR IS REMOVED FOR CLARITY) TIGHTEN THUMB SCREW TO CONNECTOR BUSHING GAS LINE STRAIN RELIEF (4 PIN) TRIGGER RECEPTACLE PLUGGED IN SHORT POWER CABLE POSITIVE"+"" OUTPUT TERMINAL WORK CLAMP WORK LEAD CONNECTION NEGATIVE "-"" OUTPUT TERMINAL

D. LOAD WIRE SPOOL

(See Figure B.15)

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 prevent the wire from unspooling.

FIGURE B.15

PIVOT ARM ASSEMBLY BEARING OUTGOING GUIDE TENSION ARM ASSEMBLY WIRE SPOOL .025" (0.8mm) L-56 SOLID MIG WIRE INCOMING GUIDE DRIVE ROLL

(See Figure B.16)

1. Feed the wire through the incoming guide, over the drive roll groove, thru the outgoing guide and wire drive outlet on the gun side.
2. 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)

1. Remove the nozzle from the gun and contact tip and straighten the gun out flat.
2. Turn the machine power switch to on and press the gun trigger 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)
3. When trigger is released, the spool of wire should not unwind. Adjust wire spool brake accordingly.

WARNING

MOVING PARTS AND ELECTRICAL CONTACT CAN CAUSE INJURY OR BE FATAL.

• 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.

DO NOT REMOVE OR CONCEAL WARNING LABELS.

1. Install the .025"(0.6mm) contact tip.
2. Install the brass MIG welding nozzle to the gun.
3. Trim the wire stickout to 3/8"(9.5mm) from the nozzle end. (See Figure B.19)

4. Close the wire drive compartment door. The machine is now ready to weld.

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

6. 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.

FIGURE B.16

PIVOT ARM ASSEMBLY WITH BEARING PRESSING AGAINST DRIVE ROLL TENSION ARM ASSEMBLY LOCKED IN UP POSITION BEARING INCOMING GUIDE DRIVE ROLL OUTGOING GUIDE WIRE SPOOL .025" (0.6mm) L-56 Solid MIG WIRE DIRECTION OF WIRE SLIDE WIRE INTO GUN CONNECTOR SIDE

FIGURE B.17

removed NOZZLE removed CONTACT TIP LAYCABLE AND GUN STRAIGHTEN INTHS POSITION

FIGURE B.18

INPUT CORD ON/OFF SWITCH FEED WIRE APPROXIMATELY 4.00" FROM THE GUN TUBE END DEPRESS TRIGGER TO ACTIVATE WIRE, WHICH FEEDS THE WIRE TRAD THE LINDER. WIRE SPOL BRAKE WORK CLAMP AND CABLE ROTATION

FIGURE B.19

TRIM WIRE STICKOUT 3/8"(9.5mm) from the Brass Nozzle INSTALL .025 (0.6mm) CONTACT TIF INSTALL BRASS NOZZLE

SETTING UP AND MAKING A ALUMINUM WELD USING SPOOL GUN

(Aluminum Welding can only be used on 140 Amp machines.)

1. Loosen the THUMB SCREW and disconnect Magnum 100L Gun.
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 section.
5. Follow the MIG welding steps in the previous section.

FIGURE B.20

IMPORTANT PRESSURE SETTINGS AFFECT WELDING PERFORMANCE LES CADRES DE PRESSION AFFECTENT LE RESULTAT DE SOUDAGE FLUX CORE WIRES 1-3 SOLID WIRES 3-5 REFER TO OPERATOR'S MANUAL TO TROUBLESHOOT FEEDING. RÉFÈRE AU MANUEL DE L'OPÉRATEUR POUR DÉPANNER L'ALIMENTATION. MAGNUM® 100SO MAGNUM® 100L SPOL GUN FEATURE IS NOT AVAILABLE TO 325 AMP MACHINES. WARNING MOWING PARTS AND ELECTRICAL CONTACT CAN GAUGE INJURY ON BE FITAL. When can trigger to be disordered drive roll, press, export & instruction are ELECTRONICALLY LIVE (MOE). KEEP ANY FROM NOVING PARTS AND POUCH POINTS. AVERTISSEMENT LES PÉCES DE MOVEMENT ET EARTH ET ELECTRARE PERVE ET PARQUIER DES BLUESURES DU FERT ENTRATOLET. Pour un apprais sur la plateau, les temps d'entralement, fl, ballage, et l'effébride sur DOTS TOURIS, BARNES DES DISTANCES PAR PAPPIER ET PIECES DE MOVEMENT ET PAINTO PICTURE.

1. Turn machine on and make weld per recommended settings on Procedure Decal inside machine door.

FIGURE B.21 (Location of Selector Switch and Thumb Screw)

SWITCH NAGNUM 100SG NAGNUM 100L THUMB SCREW FOR CONNECTING THE MAGNUM 100L GUN OR MAGNUM 100SG SPOOL GUN.

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.

Black-and-white photo of a handheld optical instrument with a circular base and mechanical components, placed in an open case (no visible text or symbols)

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 repellent. Includes a convenient side pocket to hold welding gun.

Pink hard hat with a small cable attached, no visible text or symbols on the body.

For additional Optional and Miscellaneous Parts

(See Parts Pages)

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.

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.

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)

9/32" DRILL 2 PLACES 3-11/16" 4" 16" 3-13/32"

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.

Exterior view of a gray manual cart with handle and wheels (no text or symbols visible)

1/4"-20 X 1/2" Hex Head Cap Screw (2 Required) 1/4"-20 Flange Nut (2 Required)

SAFETY PRECAUTIONS

WARNING

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.

ROUTINE MAINTENANCE

POWER SOURCE COMPARTMENT

No user serviceable parts inside! Do not attempt to perform service 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 maintenance 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 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.

FAN MOTOR

Has lifetime lubrication — requires no maintenance.

WIRE REEL SPINDLE

Requires no maintenance. Do not lubricate shaft.

GUN AND CABLE MAINTENANCE

FOR MAGNUM™ 100L GUN

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.

CAUTION

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 "hunting" arc is a typical symptom of a worn contact 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 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 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 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, trigger and diffuser. Replace the 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.

1-1/4"(31.8 mm) Liner Trim Length Gas Diffuser Gas Nozzle or Gasless Nozzle 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 interchangeability 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 counterclockwise.
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 connector 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.
9. Replace the contact tip and nozzle.

GUN HANDLE PARTS

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 collars 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 locking rib. See Figure D.3.

FIGURE D.3 Counter-clockwise

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

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.

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 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.

CAUTION

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.

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS (SYMPTOMS)	POSSIBLE CAUSE	RECOMMENDED COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage is evident.	“Do not Plug in machine or turn it on”. Contact your local Authorized Field Service Facility.	If all recommended possible areas of misadjustment have been checked and the problem persists,Contact your local Lincoln Authorized Field Service Facility.
No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate.	1. Make sure correct voltage is applied to the machine.2. Make certain that power switch is in the ON position.3. Make sure circuit breaker is reset.
No wire feed, weld output or gas flow when gun trigger is pulled. Fan operates normally.	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.

PROBLEMS (SYMPTOMS)	POSSIBLE CAUSE	RECOMMENDED COURSE OF ACTION
FEEDING PROBLEMS
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.2. Check for clogged cable liner or contact tip.3. Check for proper size cable liner and contact tip.4. For 140Amp machine only:• Check Magnum 100SG/Magnum 100L switch is properly switched to activate proper gun.	If all recommended possible areas of misadjustment have been checked and the problem persists,Contact your local Lincoln Authorized Field Service Facility.

CAUTION

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.

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS (SYMPTOMS)	POSSIBLE CAUSE	RECOMMENDED COURSE OF ACTION
GAS FLOW PROBLEMS
Low or no gas flow when gun trigger is pulled. Wire feed, weld output and fan operate normally.	1. Check gas supply, flow regulator and gas hoses.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, Contact your local Lincoln Authorized Field Service Facility.

PROBLEMS (SYMPTOMS)	POSSIBLE CAUSE	RECOMMENDED COURSE OF ACTION
WELDING PROBLEMS
Arc is unstable – Poor starting	1. Check for correct input voltage to machine.2. Check for proper electrode polarity for process.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.)5. Check work cable for loose or faulty connections.6. Check gun for damage or breaks.7. Check for proper drive roll orientation and alignment.8. Check liner for proper size.	If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.

CAUTION

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.

WIRING DIAGRAM FOR CODE 11631, 11632, 11633, 11638, 11639

WARNING HIGH VOLTAGE can kill Do not operate with covers removed. Disconnect input power by unplugging power cord before servicing. Do not touch electrically live parts Only qualified persons should install, use or service this machine. CONTROL P.C. BOARD FAN B1 N.O. CR1 J3 J2 J6 B3 B4 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 4 3 302 303 304 306 308 309 3010 3011 202 204 205 500 501 WHITE CIRCUIT BREAKER X1 WIRE FEED MOTOR MAGNUM 100L TO GROUND PER NATIONAL ELECTRICAL CODE RECTIFIER ON/OFF SWITCH WORK X4 OUTPUT CHOKE R1 SELECTOR SWITCH N.A. N.D. X1 H5 Y2 H4 X3 H3 H2 H1 X4 T1 LOCATED IN TRANSFORMER TRANSFORMER N.D. THERMOSTAT THYROSTAT P2 P3 N.C. J6 4 5/6 7 8 9/10 11 12 LATCH ELECTRICAL SYMBOLS PER E1537 A.03 NOTES: N.A. BOLTED ALUMINUM CONNECTIONS REQUIRE E2529 JOINT COMPOUND (BURNDY PENETROX A13) WHEN REATTACHING. N.B. WORK AND GUN CONNECTIONS SHOWN FOR FCAW WELDING. N.C. CAVITY NUMBERING SEQUENCE VIEWED FROM INSERTION SIDE OF CONNECTORS. N.D. COMPONENT VIEWED FROM REAR.

M22477-1
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.

WIRING DIAGRAM FOR CODE 11634, 11635, 11636, 11637

WARNING HIGH VOLTAGE can kill Do not operate with covers removed. Disconnect input power by unplugging power cord before servicing. Do not touch electrically live parts Only qualified persons should install, use of service this machine. CONTROL P.C. BOARD FAN B1 N.O. CR1 B3 B4 J3 J2 J6 202 204 206 404 MAGNUM 100SG SPOOL GUN (OPTIONAL) MOTOR ETHER MAGNUM 100L PUSH GUN WHITE CIRCUIT BREAKER BLACK TO GROUND PER NATIONAL ELECTRICAL CODE. 500 501 N.D. S3 SPOOL GUN SWITCH X1 X4 RECTIFIER N.A. OUTPUT CHOKE WIRE FEED MOTOR 306 702 + N.B. S1 ON/OFF SWITCH N.D. 602 501 N.D. S2 SELECTOR SWITCH H4 H2 H3 H5 309 R1 N.D. 308 5K WIRE FEED SPEED POT CAPACITOR T1 LOCATED IN TRANSFORMER TRANSFORMER THERMOSTAT 302 303 P2 P3 N.C. 1 2 3 4 5/6 7 8 9/10 11 12 LATCH J6 4 5/6 6 4 3 2 1 0 3 A.04 NOTES: N.A. BOLTED ALUMINUM CONNECTIONS REQUIRE E2529 JOINT COMPOUND (BURNDY PENETROX A13) WHEN REATTACHING. N.B. WORK AND GUN CONNECTIONS SHOWN FOR GMAW WELDING. N.C. CAVITY NUMBERING SEQUENCE VIEWED FROM INSERTION SIDE OF CONNECTORS. N.D. COMPONENT VIEWED FROM REAR. ELECTRICAL SYMBOLS PER E1537

M22477
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.

WIRING DIAGRAM FOR CODE 12101, 12103, 12104, 12106

WARNING HIGH VOLTAGE can kill Do not operate with covers removed. Disconnect input power by unplugging power cord before servicing. Do not touch electrically live parts Only qualified persons should install, use or service this machine. CONTROL P.C. BOARD J1 J6 MAGNUM 100SG SPOOL GUN (OPTIONAL) MOTOR EITHER MAGNUM 100L PUSH GUN WHITE CIRCUIT BREAKER BLACK TO GROUND PER NATIONAL ELECTRICAL CODE. X1 X4 RECTIFIER N.A. OUTPUT CHoke WIRE FEED MOTOR 410 702 SPOOL GUN SWITCH S2 405 N.D. N.B. S1 ON/OFF SWITCH N.D. WORK 806 501 N.D. S2 SELECTOR SWITCH H4 H2 601 H3 H5 403 C1 R2 N.A. N.D. CAPACITOR 411 402 408 406 X1 X2 X3 T1 TRANSFORMER LOCATED IN TRANSFORMER THERMOSTAT 202 401 N.C. P2 P1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 ELECTRICAL SYMBOLS PER E1537 A.02

M24969
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.

WIRING DIAGRAM FOR CODE 12100, 12102, 12105, 12107

WARNING HIGH VOLTAGE can kill Do not operate with covers removed. Disconnect input power by unplugging power cord before servicing. Do not touch electrically live parts Only qualified persons should install, use or service this machine. CONTROL P.C. BOARD J1 CR1 J2 801 3 4 5 6 7 8 9 10 11 12 J6 202 412 MAGNUM 100L PUSH GUN WHITE CIRCUIT BREAKER BLACK TO GROUND PER NATIONAL ELECTRICAL CODE. X1 407 X4 RECTIFIER N.A. OUTPUT CHOKE WIRE FEED MOTOR 410 405 N.B. S1 ON/OFF SWITCH WORK N.D. 806 N.D. S2 SELECTOR SWITCH H4 H2 601 H3 H5 402 408 406 N.D. 5K WIRE FEED SPEED POT T1 TRANSFORMER THERMOSTAT LOCATED IN TRANSFORMER N.C. J6 P2 3 2 1 4 3 2 16 6 5 4 9 8 9 12 LATCH N.D. COMPONENT VIEWED FROM REAR. ELECTRICAL SYMBOLS PER E1537 A.02

M24970
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.

Manual del Operador

Line drawing of a Lincoln Electric welding machine (no text or symbols on the diagram itself)

11631, 11632, 11633, 11634,

11635, 11636, 11637, 11638,

11639, 12100, 12101, 12102,

12103, 12104, 12105, 12106,

12107, 12191, 12192

Registre su máquina:

www.lincolnelectric.com/register

Illustration of a person in protective gear using a tool to drive a red flame from a lamp (no text or symbols)

TRABAJE EN ZONAS VENTILADAS o

Line drawing of an industrial electronic device with cooling fans and buttons (no text or symbols)

Simple line drawing of a tool or device with a handle and spout (no text or symbols)

• Pistola de Soldadura Magnum 100L

Line drawing of a welding torch with curved bracing and clasp (no text or symbols)

RANURA DE .025 RANURA DE .035

Line drawing of a portable electronic device with buttons and ventilation grilles (no text or symbols)

Simple line drawing of a tool with a handle and spout (no text or symbols)

• Pistola de Soldadura Magnum 100L

Line drawing of a handheld welding torch with curved handle and flange (no text or symbols)

RANURA DE .025 RANURA DE .035

- Brass MIG Gun Nozzle for MIG welding

5c 5b 5a 5 4 7 6

Vea la Figura B.3

Technical diagram of a mechanical assembly with numbered components labeled 8 and 9

Vea la Figura B.4

Diagram of a gas cylinder connected to a device with labeled parts 12 and 13, showing wiring and components.

Diagram of a welding torch with attached steel bar (no text or symbols)

L-56 MIG WIRE

1. Tobera Metálica de Pistola

1. Pistola de soldadur

Line drawing of a welding torch with curved handle and flange (no text or symbols)

Simple line drawing of a pliers with a curved handle and circular end (no text or symbols)

Technical line drawing of two mechanical components: a coiled pipe and a multi-cylinder valve assembly (no text or symbols)

Open hard-shell mechanical device with a cylindrical tool and two circular components (no visible text or symbols)

Pink plastic box with a black cable attached, no visible text or symbols on the object itself.

Mechanical cart with handle and wheels (no visible text or symbols)

Tornillo de Cabeza Hexagonal de 1/4"-20 X 1/2" (Se requieren 2) Tuerca de pestaña de 1/4"-20 (Se requieren 2)

MANTENIMIENTO

Paso 2. CAUSA POSIBLE.

Observe all Safety Guidelines detailed throughout this manual

Observe all Safety Guidelines detailed throughout this manual

Line drawing of a Lincoln Electric welding machine (no text or symbols on the diagram itself)

11631, 11632, 11633, 11634,

11635, 11636, 11637, 11638,

11639, 12100, 12101, 12102,

12103, 12104, 12105, 12106,

12107, 12191, 12192

Illustration of a person in protective gear using a welding torch to drive red light (no text or symbols)

DANS UNE GRANDE PIÈCE OU À L'EXTÉRIEUR, la

Silhouette of a person wearing a helmet and holding a tool, no text or symbols present

PORTER UNE PROTECTION CORRECTE DES YEUX, DES OREILLES ET DU CORPS

Installation .... Section A

Wire Feed Compartment, Fan Motor,

Wire Reel Maintenance ....D-1

Entretien Du Pistolet Et Des Câbles .....D-2

Protection Contre Les Surcharges .....D-2

Component Replacement Procedures .....D-2

Dépannage .... Section E

DESCRIPTION DU PRODUIT (CAPACITÉS DU PRODUIT)

Installation .... Section A

Wire Feed Compartment, Fan Motor,

Wire Reel Maintenance .....D-1

Entretien Du Pistolet Et Des Câbles .....D-2

Protection Contre Les Surcharges .....D-2

Component Replacement Procedures .....D-2

Dépannage ....Section E

Line drawing of a portable electronic device with buttons and ventilation grilles (no text or symbols)

Simple line drawing of a tool or device with a handle and spout (no text or symbols)

Line drawing of a welding torch with curved bracing and handle (no text or symbols)

Line drawing of an electrical device with buttons and a label (no readable text or symbols beyond branding)

Simple line drawing of a pair of scissors with a handle and spout (no text or symbols)

.035 .035 .025 .025 .025

- Bobine de 0,035"(0.9mm) de diamètre NR-211MP Fil Fourré Innershield

- Bobine de 0,025"(0.6mm) de diamètre Fil MIG Super Arc L-56

5c 5b 5a 5 4 7 6

Voir la Figure B.3

Technical diagram of a mechanical assembly with numbered components labeled 8 and 9

Voir la Figure B.4

Diagram of a welding torch with curved handle and clamped end (no text or symbols)

L-56 MIG WIRE

1. Bec de Pistolet en Laiton

1. Pistolet à Souder

Line drawing of a flexible welding torch with curved bracing (no text or symbols)

Simple line drawing of a pliers or tool with a curved handle and circular head (no text or symbols)

Technical line drawing of two mechanical components: a coiled pipe and a multi-cylinder pump assembly (no text or symbols)

(Only available on 140 Models K2480-1, K2514-1, K2658-1 and K2697-1).

Black-and-white photo of a mechanical device with a cylindrical component and two circular parts, placed in an open case (no visible text or symbols)

K2377-1 - Petite Housse en Toile

Pink hard hat with label 'TROPOL AIRL' and a cable, no visible text or symbols on the object itself.

Exterior view of a gray manual cart with handle and wheels (no text or symbols visible)

Vis Borgne à Tête Hexagonale 1/4"-20 x 1/2" (2 requises) Ecrou à Brides 1/4"-20 (2 requises)

ENTRETIEN

MESURES DE SÉCURITÉ

AVERTISSEMENT

Index of Sub Assemblies

KEY PART NUMBER DESCRIPTION QTY
	P-653-A Index of Sub Assemblies AR
	P-653-B.2 Miscellaneous Items AR
1 P-653-C Case Front Assembly AR
2 P-653-D Center Panel Assembly & Control P.C. Boa AR
3 P-653-E Case Back & Bottom Asbly AR
4 P-653-F Wraparound & Door Assembly AR

Index of Sub Assemblies

Exploded view diagram of a device showing exploded views and labeled components for assembly or maintenance.

P-653-A.jpg

Miscellaneous Items

KEY PART NUMBER DESCRIPTION QTY
	9SS11609-29 GROUND LEAD 1
	9SM12033 GROUND CLAMP ASBLY 1
	9SM15445-1 WIRE REEL SPINDLE 1
	9SS26375 INSTRUCTION DVD 1
	K530-6 MAGNUM 100L 10FT 025-035 W/4 PIN TRIGGER 1

Miscellaneous Items

NO IMAGE AVAILABLE

No Image

Case Front Assembly

KEY PART NUMBER DESCRIPTION QTY
1A 9SG48	12-2 CASE FRONT 1
1B 9SS92	25-63 THREAD FORMING SCREW (CUTTING) 4
2A 9SL12	395-22 NAMEPLATE 1
3 9SS18	425-1 KNOB 2
4A 9ST96	95-5 LOCKWASHER 2
4B 9ST10	940-10 3/8-32HJN 2
5A 9SM22	433 SWITCH	1
5B 9SS92	62-12 PLAIN WASHER	1
	9ST9695-5 LOCKWASHER 1
	9ST10940-10 3/8-32HJN 1
6 9ST10	800-59 SWITCH	1
	9SL16471	HARNESS (125A)	1
7A 9SS18	657 SQUARE FLANGE FEMALE RECEPTACLE	1
7B 9ST10	812-109 POT-ST0.75W5K10%LINEAR	1
7C 9SS80	25-96 SELF TAPPING SCREW	2
10	9SS8025-101	SELF TAPPING SCREW	1

Case Front Assembly

Technical diagram of a device with labeled components, including parts 1A through 7C and numbered parts 1B to 7B.

P-653-C.jpg

Center Panel Assembly & Control P.C. Board

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
2B 9SL12537-3 WIRE DRIVE FINAL ASBLY 1
2Ba KP2948-1 .025/.035 DRIVE ROLL KIT W/KEY 1
2Bb KP3199-1 WIRE GUIDE KIT 1
2Bc	9SL12537-3G	Thumb Screw	1
2Bd 9SL12537-3N Retaining Knob 1
	9SL12537-3U	Key	1
2C 9SS25937 OUTPUT STUD 2
2D 9SCF000014 1/4-20X.75HHCS 2
2E 9SS9262-98 PLAIN WASHER 4
	9SE106A-2	LOCKWASHER	2
	9SCF000017	1/4-20HN	2
3 9SS8025-92 SELF TAPPING SCREW 4
4 9SS19300-9 PC BOARD STANDOFF 2
4 9SS14020-10 PLASTIC EXPANSION NUT 4
5 9ST10781-10 BOW WASHER 1
6 9SS18423-1 BRAKE PLATE 1
7 9SS24227-1 SPINDLE SHAFT 1
8 9SS24226 SPINDLE SPACER 1
9 9ST9968-5 WING NUT 1
10	9SS9262-120	PLAIN WASHER	1
11	9SE106A-16	LOCKWASHER	1
12	9SCF000018	3/8-16X.625HHCS	1
	9SS8025-92	SELF TAPPING SCREW	5
17	9SL16253-1 125A CONTROL PC BD ASBLY 1
	9SS8025-76	SELF TAPPING SCREW	2
18	9ST13086-211	WARNING INFO DECAL	1
19	9ST9968-6	WING NUT	2
20	9ST10800-59	SWITCH	1

Center Panel Assembly & Control P.C. Board

Technical diagram of a mechanical assembly with numbered components and labeled parts (A-E)

P-653-D.jpg

Case Back & Bottom Asbly

KEY PART NUMBER DESCRIPTION QTY
1 9SG6874 CASE BACK & BOTTOM 1
2A 9SS18977-12 FAN 1
2B 9SS9225-94 THREAD FORMING SCREW 4
4A 9SL15734-2 125A TRANS./CHOKE ASBLY 1
	9SS9225-94 THREAD FORMING SCREW 4
	9SE106A-1 LOCKWASHER 4
5A 9SL15838 RECTIFIER		1
5B 9SS22168	HEAT SINK HOLDER	2
	9SCF000015	1/4-20X1.00HHCS	2
	9SE106A-2 LOCKWASHER 2
	9SS9262-98 PLAIN WASHER	4
	9SCF000017	1/4-20HN	2
6 9ST12287-40	CIRCUIT BREAKER-25A250VAC32VDC	1
7A 9ST10397-23	PLUG BUTTON 1
	9SS15254-26 INPUT CORD	1
8B 9ST9274-13	GROMMET	1
	9SS26499-1 RATING PLATE	1

Case Back & Bottom Asbly

Exploded view diagram of an electronic device with labeled components from 1 to 11A

P-653-E.jpg

Wraparound & Door Assembly

KEY PART NUMBER DESCRIPTION QTY
	9SM20452-5 SIDE & DOOR ASBLY 1
1A 9SL12320-1 DOOR 1
1B 9SG6875 CASE SIDE 1
1C 9SS25898-1 HINGE (DOOR) 2
1D 9SS8025-92 SELF TAPPING SCREW 4
1E 9SL12602 HANDLE 1
1F 9SS9225-53 THREAD FORMING SCREW		1
1G	9SM16196	DECAL-WARNING	1
1H 9SS27368-2 DECAL - 7IN LINCOLN LOGO		2
1J	9SS27370-2 NASCAR LOGO		1
1K 9SS21033	DOOR LATCH		1
2	9SS8025-92 SELF TAPPING SCREW 9
	9SM24970	Wiring Diagram	1
10	9SL12603-9 PROCEDURE	DECAL	1

Wraparound & Door Assembly

1E 1D 2 1G 1C 1B 1F 1A 10 LINCOLN ELECTRIC 1H 1J 1K

P-653-F.jpg

Magnum Pro 100L - K3080-1

General Assembly

KEY PART NUMBER DESCRIPTION QTY
	K3080-1 MAGNUM PRO 100L 10' 1
1 9SM16318-2 CABLE ASSEMBLY 1
2 9SG2209 GUN HANDLE SET 1
3 9SS19725 TRIGGER ASBLY 1
4 KP2744-035T TAPERED CONTACT TIP 350A .035 1
5 9SS19580 HEX LOCKING NUT 7/16-20 1
6 KP3082-60 MAGNUM PRO 100L 60 DEG. GUN TUBE 1
7 9SS19701 COLLAR		2
8 KP3075-1-50F NOZZLE PRO 100L THREAD-ON FLUSH .5 ID 1
10	KP3076-1	MAGNUM PRO 100L GAS DIFFUSER	1
11	KP45-40-15	LINER 035 - 045 MAG 100L	1

General Assembly

Technical diagram of a mechanical device with numbered components for identification

P-202-AJ_1.jpg

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WARNING	Do not touch electrically live parts or electrode with skin or wet clothingInsulate yourself from work and ground.	Keep flammable materials away.	Wear eye, ear and body protection.
SpanishAVISO DE PRECAUCION	No toque las partes o los electrodos bajo carga con la piel o ropa moja-da.Aislese del trabajo y de la tierra.	Mantenga el material combustible fuera del área de trabajo.	Protéjase los ojos, los oídos y el cuerpo.
FrenchATTENTION	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.	Gardez à l'écart de tout matériel inflammable.	Protégez vos yeux, vos oreilles et votre corps.
GermanWARNUNG	Berühren Sie keine stromführenden Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!Isolieren Sie sich von den Elektroden und dem Erdboden!	Entfernen Sie brennbarres Material!	Tragen Sie Augen-, Ohren- und Kör-perschutz!
PortugueseATENÇÃO	Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.Isole-se da peça e terra.	Mantenha inflamáveis bem guarda-dos.	Use proteção para a vista, ouvido e corpo.
Japanese注意事項	通電中の電気部品、又は溶材にヒフやぬれた布で触れないこと。施工物やアースから身体が絶縁されている様にして下さい。	燃えやすいものの側での溶接作業は絶対にしてはなりません。	目、耳及び身体に保護具をして下さい。
Chinese警告	皮肤或漏衣物切勿接觸帶電部件及錚條。使你自己與地面和工件絶縁。	把一切易燃物品移離工作場所。	佩戴眼、耳及身體勞動保護用具。
Korean위험	전도체나 용접봉을 젖은 형 cup 또는 피부로 질대 접촉치 마십시오 모재와 접지를 접촉치 마십시오.	인화성 물질을 접근 시키지 마시요.	눈, 귀와 몇에 보호장구를 착용하십시오.
Arabicتحذير	لا تلمس الاجزاء التي يسري فيها التياراكهربائي أو الالكترود بجلد الجسم او بالملابس المبلقة بالமاء.• ضع عازلا على جسمك خلال العمل.	ضع #: √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∞ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∦ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∨ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∪ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∮ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∭ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∤ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∥ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∶ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∯ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∫ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∟ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∧ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∩ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∸ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∜ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∎ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∠ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∑ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∢ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∡ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∞ √ √ √ √ √ √ √ √ √ √ √ √ √ ∞ √ √ √ √ √ √ √ √ √ √ ∞ √ √ √ √ √ √ √ ∞ √ √ √ √ √ √ ∞ ∞ √ √ √ √ √ √ ∞ ∞ √ √ √ √ √ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∩ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ∞ √ √ √ √ √ √ √ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∞ ∩ √ √ √ √ ∞√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√√

READ AND UNDERSTAND THE MANUFACTURER'S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER'S SAFETY PRACTICES.

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.

POLITIQUE D'ASSISTANCE AU CLIENT