Lincoln Electric POWER MIG 140, POWER MIG 180 User Manual

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IM890-A

POWER MIG (140, 180 MODELS)	May, 2007
For use with machines having Code Numbers: 11254, 11255, 11256, 11257 and
11444

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.

LINCOLN ELECTRIC

OPERATOR’S MANUAL

Copyright © 2007 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

i

SAFETY

i

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents

The engine exhaust from this product contains

are known to the State of California to cause can-

chemicals known to the State of California to cause

cer, birth defects, and other reproductive harm.

cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines

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

1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is

powered equipment.

hot.

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.

ELECTRIC AND

MAGNETIC FIELDS

____________________________________________________

may be dangerous

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

2.a. Electric current flowing through any conductor causes

refueling to prevent spilled fuel from vaporiz-

localized Electric and Magnetic Fields (EMF). Welding

ing on contact with hot engine parts and

current creates EMF fields around welding cables and

igniting. Do not spill fuel when filling tank. If

welding machines

fuel is spilled, wipe it up and do not start

engine until fumes have been eliminated.

2.b. EMF fields may interfere with some pacemakers, and

____________________________________________________

welders having a pacemaker should consult their physician

1.d. Keep all equipment safety guards, covers and devices in

before welding.

position and in good repair.Keep hands, hair, clothing and

tools away from V-belts, gears, fans and all other moving

2.c. Exposure to EMF fields in welding may have other health

parts when starting, operating or repairing equipment.

effects which are now not known.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

guards to perform required maintenance. Remove

guards only when necessary and replace them when the

2.d.1. Route the electrode and work cables together - Secure

maintenance requiring their removal is complete.

Always use the greatest care when working near moving

them with tape when possible.

parts.

2.d.2. Never coil the electrode lead around your body.

___________________________________________________

1.f. Do not put your hands near the engine fan.

2.d.3. Do not place your body between the electrode and

Do not attempt to override the governor or

idler by pushing on the throttle control rods

work cables. If the electrode cable is on your right

while the engine is running.

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.

1.g. To prevent accidentally starting gasoline engines while

2.d.5. Do not work next to welding power source.

turning the engine or welding generator during maintenance

work, disconnect the spark plug wires, distributor cap or

Mar ʻ95

magneto wire as appropriate.

ii

SAFETY

ii

ELECTRIC SHOCK can

ARC RAYS can burn.

kill.

plates to protect your eyes from sparks and

4.a. Use a shield with the proper filter and cover

3.a. The electrode and work (or ground) circuits

the rays of the arc when welding or observing

are electrically “hot” when the welder is on.

open arc welding. Headshield and filter lens

Do not touch these “hot” parts with your bare

should conform to ANSI Z87. I standards.

skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

4.b. Use suitable clothing made from durable flame-resistant

3.b. Insulate yourself from work and ground using dry insulation.

material to protect your skin and that of your helpers from

the arc rays.

Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

4.c. Protect other nearby personnel with suitable, non-flammable

In addition to the normal safety precautions, if welding

screening and/or warn them not to watch the arc nor expose

themselves to the arc rays or to hot spatter or metal.

must be performed under electrically hazardous

FUMES AND GASES

scaffolds; when in cramped positions such as sitting,

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

can be dangerous.

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

5.a. Welding may produce fumes and gases

the following equipment:

hazardous to health. Avoid breathing these

• Semiautomatic DC Constant Voltage (Wire) Welder.

fumes and gases. When welding, keep

• DC Manual (Stick) Welder.

your head out of the fume. Use enough

• AC Welder with Reduced Voltage Control.

ventilation and/or exhaust at the arc to keep

3.c. In semiautomatic or automatic wire welding, the electrode,

fumes and gases away from the breathing zone.

When

welding with electrodes which require special

electrode reel, welding head, nozzle or semiautomatic

ventilation such as stainless or hard facing (see

welding gun are also electrically “hot”.

instructions on container or MSDS) or on lead or

3.d. Always be sure the work cable makes a good electrical

cadmium plated steel and other metals or coatings

which produce highly toxic fumes, keep exposure as

connection with the metal being welded. The connection

low as possible and below Threshold Limit Values (TLV)

should be as close as possible to the area being welded.

using local exhaust or mechanical ventilation. In

3.e. Ground the work or metal to be welded to a good electrical

confined spaces or in some circumstances, outdoors, a

respirator may be required. Additional precautions are

(earth) ground.

also required when welding on galvanized steel.

3.f.

Maintain the electrode holder, work clamp, welding cable and

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

welding machine in good, safe operating condition. Replace

by various factors including proper use and positioning of

damaged insulation.

the equipment, maintenance of the equipment and the spe-

cific welding procedure and application involved. Worker

3.g. Never dip the electrode in water for cooling.

exposure level should be checked upon installation and

periodically thereafter to be certain it is within applicable

3.h. Never simultaneously touch electrically “hot” parts of

OSHA PEL and ACGIH TLV limits.

electrode holders connected to two welders because voltage

5.c. Do not weld in locations near chlorinated hydrocarbon vapors

between the two can be the total of the open circuit voltage

of both welders.

coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors to

3.i. When working above floor level, use a safety belt to protect

form phosgene, a highly toxic gas, and other irritating prod-

yourself from a fall should you get a shock.

ucts.

3.j.

Also see Items 6.c. and 8.

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 manufacturerʼs instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employerʼs safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

AUG 06

	iii	SAFETY		iii
		WELDING and CUTTING		CYLINDER may explode
		SPARKS can		if damaged.
		cause fire or explosion.		7.a. Use only compressed gas cylinders
		6.a. Remove fire hazards from the welding area.		containing the correct shielding gas for the
		If this is not possible, cover them to prevent		process used and properly operating
		the welding sparks from starting a fire.		regulators designed for the gas and
		Remember that welding sparks and hot		pressure used. All hoses, fittings, etc. should be suitable for
		materials from welding can easily go through small cracks		the application and maintained in good condition.
		and openings to adjacent areas. Avoid welding near
		hydraulic lines. Have a fire extinguisher readily available.	7.b. Always keep cylinders in an upright position securely
	6.b. Where compressed gases are to be used at the job site,			chained to an undercarriage or fixed support.
		special precautions should be used to prevent hazardous	7.c. Cylinders should be located:
		situations. Refer to “Safety in Welding and Cutting” (ANSI		• Away from areas where they may be struck or subjected to
		Standard Z49.1) and the operating information for the		physical damage.
		equipment being used.		• A safe distance from arc welding or cutting operations and
	6.c. When not welding, make certain no part of the electrode
				any other source of heat, sparks, or flame.
		circuit is touching the work or ground. Accidental contact
		can cause overheating and create a fire hazard.	7.d. Never allow the electrode, electrode holder or any other
	6.d. Do not heat, cut or weld tanks, drums or containers until the			electrically “hot” parts to touch a cylinder.
		proper steps have been taken to insure that such procedures	7.e. Keep your head and face away from the cylinder valve outlet
		will not cause flammable or toxic vapors from substances		when opening the cylinder valve.
		inside. They can cause an explosion even though they have
		been “cleaned”. For information, purchase “Recommended	7.f. Valve protection caps should always be in place and hand
		Safe Practices for the Preparation for Welding and Cutting of		tight except when the cylinder is in use or connected for
		Containers and Piping That Have Held Hazardous		use.
		Substances”, AWS F4.1 from the American Welding Society
		(see address above).	7.g. Read and follow the instructions on compressed gas
	6.e. Vent hollow castings or containers before heating, cutting or			cylinders, associated equipment, and CGA publication P-l,
				“Precautions for Safe Handling of Compressed Gases in
		welding. They may explode.		Cylinders,” available from the Compressed Gas Association
	6.f.	Sparks and spatter are thrown from the welding arc. Wear oil		1235 Jefferson Davis Highway, Arlington, VA 22202.
				FOR ELECTRICALLY
		ear plugs when welding out of position or in confined places.
		free protective garments such as leather gloves, heavy shirt,
		cuffless trousers, high shoes and a cap over your hair. Wear		powered equipment.
		Always wear safety glasses with side shields when in a
		welding area.		8.a. Turn off input power using the disconnect
	6.g. Connect the work cable to the work as close to the welding
				switch at the fuse box before working on
		area as practical. Work cables connected to the building		the equipment.
		framework or other locations away from the welding area	8.b. Install equipment in accordance with the U.S. National
		increase the possibility of the welding current passing
		through lifting chains, crane cables or other alternate cir-		Electrical Code, all local codes and the manufacturerʼs
		cuits. This can create fire hazards or overheat lifting chains		recommendations.
		or cables until they fail.	8.c. Ground the equipment in accordance with the U.S. National
	6.h. Also see item 1.c.
				Electrical Code and the manufacturerʼs recommendations.
	6.I. Read and follow NFPA 51B “ Standard for Fire Prevention		Jan, 07
		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.

iv		SAFETY						iv
	PRÉCAUTIONS DE SÛRETÉ					5.	Toujours porter des lunettes de sécurité dans la zone de
							soudage. Utiliser des lunettes avec écrans lateraux dans les
Pour votre propre protection lire et observer toutes les instructions							zones où lʼon pique le laitier.
et les précautions de sûreté specifiques qui parraissent dans ce						6.	Eloigner les matériaux inflammables ou les recouvrir afin de
manuel aussi bien que les précautions de sûreté générales suiv-
antes:							prévenir tout risque dʼincendie dû aux étincelles.
Sûreté Pour Soudage A LʼArc						7.	Quand on ne soude pas, poser la pince à une endroit isolé de
	1. Protegez-vous contre la secousse électrique:						la masse. Un court-circuit accidental peut provoquer un
							échauffement et un risque dʼincendie.
	a. Les circuits à lʼélectrode et à la piéce sont sous tension					8.	Sʼassurer que la masse est connectée le plus prés possible
	quand la machine à souder est en marche. Eviter toujours
	tout contact entre les parties sous tension et la peau nue						de la zone de travail quʼil est pratique de le faire. Si on place
	ou les vétements mouillés. Porter des gants secs et sans						la masse sur la charpente de la construction ou dʼautres
	trous pour isoler les mains.						endroits éloignés de la zone de travail, on augmente le risque
	b. Faire trés attention de bien sʼisoler de la masse quand on						de voir passer le courant de soudage par les chaines de lev-
	soude dans des endroits humides, ou sur un plancher						age, câbles de grue, ou autres circuits. Cela peut provoquer
	metallique ou des grilles metalliques, principalement dans						des risques dʼincendie ou dʼechauffement des chaines et des
	les positions assis ou couché pour lesquelles une grande						câbles jusquʼà ce quʼils se rompent.
	partie du corps peut être en contact avec la masse.					9.	Assurer une ventilation suffisante dans la zone de soudage.
	c. Maintenir le porte-électrode, la pince de masse, le câble
	de soudage et la machine à souder en bon et sûr état						Ceci est particuliérement important pour le soudage de tôles
	defonctionnement.						galvanisées plombées, ou cadmiées ou tout autre métal qui
	d.Ne jamais plonger le porte-électrode dans lʼeau pour le						produit des fumeés toxiques.
	refroidir.					10. Ne pas souder en présence de vapeurs de chlore provenant
	e. Ne jamais toucher simultanément les parties sous tension
	des porte-électrodes connectés à deux machines à souder						dʼopérations de dégraissage, nettoyage ou pistolage. La
	parce que la tension entre les deux pinces peut être le						chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
	total de la tension à vide des deux machines.						du solvant pour produire du phosgéne (gas fortement toxique)
	f. Si on utilise la machine à souder comme une source de						ou autres produits irritants.
	courant pour soudage semi-automatique, ces precautions					11. Pour obtenir de plus amples renseignements sur la sûreté,
	pour le porte-électrode sʼapplicuent aussi au pistolet de
	soudage.						voir le code “Code for safety in welding and cutting” CSA
							Standard W 117.2-1974.
	2. Dans le cas de travail au dessus du niveau du sol, se protéger
	contre les chutes dans le cas ou on recoit un choc. Ne jamais
	enrouler le câble-électrode autour de nʼimporte quelle partie					PRÉCAUTIONS DE SÛRETÉ POUR
	du corps.
	3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,					LES MACHINES À SOUDER À
	donc:					TRANSFORMATEUR ET À
	a. Utiliser un bon masque avec un verre filtrant approprié					REDRESSEUR
	ainsi quʼun verre blanc afin de se protéger les yeux du ray-
	onnement de lʼarc et des projections quand on soude ou
	quand on regarde lʼarc.					1.	Relier à la terre le chassis du poste conformement au code de
	b. Porter des vêtements convenables afin de protéger la						lʼélectricité et aux recommendations du fabricant. Le dispositif
	peau de soudeur et des aides contre le rayonnement de						de montage ou la piece à souder doit être branché à une
	lʻarc.						bonne mise à la terre.
	c. Protéger lʼautre personnel travaillant à proximité au
	soudage à lʼaide dʼécrans appropriés et non-inflammables.					2.	Autant que possible, Iʼinstallation et lʼentretien du poste seront
	4. Des gouttes de laitier en fusion sont émises de lʼarc de						effectués par un électricien qualifié.
	soudage. Se protéger avec des vêtements de protection libres					3.	Avant de faires des travaux à lʼinterieur de poste, la debranch-
	de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-						er à lʼinterrupteur à la boite de fusibles.
	talons sans revers, et chaussures montantes.					4.	Garder tous les couvercles et dispositifs de sûreté à leur
							place.
							Mar. ʻ93

v	INSTALLATION					v

EN 60974-10

POWER MIG (140, 180 MODELS)

vi	INSTALLATION					vi

EN 60974-10:

POWER MIG (140, 180 MODELS)

vii

Thank You

QUALITY vii for selecting a product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

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 customerʼs particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

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

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

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

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

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

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

On-Line Product Registration

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

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then “Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WARNING

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

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

viii	TABLE OF CONTENTS	viii
		Page
	––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
	Installation .......................................................................................................	Section A
	Technical Specifications.................................................................................	A-1, A-2
	Safety Precautions.................................................................................................	A-3
	Location...........................................................................................................	A-3
	Stacking ..........................................................................................................	A-3
	Tilting...............................................................................................................	A-3
	Identify and Locate Components...........................................................................	A-4
	________________________________________________________________________________
	Operation .........................................................................................................	Section B
	Safety and Product Description .............................................................................	B-1
	Controls and Settings.....................................................................................	B-2, B-3
	Drive Roll and Wire Guides Table .........................................................................	B-4
	Setting Up and Making a Flux-Cored Weld.............................................	B-5 thru B-7
	Setting Up and Making a MIG Weld and Install Shielding Gas..............	B-8 thru B-11
	Setting Up and Making a Aluminum Weld ...........................................................	B-12
	________________________________________________________________________
	Accessories .....................................................................................................	Section C
	Optional Accessories.............................................................................................	C-1
	Utility Carts ....................................................................................................	C-2, C-3
	________________________________________________________________________
	Maintenance..............................................................................................	Section D
	Safety Precautions ................................................................................................	D-1
	Wire Feed Compartment, Fan Motor, Wire Reel Maintenance .............................	D-1
	Gun And Cable Maintenance ................................................................................	D-2
	Overload Protection...............................................................................................	D-2
	Component Replacement Procedures ..................................................................	D-3
	________________________________________________________________________
	Troubleshooting ..............................................................................................	Section E
	Safety Precautions.................................................................................................	E-1
	How to Use Troubleshooting Guide.......................................................................	E-1
	Troubleshooting Guide.............................................................................	E-2 thru E-4
	________________________________________________________________________
	Wiring Diagram and Dimension Print ............................................................	Section F
	________________________________________________________________________
	Parts Lists................................................................................................	P-533, P-202-E
	________________________________________________________________________

INSTALLATION

A-1

A-1

TECHNICAL SPECIFICATIONS

180 Amp units (K2472-1 180T, K2473-1 180C)

Standard Voltage/Frequency

Input Current

230 V

60 Hz

20 Amps @ rated output

208 V

60 Hz

20 Amps @ rated output

RATED OUTPUT

Voltage/Duty

Cycle

Current

Voltage at Rated Amperes

230 V

30%

130 Amps

20

208 V

30%

130 Amps

17

OUTPUT

Welding Current Range

Open Circuit Voltage

Wire Speed Range

30-180 Amps

34 V

50 - 500 in/min.

(1.3 - 12.7 m/min.)

RECOMMENDED INPUT CABLE AND FUSE SIZES

Input Voltage/Frequency

Fuse or Breaker Size1

Input Amps

Power Cord

230 V

60 Hz

40 Amp Super Lag

20

50 Amp, 250 V,

Three Prong Plug

(NEMA Type 6-50P)

PHYSICAL DIMENSIONS

Height

Width

Depth

Weight

14.0 in

10.15 in

18.6 in

66 Ibs

357 mm

258 mm

472 mm

30 kg

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

140 Amp units

(K2470-1 140T, K2471-1 140C)

Standard Voltage/Frequency

Input Current

120 V / 60 Hz

20 Amps @ rated output

RATED OUTPUT

Duty Cycle

Current

Voltage at Rated Amperes

20% Duty Cycle

90 Amps

19.5

OUTPUT

Welding Current Range

Open Circuit Voltage

Wire Speed Range

30-140 Amps

33 V

50 - 500 in/min.

(1.3 - 12.7 m/min.)

RECOMMENDED

INPUT CABLE AND FUSE

SIZES

Input Voltage/Frequency

Fuse or Breaker Size1,2

Input Amps

Power Cord

Extension Cord

120 V

60 Hz

20 Amp

20

15 Amp, 125 V,

3 Conductor # 12 AWG

Three Prong Plug

(4mm2) or Larger

(NEMA Type 5-15P)

up to 50 ft.(15.2m)

PHYSICAL DIMENSIONS

Height

Width

Depth

Weight

14.0 in

10.15 in

18.6 in

58 Ibs

357 mm

258 mm

472 mm

26.3 kg

1If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.

POWER MIG (140, 180 MODELS)

INSTALLATION

A-2

A-2

TECHNICAL SPECIFICATIONS

180 Amp units (K2668-1 180C)

Standard Voltage/Frequency

Input Current

240 V

50 Hz

I1 max 20 Amps

I1 eff 10.7 Amps

RATED OUTPUT

Voltage/Duty Cycle

Current

Voltage at Rated Amperes

240 V

25%

130 Amps

20

OUTPUT

Welding Current Range

Open Circuit Voltage

Wire Speed Range

30 - 180 Amps

34 V

50 - 500 in/min.

1.3 - 12.7 ( m/min.)

RECOMMENDED INPUT CABLE AND FUSE SIZES

Input Voltage/Frequency

Fuse or Breaker Size1

Input Amps

Power Cord

240 V 50 Hz

40 Amp Super Lag

20

15 Amp, 240 V,

Three Pin Plug

PHYSICAL DIMENSIONS

Height

Width

Depth

Weight

14.0 in

10.15 in

18.6 in

66 Ibs

357 mm

258 mm

472 mm

30 kg

1

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

2

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.

POWER MIG (140, 180 MODELS)

		INSTALLATION		A-3
A-3
	Read entire installation section before starting
	installation.
	SAFETY PRECAUTIONS
		WARNING
		ELECTRIC SHOCK can kill.
		• Only qualified personnel should perform
		this installation.
		• Only personnel that have read and under-
		stood the POWER MIG Operating Manual
		should install and operate this equipment.
		• Machine must be plugged into a receptacle
		which is grounded per any national, local
		or other applicable electrical codes.
		• The POWER MIG power switch is to be in
		the OFF (“O”) position when installing
		work cable and gun and when connecting
		power cord to input power.
	SELECT SUITABLE LOCATION
	Locate the welder in a dry location where there is free
	circulation of clean air into the louvers in the back and
	out the front of the unit. A location that minimizes the
	amount of smoke and dirt drawn into the rear louvers
	reduces the chance of dirt accumulation that can
	block air passages and cause overheating.
	STACKING
	POWER MIG (140, 180 MODELS) cannot be stacked.
	TILTING
	Each machine must be placed on a secure, level sur-
	face, directly or on recommended cart. The machine
	may topple over if this procedure is not followed.

POWER MIG (140, 180 MODELS)

A-4	INSTALLATION		A-4
IDENTIFY AND LOCATE COMPONENTS		• .030” -.045” (0.8 - 1.1mm) Knurled Drive Roll
INCLUDED COMPONENTS		(Installed on Machine)
• Wire Feeder Welder.		030
		.
		045
		.

•Work Cable & Clamp.

•Magnum 100L Welding Gun.

•.025” -.035” (0.6 - 0.9mm) Inner Wire guide

•.035” -.045” (0.9 - 1.1mm) Inner Wire Guide (Installed on Machine)

•Outer Wire Guide (Installed on Machine)

.025-.035 (.6-.9mm)	INNER WIRE GUIDE	OUTER WIRE GUIDE
	.035-.045 (.9-1.1mm)

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

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

• 3 .025” (0.6mm) Contact Tips.

.035 .035

.025

.025

.025

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

• Spool of .025” (0.6 mm) diameter L-56 MIG Wire.

MP	L-
	56 MIG
NR-211
	WIRE

• .025”-.030” (0.6 - 0.8mm)	• .035” (0.9mm)
Smooth Drive Roll	Smooth Drive Roll

•Brass MIG Gas Gun Nozzle

•2”(51mm) Spindle Adapter (For 8”(203mm) Reel of wire)

•Regulator

•Gas Hose

•Learn to Weld (LTW1 Manual)

•DVD

REGULATOR

2" SPINDLE ADAPTER (FOR 8" REEL OFWIRE)

GAS HOSE

LTW1

"LEARNTOWELD"

DVD

POWER MIG (140, 180 MODELS)