Lincoln Electric 125, 11631, 11634, 11635, 140 Operator's Manual

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Page 1

Operator’s Manual

WIRE FEEDER WELDERS (125, 140 MODELS)

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Authorized Service and Distributor Locator:

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IM10049-A | Issue D ate Mar- 14

For use with machines having Code Numbers:

11631, 11632, 11633, 11634, 11635, 11636, 11637, 11638, 11639, 12100, 12101, 12102, 12103, 12104, 12105, 12106, 12107

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

OPERATOR’S MANUAL

MANUAL DE OPERACIÓN

MANUEL DE L’OPÉRATEUR

Page 2

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

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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.

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Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you

act and be careful.

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

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

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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 Material Safety Data Sheet (MSDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

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PROTECT your eyes and face with welding helmet properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

AT ALL

TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken. They can release highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat, mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Page 3

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Gasoline Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

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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.

SAFETY

OPERATOR’S MANUAL

Page 4

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.

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• 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.

FUMES AND GASES CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes

and gases away from the breathing zone. +(09(.',0*

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5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Page 5

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-l, “Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

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.

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SAFETY

Welding Safety Interactive Web Guide for mobile devices

OPERATOR’S MANUAL

Page 6

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 . . . . . . . . . . . . . . . . . . . .P-653, P-202-E

Page 7

PRODUCT DESCRIPTION

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. Fluxcored 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

WIRE FEEDER WELDERS (125, 140)

OPERATOR’S MANUAL

Page 8

A-1

INSTALLATIONWIRE FEEDER WELDERS (125, 140)

TECHNICAL SPECIFICATIONS

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

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

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

Requirements For Maximum Output

In order to utilize the maximum output capability of the machine, a branch circuit capable

of 25 amps at 120 volts, 60 Hertz is required.

INPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

Standard Voltage/Frequency

120 V / 60 Hz

Duty Cycle

20% Duty Cycle

Current

90 Amps

Voltage at Rated Amperes

Welding Current Range

30-125 Amps

Input Voltage / Frequence

120V 60Hz

Height

13.7 in.

347 mm

Width

10.15 in. 258 mm

Depth

17.9 in.

454 mm

Weight

49.5 lbs.

22.5 kg.

Fuse or Breaker Size

1,2

20 Amp

Input Amps

Power Cord

15 Amp, 125 V,

Three Prong Plug

(NEMA Type 5-15P)

Extension Cord

3 Conductor # 12 AWG

(4mm2) or Larger

up to 50 ft.(15.2m)

Maximum-Open Circuit Voltage

33 V

Wire Speed Range

50 - 500 in/min.

(1.3 - 12.7 m/min.)

Input Current

20 Amps @ rated output

RECOMMENDED INPUT CABLE AND FUSE SIZES

PHYSICAL DIMENSIONS

INPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

Standard Voltage/Frequency

120 V / 60 Hz

Duty Cycle

20% Duty Cycle

Current

90 Amps

Voltage at Rated Amperes

19.5

Welding Current Range

30-140 Amps

Input Voltage / Frequence

120V 60Hz

Height

13.7 in.

347 mm

Width

10.15 in.

258 mm

Depth

17.9 in.

454 mm

Weight

49.5 lbs.

22.5 kg.

Fuse or Breaker Size

1,2

20 Amp

Input Amps

Power Cord

15 Amp, 125 V,

Three Prong Plug

(NEMA Type 5-15P)

Extension Cord

3 Conductor # 12 AWG

(4mm2) or Larger up to 50 ft.(15.2m)

Maximum-Open Circuit Voltage

33 V

Wire Speed Range

50 - 500 in/min.

(1.3 - 12.7 m/min.)

Input Current

20 Amps @ rated output

RECOMMENDED INPUT CABLE AND FUSE SIZES

PHYSICAL DIMENSIONS

Page 9

A-2

INSTALLATIONWIRE FEEDER WELDERS (125, 140)

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

• Black Gun Nozzle (Installed on Welding Gun)

• 2”(51mm) Spindle Adapter (For 8”

(203mm) reel of wire)

• Instruction Manual

• How to Weld “DVD”

• Wire Feeder Welder

• Work Cable & Clamp

• Magnum 100L Welding Gun

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

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

IDENTIFY AND LOCATE COMPONENTS for 125 AMP UNIT

.035

.035 NR-211 MP

.025 GROOVE

.035 GROOVE

"INSTRUCTION MANUAL"

DVD

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

OPERATOR’S MANUAL

Page 10

A-3

INSTALLATIONWIRE FEEDER WELDERS (125, 140)

• Wire Feeder Welder

• Work Cable & Clamp

• 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).

• 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”

.025

.035

NR-211 MP

WIRE

L-56 MIG

WIRE

L-56 MIG

IM10049

"INSTRUCTION MANUAL"

DVD

GAS HOSE

REGULATOR

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

IDENTIFY AND LOCATE COMPONENTS for 140 AMP UNIT

.025 GROOVE

.035 GROOVE

Page 11

B-1

OPERATION

WIRE FEEDER WELDERS (125, 140)

Read entire operation section before operating the

WIRE FEEDER WELDERS.

ELECTRIC SHOCK can kill.

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

• Always wear dry insulating gloves.

FUMES AND GASES can be 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.

------------------------------------------------------

OPERATOR’S MANUAL

WARNING

Page 12

B-2

OPERATION

WIRE FEEDER WELDERS (125, 140)

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

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

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

5. WELDING GUN – Delivers wire and welding current to the work piece. a. Gun Liner – wire travels through the liner from the wire

drive. The gun liner will feed .025” to .035”(0.6mm to

0.9mm) wire.

b. Contact Tip – provides electrical contact to the wire.

c. Nozzle – When flux-cored welding, the black nozzle pro-

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

6. WORK CLAMP & CABLE – Clamps to the work piece being welded and completes the electrical welding circuit.

7. GUN TRIGGER CONNECTOR RECEPTACLE – Plug the 4 pin gun trigger connector into this receptacle.

FIGURE B.1

FIGURE B.2

Page 13

B-3

OPERATION

WIRE FEEDER WELDERS (125, 140)

See Figure B.3

8. 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).

9. OUTPUT TERMINALS - Connections to these terminals deter-

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

See Figure B.4

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

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

See Figure B.5

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

spool through the drive and through the welding gun to the work piece.

a. Drive Roll – Drives the wire through the drive system. The

drive roll has grooves to match the specific wire type and diameter. Refer to Table B.1 for available drive rolls.

b. Incoming & Outgoing Guide – The wire is fed through

both guides. The Pivot Arm Assembly, Tension Arm Assembly and Drive Roll keep pressure on the wire in the groove.

c. Tension Arm Assembly – Turning clockwise increases the

forward force on the wire and turning counterclockwise decreases the force.

FIGURE B.3

FIGURE B.4

FIGURE B.5

FIGURE B.5a

WIRE SPOOL .035" (0.9mm)

NR-211-MP

DRIVE ROLL

PIVOT ARM AS SEMB LY

TENSION ARM ASSEMBL

OUTGOING GUIDE

INCOMING GUIDE

BEARING

See Figure B.5a Magnum 100SG / Magnum 100L Switch - The spool gun

switch is available on 140 Amp machines only. The Magnum 100SG Spool Gun can be purchased at authorized retailers. The part number is K2532-1.

MAGNUM 100SG

SWITCH

MAGNUM 100L

OPERATOR’S MANUAL

Page 14

B-4

OPERATION

WIRE FEEDER WELDERS (125, 140)

A. ITEMS NEEDED FOR FLUX

CORED WELDING

1. .035”(0.9mm) Contact Tip

2. Dual Groove Drive Roll.

3. .035”(0.9mm) NR-211MP Flux-Cored Wire

4. Black Flux Cored gun nozzle

5. Welding Gun

7. Work Cable & Clamp

.035

.035 NR-211 MP

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

TABLE B.1

DRIVE ROLLS

See Figure B.6

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

exceeded this circuit breaker will trip. Press to reset.

13. GAS INLET –Shielding gas connects to this inlet (This is not available on 125 Amp Unit.)

FIGURE B.6

125/140 Amp

.025 GROOVE

.035 GROOVE*

Wire Diameter & Type

.025”(0.6mm) MIG wire

.030”(0.8mm) MIG wire

.035”(0.9mm) MIG wire

.030”(0.8mm) flux-cored

.035”(0.9mm) flux-cored

Smooth Drive Roll

(Dual Grooves)

Use .025”(0.6mm) Drive Roll Groove

Use .035”(0.9mm) Drive Roll Groove

Drive Roll Part

Number

KP2948-1

Page 15

B-5

OPERATION

WIRE FEEDER WELDERS (125, 140)

B. CONNECT LEADS AND CABLES ON THE MACHINE

(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.

C. LOAD WIRE SPOOL

(See Figure B.8)

1. Locate the sample spool of .035”(0.9mm) NR-211MP fluxcored 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 dr ive roll on. In stall th e Dual Groov e drive rol l 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.

WORK CLAMP

(4 PIN) TRIGGER RECEPTACLE PLUGGED IN

ALL COMPONENTS SHOWN CONNECTED (FRONT AND SIDE DOOR IS REMOVED

FOR CLARITY)

SHORT POWER CABLE NEGATIVE "-" OUT PU T T ER M IN AL

WORK LEAD

STRAIN RELIEF

CONNECTION POSITIVE "+" OU TP UT TE R MI NA L

TIGHTEN THUMB SCREW TO CONNECTOR BUSHING

GUN AND CABLE

WORK CLAMP

(4 PIN) LEAD CONNECTOR

TERMINAL END (FITS ON STUD INSIDE SEE FIGURE BELOW)

SLIDE CONNECTOR END HERE

OPEN LATCH DOOR

FIGURE B.7

WIRE SPOOL .035" (0.9mm)

NR-211-MP

DRIVE ROLL

PIV OT ARM ASSEM BLY

TENSION ARM ASSEMBL

OUTGOING GUIDE

BEARING

INCOMING GUIDE

FIGURE B.8

OPERATOR’S MANUAL

Page 16

B-6

OPERATION

WIRE FEEDER WELDERS (125, 140)

(See Figure B.9)

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

7. Close the Pivot Arm Assembly and secure by rotating the Tension Arm Assembly back to the up position. (See Tension information on decal.)

(See Figure B.10)

8. Remove the nozzle from the gun and contact tip and straighten the gun out flat.

9. Turn the machine power to on and depress the gun trigger to feed the wire through the gun liner until the wire comes out of the threaded end of the gun several inches. (See fig-

ure B.11)

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

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.

-------------------------------------------------------------------

11. Install the .035”

(0.9mm)

contact tip.

12. Install the black welding nozzle to the gun.

13. Trim the wire stickout to 3/8”

(9.5mm)

from the contact tip.

(See Figure B.12)

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

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

16. Based on the thickness of the material you are going to weld and the type and diameter of the welding wire, set the voltage and the wire feed speed per the procedure decal attached to the inside of the wire drive compartment door.

REMOVED NOZZLE

REMOVED CONT

ACT

TIP

LAY

CABLE AND GUN STRAIGHTEN

THIS POSITION

.035"(0.9mm) NR-211-MP

WIRE SPOOL

PLUG IN POWER INPUT CORD

DEPRESS

TRIGGER

ACTIVATE WIRE,

WHICH FEEDS

THE WIRE

THRU THE L INER.

FEED WIRE APPROXIMA

TEL

Y 4.00"

FROM THE GUN

TUBE END

ON/OFF SWITCH

WORK CLAMP AND CABLE

ROTATION

.035"(0.9mm)

NR-211-MP

WIRE SPOOL

WIRE SPOOL BRAKE

TENSI ON AR M ASSE MBL

LOCKED IN UP POSITION

PIVOT ARM AS SEMBLY WITH BEARING PRESSING AGAINST DRIVE ROLL

DIRECTION

OF WIRE

WIRE SPOOL .035" (0.9mm)

NR-211-MP

DRIVE ROLL

INCOMING GUIDE

OUTGOING GUIDE

BEARING

SLIDE WIRE INTO GUN CONNECTOR SIDE

FIGURE B.10

FIGURE B.11

INSTALL .035 CONTACT TIP

INSTALL BLACK NOZZLE

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

FIGURE B.9

FIGURE B.12

WARNING

Page 17

B-7

OPERATION

WIRE FEEDER WELDERS (125, 140)

A. ITEMS NEEDED FOR MIG WELDING

1. .025”(0.6mm) Contact Tip

3. .025”(0.6mm) Dual Groove drive roll is used with L-56 Solid Mig wire.

4. .025”(0.6mm) SuperArc L-56 Solid MIG Wire

5. Brass gun nozzle

6. Welding Gun

.025

WIRE

L-56 MIG

7. Work Cable & Clamp

8. Gas Regulator & Gas Line

9. Bottle of 75/25 Ar/

CO2shielding gas (or 100%

CO2shielding

gas) (note this requires a

CO2regulator adapter which is sold

separately).

75/25

FEMALE END

MIXES

MALE END

100%

(REQUIRES ADAPTER SOLD SEPARATELY)

SETTING UP AND MAKING A MIG WELD 140AMP MACHINE*

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

OPERATOR’S MANUAL

Page 18

B-8

OPERATION

WIRE FEEDER WELDERS (125, 140)

B. INSTALL SHIELDING GAS

MIG welding requires an appropriate bottle of shielding gas. For mild steel a cylinder of Ar/CO2or 100% CO2can be used; refer to

the following instructions to properly connect shielding gas to the machine.

CYLINDER may explode if damaged. Keep cylinder upright and chained to support

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

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

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

75/25

FEMALE END

MALE END

S19298

REGULATOR ADAPTER

PLASTIC WASH ER

MIXES

100%

3. Attach the flow regulator to the cylinder valve and tighten the union nut securely with a wrench.

NOTE: If connecting to 100%

CO2cylinder, a

CO2regulator

adapter is required. Purchase separately S19298

CO2adapter, be sure to install plastic washer included in the fitting on the bottle side.(See Figure B.13 )

4. Refer to Figure B.13. Attach one end of inlet gas hose to the outlet fitting of the flow regulator and tighten the union nut securely with a wrench. Connect the other end to the machine Solenoid Inlet Fitting (5/8-18 female threads — for CGA — 032 fitting). Make certain the gas hose is not kinked or twisted.

FIGURE B.13

BUILDUP OF SHIELDING GAS may harm health or kill.

• Shut off shielding gas supply when not in use.

1. Secure the cylinder to a wall or other stationary support to prevent the cylinder from falling over. Insulate the cylinder from the work circuit and earth ground. Refer to Figure B.13.

2. With the cylinder securely installed, remove the cylinder cap. Stand to one side away from the outlet and open the cylinder valve very slightly for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet.

BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE 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.

SHIELDING GAS

1. For

CO2, 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.

WARNING

Page 19

B-9

OPERATION

WIRE FEEDER WELDERS (125, 140)

C. CONNECT LEADS AND CABLES ON THE MACHINE

(See Figure B.14)

1. Open the case side door.

2. Slide the connector end of the gun and cable through the hole of the machine front and into the gun connector bushing on the wire drive. Tighten thumbscrew to connector bushing.

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

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.

GUN AND CABLE

WORK CLAMP

(4 PIN) LEAD CONNECTOR

TERMINAL END (FITS ON STUD INSIDE SEE FIGURE BELOW)

SLIDE CONNECTOR END HERE

OPEN LATCH DOOR

LOCATE COMPONENTS TO CONNECT TO THE FRONT OF MACHINE

WORK CLAMP

(4 PIN)

TRIGGER RECEPTACLE

PLUGGED IN

ALL COMPONENTS SHOWN CONNECTED (FRONT AND SIDE DOOR IS REMOVED FOR CLARITY)

SHORT POWER CABLE POSITIVE

"+"

OU TP U T T ER MI NA L

WORK LEAD CONNECTION NEGATIVE "-" OU TP U T T ER MI NA L

GAS LINE

TIGHTEN THUMB SCREW TO CONNECTOR BUSHING

STRAIN RELIEF

FIGURE B.15

FIGURE B.14

WIRE SPOOL .025" (0.6mm)

L-56 SOLID MIG WIRE

DRIVE ROLL

PIV OT ARM ASSEM BLY

TENSION ARM ASSEMBL

OUTGOING GUIDE

BEARING

INCOMING GUIDE

OPERATOR’S MANUAL

Page 20

B-10

OPERATION

WIRE FEEDER WELDERS (125, 140)

(See Figure B.16)

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

7. Close the Pivot Arm Assembly and secure by rotating the Tension Arm Assembly back to the up position. (See Tension information on decal.)

(See Figure B.17)

8. Remove the nozzle from the gun and contact tip and straighten the gun out flat.

9. Turn the machine power switch to on and press the gun 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)

10. When trigger is released, the spool of wire should not unwind. Adjust wire spool brake accordingly.

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.

--------------------------------------------------------------------

11. Install the .025”(0.6mm) contact tip.

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

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

(See Figure B.19)

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

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

TENS ION A RM ASS EMBL

LOCKED IN UP POSITION

PIVO T ARM ASSEM BLY WITH BEARING PRESSING

AGAINST DRIVE ROLL

DIRECTION

OF WIRE

WIRE SPOOL .025" (0.6mm)

L-56 Solid MIG WIRE

DRIVE ROLL

INCOMING GUIDE

OUTGOING GUIDE

BEARING

SLIDE WIRE INTO GUN CONNECTOR SIDE

WIRE SPOOL .025" (0.6mm)

REMOVED NOZZLE

REMOVED CONTACTTIP

LAY CABLE

AND GUN STRAIGHTEN

IN T H IS P O SI T I ON

PLUG IN POWER INPUT CORD

DEPRESS

TRIGGER

ACTIVA

TE WIRE, WHICH FEEDS THE WIRE THRU

THE LINER.

FEED WIRE APPROXIMATELY

4.00"

FROM

THE GUN

TUBE END

ON/OFF SWITCH

WORK CLAMP AND CABLE

ROTATION

WIRE SPOOL

WIRE SPOOL BRAKE

.025" (0.6mm)

INSTALL .025 (0.6mm) CONTACT TIP

INSTALL BRASS NOZZLE

TRIM WIRE STICKOUT 3/8"(9.5mm) from the Brass Nozzle

FIGURE B.17

FIGURE B.18

FIGURE B.19

FIGURE B.16

WARNING

Page 21

B-11

OPERATION

WIRE FEEDER WELDERS (125, 140)

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

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

SETTING UP AND MAKING A ALUMINUM WELD USING SPOOL GUN

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

FIGURE B.21

(Location of Selector Switch and Thumb Screw)

MAGNUM 100SG

SWITCH

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

MAGNUM 100L

OPERATOR’S MANUAL

Page 22

C-1

ACCESSORIES

WIRE FEEDER WELDERS (125, 140)

K2532-1 - Magnum 100SG Spool Gun

(Only available on 140 Models K2480-1, K2514-1, K2658-1 and K2697-1). Designed to easily feed small 4" diameter (1lb. spools of) .030 or .035 aluminum wire. Includes gun, adapter kit, three extra .035 contact tips, gas nozzle, and spool of Superglaze 4043 .035" diameter welding wire. Packaged in a convenient carry case.

K2377-1 - Small Canvas Cover

Protect your machine when not in use. Made from attractive red canvas that is flame retardant, mildew resistant and water repellent. Includes a convenient side pocket to hold welding gun.

For additional Optional and Miscellaneous Parts

(See Parts Pages)

Page 23

C-2

ACCESSORIES

WIRE FEEDER WELDERS (125, 140)

K520—Utility Cart

Heavy duty cart stores and transports welder, 150 cubic foot shielding gas cylinder, welding cables and accessories. Includes stable platforms for welder and gas bottle platform, lower tray for added storage capacity and adjustable height handle.

16"

3-11/16"

3-13/32"

9/32" DRILL 2 PLACES

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

1/4"-20 X 1" Thread Forming Screw (1 Required)

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

For mounting welding machines to K520 carts that do not have slotted mounting holes. Drill 9/32” holes (2 places) into the cart top as shown and attach the welding machine to the cart with the proper hardware shown.

OPERATOR’S MANUAL

Page 24

C-3

ACCESSORIES

WIRE FEEDER WELDERS (125, 140)

1/4"-20 Flange Nut (2 Required)

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

K2275-3 - Welding Cart

Lightweight cart stores and transports welder, 80 cubic foot shielding gas cylinder, welding cables and accessories. Includes an angled top shelf for easy access to controls, lower tray for added storage capacity, a sturdy fixed handle and convenient cable wrap hanger.

Page 25

D-1

MAINTENANCE

WIRE FEEDER WELDERS (125, 140)

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Disconnect input power by removing plug from receptacle before working inside WIRE FEEDER WELDERS (125 and 140 MODELS).

Use only grounded receptacle. Do not touch electrically “hot” parts inside WIRE FEEDER WELDERS (125 and 140 MODELS).

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

-----------------------------------------------------------------

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.

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.

CAUTION

WARNING

OPERATOR’S MANUAL

Page 26

D-2

MAINTENANCE

WIRE FEEDER WELDERS (125, 140)

1-1/4”(31.8 mm) Liner Trim Length

Gas Diffuser

Gas Nozzle or Gasless Nozzle

OVERLOAD PROTECTION

Output Overload

The WIRE FEEDER WELDERS (125 and 140 MODELS) are equipped with a circuit breaker and a thermostat which protects the machine from damage if maximum output is exceeded. The circuit breaker button will extend out when tripped. The circuit breaker must be manually reset.

Thermal Protection

The WIRE FEEDER WELDERS (125 and 140 MODELS) have a rated output duty cycle as defined in the Technical Specification page. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools to a reasonable operating temperature. This is an automatic function of the WIRE FEEDER WELDERS (125 and 140 MODELS) and does not require user intervention. The fan continues to run during cooling.

Electronic Wire Drive Motor Protection

The WIRE FEEDER WELDERS (125 and 140 MODELS) have built-in protection for wire drive motor overload.

Set Screw Brass Cable

Connector

Liner Assembly (Liner bushing to be sealed tight against brass cable connector)

FIGURE D.2

Liner trim length

CHANGING LINER

NOTICE: The variation in cable lengths prevents the 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.

„

Counter-clockwise

FIGURE D.3

Page 27

CAUTION

E-1

TROUBLE SHOOTING

WIRE FEEDER WELDERS (125, 140)

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the threestep 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 yo u do no t understand or are una b l e to perfor m the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs 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.

__________________________________________________________________________

OPERATOR’S MANUAL

WARNING

Page 28

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

E-2

TROUBLE SHOOTING

WIRE FEEDER WELDERS (125, 140)

PROBLEMS (SYMPTOMS)

Major physical or electrical damage is evident.

No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate.

No wire feed, weld output or gas flow when gun trigger is pulled. Fan operates normally.

POSSIBLE CAUSE

“Do not Plug in machine or turn it on”. Contact your local Authorized Field Service Facility.

1. Make sure correct voltage is applied to the machine.

2. Make certain that power switch is in the ON position.

3. Make sure circuit breaker is reset.

1. The thermostat may be tripped due to overheating. Let machine cool. Weld at lower duty cycle.

2. Check for obstructions in air flow. Check Gun Trigger connections. See Installation section.

3. Gun trigger may be faulty.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local

Lin c o l n Au t h o r i z ed Fi e l d Se r v i c e Facility.

OUTPUT PROBLEMS

PROBLEMS (SYMPTOMS)

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

POSSIBLE CAUSE

1. If the wire drive motor is running make sure that the correct drive rolls are installed in the machine.

2. Check for clogged cable liner or 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.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local

Lin c o l n Au t h o r i z ed Fi e l d Se r v i c e Facility.

FEEDING PROBLEMS

Page 29

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

E-3

TROUBLE SHOOTING

WIRE FEEDER WELDERS (125, 140)

PROBLEMS (SYMPTOMS)

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

POSSIBLE CAUSE

1. Check gas supply, flow regulator and gas hoses.

2. Check gun connection to machine for obstruction or leaky seals.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local

Lin c o l n Au t h o r i z ed Fi e l d Se r v i c e Facility.

GAS FLOW PROBLEMS

PROBLEMS (SYMPTOMS)

Arc is unstable – Poor starting

POSSIBLE CAUSE

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.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local

Lin c o l n Au t h o r i z ed Fi e l d Se r v i c e Facility.

WELDING PROBLEMS

OPERATOR’S MANUAL

Page 30

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

N.C.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a

particular code is pasted inside the machine on one of the enclosure panels.

F-1

DIAGRAMS

WIRE FEEDER WELDERS (125, 140)

Page 31

F-2

DIAGRAMS

WIRE FEEDER WELDERS (125, 140)

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a

particular code is pasted inside the machine on one of the enclosure panels.

WIRING DIAGRAM FOR CODE 11634, 11635, 11636, 11637

N.C.

OPERATOR’S MANUAL

Page 32

F-3

DIAGRAMS

WIRE FEEDER WELDERS (125, 140)

M24969

WIRING DIAGRAM FOR CODE 12101, 12103, 12104, 12106

A.02

WARNING

HIGH VOLTAGE

can kill

Only qualified persons should install,

use or service this machine.

Do not operate with covers removed.

Disconnect input power by unplugging

power cord before servicing.

Do not touch electrically live parts

LATCH

ELECTRICAL SYMBOLS PER E1537

7 8 9 10 11 124 5 6

1 2 3 4 5 61 2 3

WORK

402

403

405

406

408

409

410

412

500

501

GAS

SOLENOID

804

115V FAN

805

801

803

TO GROUND

PER NATIONAL

ELECTRICAL

CODE.

WIRE FEED MOTOR

410

202

412

409

404

CAPACITOR

OUTPUT

THERMOSTAT

401

202

RECTIFIER

601

702

408

406

402

LOCATED IN TRANSFORMER

501

502

403

411

BLACK

N.B.

ON/OFF SWITCH

H2H3H5

WHITE

CIRCUIT BREAKER

N.A.

N.O.

CR1

N.C. CAVITY NUMBERING SEQUENCE VIEWED FROM INSERTI

ON SIDE

OF CONNECTORS.

N.B. WORK AND GUN CONNECTIONS SHOWN FOR GMAW WELDI

NG.

COMPOUND (BURNDY PENETROX A13) WHEN REATTACHING.

N.A. BOLTED ALUMINUM CONNECTIONS REQUIRE E2529 JOI

NOTES:

CHOKE

5K WIRE FEED SPEED POT

806

120 VAC

N.D. COMPONENT VIEWED FROM REAR.

N.D.

TRANSFORMER

N.D.

N.C.

SELECTOR SWITCH

N.D.

CONTROL P.C. BOARD

N.A.

801

805

803

804

806

401

MOTOR

MAGNUM 100SG

SPOOL GUN

(OPTIONAL)

EITHER

MAGNUM 100L

PUSH GUN

SPOOL GUN

SWITCH

405

N.D.

411

1 2 3 4 5 6 7 8 9 10 1112

1 2 3 4

1 2 3 4 5 6

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.

Page 33

F-4

DIAGRAMS

WIRE FEEDER WELDERS (125, 140)

M24970

A.02

WARNING

HIGH VOLTAGE

can kill

Only qualified persons should install,

use or service this machine.

Do not operate with covers removed.

Disconnect input power by unplugging

power cord before servicing.

Do not touch electrically live parts

LATCH

ELECTRICAL SYMBOLS PER E1537

9 8 7

5 4 3 2 1

6 5 4

3 2 1

10 12

WORK

402

407

405

406

408

410

412

500

501

115V FAN

805

801

TO GROUND

PER NATIONAL

ELECTRICAL

CODE.

WIRE FEED MOTOR

410

202

412

OUTPUT

THERMOSTAT

401

202

RECTIFIER

601

405

408

406

402

LOCATED IN TRANSFORMER

501

502

BLACK

N.B.

ON/OFF SWITCH

H2H3H5

WHITE

CIRCUIT BREAKER

N.O.

CR1

N.C. CAVITY NUMBERING SEQUENCE VIEWED FROM INSERTION SIDE

OF CONNECTORS.

N.B. WORK AND GUN CONNECTIONS SHOWN FOR FCAW WELDING.

COMPOUND (BURNDY PENETROX A13) WHEN REATTACHING.

N.A. BOLTED ALUMINUM CONNECTIONS REQUIRE E2529 JOINT

NOTES:

CHOKE

5K WIRE FEED SPEED POT

806

N.D. COMPONENT VIEWED FROM REAR.

N.D.

TRANSFORMER

N.D.

SELECTOR SWITCH

N.D.

CONTROL P.C. BOARD

801

805

806

401

411

MAGNUM 100L

PUSH GUN

405

407

N.A.

N.C.

WIRING DIAGRAM FOR CODE 12100, 12102, 12105,12107

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a

particular code is pasted inside the machine on one of the enclosure panels.

OPERATOR’S MANUAL

Page 34

F-5

DIMENSION PRINT

WIRE FEEDER WELDERS (125, 140)

Page 35

F-6

NOTES

OPERATOR’S MANUAL

Page 36

Easy-MIG® 140

ISO

9001:2000

14001:2004

WIRE FEEDER/WELDERS

Processes

MIG, Flux-Cored

Product Number

K2697-1

See back for complete specs

120 Volt AC Input Compact Wire Feeder/Welder

Requiring common 120 volt input power, the Easy-MIG® 140 can be used almost anywhere. With simple two knob control, the machine is easy to set up for gasless ﬂux-cored welding for deep penetration on thicker steel or gas-shielded MIG welding on thin gauge steel, stainless or aluminum. Compare the precise drive, rugged construction and full list of standard accessories. . . the Lincoln Electric Easy-MIG® 140 is an excellent choice!

FEATURES

 Heavy Duty Wire Drive

– Fully adjustable drive system reduces

the chance of wire tangling and crushing.

– Brass-to-brass gun connection

enhances conductivity.

– Durable cast aluminum gear box

delivers added drive torque and quiet operation.

– Easy-turn numeric drive tension

indicator identiﬁes optimized ranges for different wire diameters.

 Capable Performance

– Forgiving arc makes dialing in your

application easy.

– Smooth arc starts with minimal

spatter.

– Wide 30-140 amp welding

output range.

– MIG weld 24 gauge up to 3/16 in.

(4.8 mm) sheet metal in a single pass. Weld up to 5/16 in. (7.9 mm) steel using self-shielded Lincoln Electric Innershield (FCAW-S) wires.

Input Power 120/1/60

Input Current at Rated Output 20A

Rated Output Current/Voltage/Duty Cycle 90A/19.5V @ 20%

Output Range

APPLICATIONS

 Shop

 Farm  Home

WHAT’S INCLUDED

Gun

 Magnum® 100L gun and 10 ft. (3.0 m)

cable assembly with brass connection and 4-pin MS-Type connection for trigger control (K530-6)

 .025 in (0.6 mm) contact tips

(Qty 3) (KH710)

 .035 in. (0.9 mm) contact tips

(Qty. 3) (KH712)

 Gasless nozzle for Innershield®

welding (KH726)

 Gas nozzle for MIG welding (KH725)  Spindle adapter for 8 in. (203 mm)

diameter spools (KH720)

 .025 - .035 in. (0.6 - 0.9 mm) wire

diameter dual track drive roll for MIG and ﬂux-cored welding (KP2948-1)

Shielding Gas Apparatus

 Harris® 3000290 Gas Regulator

(S25805) and 52 in. (1.3 m) hose (S19303) for use with Ar/CO2 or CO2 gases. For use with CO2 shielding gas, order a Lincoln Electric S19298 CO2 shielding gas bottle adapter.

Welding Wire

 Sample spool of .025 in. (0.6 mm)

diameter SuperArc® L-56® premium MIG wire

 Sample spool of .035 in. (0.9 mm)

diameter Innershield® NR®-211-MP ﬂux-cored wire

30-140 A 50-500 WFS (1.3-12.7 m/min) Max. OCV: 33

Weight/Dimensions (H x W x D) 50 lbs. (22.7 kg)

13.7 x 10.15 x 17.9 in. (357 x 258 x 472 mm)

Shown K2697-1

INPUT

OUTPUT

Two Year Extended

Warranty Available in

the U.S.A. and Canada.

Other

 Work clamp and 10 ft. (3.0 m)

cable

 How TO MIG Weld DVD  Instruction manual

THE LINCOLN ELECTRIC COMPANY

22801 St. Clair Avenue • Cleveland, OH • 44117-1199 • U.S.A.

PH: +1.216-481-8100 • www.lincolnelectric.com

Page 37

HEAVY DUTY WIRE DRIVE

Enhanced Quality

1. Brass-to-brass gun connection enhances conductivity.

2. Rigid drive aids wire alignment. The cast aluminum body with an enclosed multi-stage gear box delivers improved torque and quiet operation.

Easy to Use

3. Easy-turn drive tension adjustment with numeric tension indicators.

4. Fast tool-less drive roll changeovers. The dual track drive roll ensures positive ﬂux-cored wire feeding with common wire diameters.

5. Easy tool-less polarity changes for MIG or ﬂux-cored welding.

6. Spool gun ready switch allows user to select spool gun or standard push gun drive operation.

PERFORMANCE PLUS

(1)

Aluminum welding requires optional K2532-1 Magnum® spool gun.

RECOMMENDED ACCESSORIES

GENERAL OPTIONS

Welding Cart

Full-featured cart is designed to store and transport a welder, 80 cubic foot gas cylinder, welding cables and accessories. Includes an angled top shelf for easy access to welder controls, a lower tray for added storage space, a sturdy handle also used as a convenient cable wrap hanger.

Order K2275-1

PRODUCT SPECIFICATIONS

Product

Name

Easy-MIG

140

Product Number

K2697-1 120/1/60 90/19.5V/20% 20A 30-140 Amps DC

Input

Power

Rated Output

Current/Voltage/Duty Cycle

SP - Single Pass MP - Multiple Pass

L12603-10

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.

Order K520

Small Canvas Cover

Protect your welder 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 your welding torch or gun.

Order KH495

Input Current

@ Rated Output

Product Number

KP2948-1 KP3285-1

Output

Range

50-500 ipm WFS (1.3-12.7 m/min)

Max. OCV: 33

DRIVE ROLLS

Wire Diameter

in. (mm)

.025 - .035 (0.6 - 0.9) .035 - .045 (0.9 - 1.1)

WIRE FEEDER OPTIONS

Magnum

Designed to easily feed 4 in. (102 mm) diameter 1 lb. (0.45 kg) spools of .030 in. (0.8 mm) or .035 in. (0.9 mm) diameter SuperGlaze Includes gun, adapter kit, .035 in. (0.9 mm) contact tips (qty. 3), gas nozzle, and a 1 lb. (0.45 kg) spool of SuperGlaze MIG wire. Packaged in a convenient carrying case.

Order K2532-1

H x W x D

inches (mm)

13.7 x 10.15 x 17.9 (357 x 258 x 472)

Process

MIG/Flux-Cored

100SG Spool Gun

aluminum MIG wire.

4043 .035 in. (0.9 mm)

Net

Weight

lbs. (kg)

(22.7)

For best welding results with Lincoln Electric equipment, always use Lincoln Electric consumables. Visit www.lincolnelectric.com for more details.

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 information or advice about their use of our products. Our employees respond to inquiries to the best of their ability based on information provided to them by the customers and the knowledge they may have concerning the application. Our employees, however, are not in a position to verify the information provided or to evaluate the engineering requirements for the particular weldment. Accordingly, Lincoln Electric does not warrant or guarantee or assume any liability with respect to such information or advice. Moreover, the provision of such information or advice does not create, expand, or alter any warranty on our products. Any express or implied warranty that might arise from the information or advice, including any implied warranty of merchantability or any warranty of ﬁtness for any customers’ particular purpose is speciﬁcally disclaimed.

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.

Lincoln Electric 125, 11631, 11634, 11635, 140 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual