Lincoln Electric 125, 180, 140 Operator's Manual

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Page 1

WIRE FEEDER

WELDER (125, 140, 180 MODELS)

IM891-C

January, 2009

For use with machines having Code Numbers:

TABLE OF CONTENTS

Installation ...........................Section A

Technical Specifications ...................A-1,A-2

SafetyPrecautions...........................A-2

Location .................................A-2

Stacking .................................A-2

Tilting ...................................A-2

Identify and Locate Components for 180 Amp

and140AmpUnits .........................A-3

Identify and Locate Components for 125 Amp

FluxCoreUnit.............................A-3

Operation ............................Section B

Safety and Product Description .................B-1

ControlsandSettings.....................B-2,B-3

DriveRollandWireGuidesTable ...............B-4

Setting Up and Making a Flux-Cored Weld .B-4 thru B-6 Setting Up and Making a MIG Weld and

InstallShieldingGas ................B-7thruB-10

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

11173 thru 11506, 11550

ISO 9001

ANSI RAB

QMS

Designed and Manufactured Under aI

Quality Program Certified byI ABS Quality Evaluations, Inc.I

to ISO 9001 Requirements.

CERTIFICATE NUMBER: 30273

OPERATOR’S MANUAL

Accessories . . . .......................Section C

Optional Accessories .........................C-1

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

Maintenance..........................Section D

SafetyPrecautions ..........................D-1

Wire Feed Compartment, Fan Motor, Wire Reel

Maintenance ..............................D-1

GunAndCableMaintenance ..................D-2

OverloadProtection..........................D-2

Component Replacement Procedures ...........D-2

Troubleshooting ......................Section E

SafetyPrecautions...........................E-1

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

Troubleshooting Guide .................E-2thruE-3

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

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.

MANUAL DE OPERACIÓN

MANUEL DE L’OPÉRATEUR

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Page 2

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel 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.

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

The Above For Gasoline Engines

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.d. Keep

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. I n so me cases it may be ne cessary to remove

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

1.c. Do not add the fuel 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.

all equipment safety guards, covers and devices in

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.

near an open flame

safety

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. E MF 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:

Route the electrode and work cables together - Secure

2.d.1.

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.

___________________________________________________

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.

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.

Mar ‘95

Page 3

SAFETY

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

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. When

welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

OPERATOR’S MANUAL

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 Items 6.c. and 8.

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.

Do not weld in locations near chlorinated hydrocarbon

5.c.

coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors 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.

vapors

AUG 06

Page 4

iii

SAFETY

iii

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

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 been “cleaned”. For information, purchase “Recommended Safe Practices for the 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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. 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.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

7.a. Us e 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.

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.

Jan, 07

Page 5

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

OPERATOR’S MANUAL

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 n’importe quelle partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

Page 6

Thank You

iviv

for selecting a QUALITY 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!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

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

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

CUSTOMER ASSISTANCE POLICY

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

“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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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.

Page 7

INSTALLATION

A-1A-1

TECHNICAL SPECIFICATIONS

180 Amp units (K2481-1, K2515-1, K2659-1, K2689-1, K2698-1)

INPUT – SINGLE PHASE ONLY

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

230 V 30% 130 Amps 20 208 V 30% 130 Amps 17

Cycle Current Voltage at Rated Amperes

OUTPUT

Welding Current Range

30-180 Amps 34 V 50 - 500 in/min.

Open Circuit Voltage Wire Speed Range

RECOMMENDED INPUT CABLE AND FUSE SIZES

Input Voltage/Frequency Fuse or Breaker Size

230 V 60 Hz 40 Amp Super Lag 20 50 Amp, 250 V,

Input Amps Power Cord

PHYSICAL DIMENSIONS

Height Width Depth Weight

13.7 in 10.15 in 17.9 in 64 Ibs 347 mm 258 mm 454 mm 29 kg

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

(1.3 - 12.7 m/min.)

OPERATOR’S MANUAL

Three Prong Plug

(NEMA Type 6-50P)

140 Amp units (K2480-1, K2514-1, K2658-1, K2688-1, K2697-1)

INPUT – SINGLE PHASE ONLY

Standard Voltage/Frequency Input Current

Input Voltage/Frequency Fuse or Breaker Size

120 V 60 Hz 20 Amp 20 15 Amp, 125 V,

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

120 V / 60 Hz 20 Amps @ rated output

RATED OUTPUT

Cycle Current Voltage at Rated Amperes

Duty

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.

RECOMMENDED INPUT CABLE AND FUSE SIZES

1,2

Input Amps Power Cord Extension Cord

Three Prong Plug (4mm2) or Larger (NEMA Type 5-15P) up to 50 ft.(15.2m)

PHYSICAL DIMENSIONS

Height Width Depth Weight

13.7 in 10.15 in 17.9 in 54 Ibs 347 mm 258 mm 454 mm 24.5 kg

(1.3 - 12.7 m/min.)

3 Conductor # 12 AWG

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

Page 8

A-2

INSTALLATION

A-2

TECHNICAL SPECIFICATIONS

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

INPUT – SINGLE PHASE ONLY

Standard Voltage/Frequency Input Current

120 V / 60 Hz 20 Amps @ rated output

RATED OUTPUT

Cycle Current Voltage at Rated Amperes

Duty

20% Duty Cycle 90 Amps 19

OUTPUT

Welding Current Range Maximum-Open Circuit Voltage Wire Speed Range

30-125 Amps 33 V 50 - 500 in/min.

RECOMMENDED INPUT CABLE AND FUSE SIZES

Input Voltage / Frequency Fuse or Breaker Size

120 V 60 Hz 20 Amp 20 15 Amp, 125 V,

1,2

Input Amps Power Cord Extension Cord

Three Prong Plug (4mm2) or Larger (NEMA Type 5-15P) up to 50 ft.(15.2m)

PHYSICAL DIMENSIONS

Height Width Depth Weight

13.7 in 10.15 in 17.9 in 48 Ibs 347 mm 258 mm 454 mm 21.7 kg

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.

(1.3 - 12.7 m/min.)

3 Conductor # 12 AWG

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 understood 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.

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

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

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

TILTING

Each machine must be placed on a secure, level surface, directly or on recommended cart. The machine may topple over if this procedure is not followed.

Page 9

A-3

INSTALLATION

A-3

IDENTIFY AND LOCATE COMPONENTS

for 140 AMP and 180 AMP UNITS

INCLUDED COMPONENTS

• Wire Feeder Welder.

• Work Cable & Clamp.

• Magnum 100L Welding Gun.

• 3 .035 Contact Tips (1 installed

on the welding gun).

• 3 .025 Contact Tips.

• Handshield

LINCOLN

ELECTRIC

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

• Brass MIG Gas Gun Nozzle

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

• Regulator

• Gas Hose

• Learn to Weld (LTW1 Manual)

• DVD

REGULATOR

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

• Magnum 100L Welding Gun.

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

.035

• Spool of .035 diameter NR211MP Innershield Flux-cored Wire.

.035 NR-211 MP

• .030 -.045 Knurled Drive Roll (Installed on

Machine)

• Handshield

LINCOLN

ELECTRIC

OPERATOR’S MANUAL

.035

.025

• Spool of .035 diameter NR211MP Innershield Flux-cored Wire.

• Spool of .025 diameter L-56 MIG Wire.

NR-211 MP

.025-.030 Smooth Drive Roll

•

L-56 MIG

WIRE

• .035 Smooth Drive Roll

• .030 -.045 Knurled

Drive Roll (Installed on Machine)

.025

GAS HOSE

IDENTIFY AND LOCATE COMPONENTS

for 125 AMP FLUX CORE UNIT

INCLUDED COMPONENTS

•

• Wire Feeder Welder.

• Work Cable & Clamp.

"LEARN TO WELD"

LTW1

DVD

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

• 2” Spindle Adapter (For 8” Reel of

wire)

• Learn to Weld (LTW1 Manual)

• DVD

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

"LEARN TO WELD"

LTW1

DVD

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

Page 10

B-1

OPERATION

B-1

Read entire operation section before operating the

WIRE FEEDER WELDERS.

WARNING

ELECTRIC SHOCK can kill.

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

• Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

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

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

• Do not weld on closed containers.

ARC RAYS can burn eyes and skin.

• Wear eye, ear and body protection.

PRODUCT DESCRIPTION (PRODUCT CAPABILITIES)

These small portable wire feed welders are capable of MIG welding on steel, stainless steel, and aluminum. They are also capable of flux-cored welding on mild steel.

MIG welding stands for Metal Inert Gas welding and requires a separate bottle of shielding gas to protect the weld until it cools. Appropriate shielding gas based on the type of material you are welding can be purchased separately from your local welding gas distributor. MIG welding is ideal for welding on thinner and clean materials when a very clean excellent cosmetic looking weld is required. An example would be automotive body panels.

Self Sheilding Flux-cored Welding does not require separate shielding gas to protect the weld since the welding wire has special additives known as flux to protect the weld until it cools. Flux-cored welding is ideal for medium to thicker material and if welding on painted or rusty steel. Flux-cored welding is also ideal in outdoor applications where windy conditions might blow the MIG shielding gas away from the weld. Fluxcored welding produces a good looking weld but does not produce an excellent weld appearance as MIG welding does.

Your machine includes the necessary items to weld with either the MIG or the flux-cored welding process on steel. To weld on stainless steel optional stainless steel welding wire can be purchased separately. This machine can weld aluminum using .035 diameter 4043 aluminum welding wire. Since aluminum welding wire is soft an optional aluminum spool gun is recommended for best results. A welding Procedure Decal is located inside machine door to help provide suggested settings for welding.

Observe all safety information throughout this manual.

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

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

COMMON WELDING ABBREVIATIONS

GMAW (MIG)

• Gas Metal Arc Welding

FCAW (Innershield or Outershield)

• Flux Core Arc Welding

Page 11

B-2

CONTROLS AND SETTINGS

This machine has the following controls:

OPERATION

B-2

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 inside wire drive compartment door to set a correct welding procedure based on type of material and thickness being welded.

3. WIRE FEED SPEED CONTROL (WFS) – The 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 inside wire drive compartment door to set a correct welding procedure based on type of material and thickness being welded.

See Figure B.2

4. GUN TRIGGER – Depress the trigger to activates

the wire drive to feed wire and energizes the output of the machine. Depress the trigger to weld and release the trigger to stop welding.

5. WELDING GUN – Delivers wire and welding cur-

rent to the weld. a. Gun Liner – wire travels through the liner from

the wire drive. The gun liner will feed .025 to .035 wire. The 180A machine can weld with .045 wire if an optional .045 liner is installed in the gun.

b. Contact Tip – provides electrical contact to the

wire.

FIGURE B.1

OPERATOR’S MANUAL

FIGURE B.2

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

WIRE SPOOL

c. Nozzle – When flux-cored welding the black noz-

zle protects 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.

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

Page 12

B-3

OPERATION

B-3

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 of Machine, Side Door and Wire Drive Cover have been removed for clarity of Items 8 and 9).

9. OUTPUT TERMINALS –These connections allow to change the welding polarity of the machine depending on whether you are MIG welding or fluxcored welding.

See Figure B.4

10. WIRE SPOOL SPINDLE AND BRAKE – Holds a

4 inch diameter spool. Use the 2 inch spindle adapter included with the machine to use 8 inch diameter spools. The thumbscrew sets the brake friction to prevent the spool from over rotating when the trigger is released.

FIGURE B.3

FIGURE B.4

See Figure B.5

11. WIRE DRIVE & COMPONENTS – Feeds wire

from the wire spool through the drive and through the welding gun to the weld.

a. Drive Roll – Drives the wire through the drive

system. The drive roll has a groove to match the specific wire type and diameter. Refer to Table B.1 for available drive rolls.

b. Liner & Outgoing Guide – The liner guides the

wire between the bearing on the Pivot Arm Assembly and Drive Roll and through the outgoing guide.

c. Drive Roll Tension Thumbscrew – Turning

clockwise increases the force on the drive roll and turning counterclockwise decreases the force.

FIGURE B.5

PIVOT ARM ASSEMBLY

BEARING

OUTGOING GUIDE

TENSION ARM ASSEMBLY

LINER

DRIVE ROLL

WIRE SPOOL .035" (0.9mm)

NR-211-MP

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

Page 13

B-4

OPERATION

TABLE B.1

DRIVE ROLLS

B-4

Wire Diameter &

Type

.025 MIG wire

.025/.030 Smooth Drive Roll

.030 MIG wire

.035 MIG wire

.035 Smooth Drive Roll

.030 flux-cored

.030/.045 Knurled Drive Roll

.035 flux-cored

.045 flux-cored

.030/.045 Knurled Drive Roll

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 optional on 125 Amp Unit.)

Drive Roll

Drive Roll Part

Number

KP2529-1

KP2529-2

KP2529-3

FIGURE B.6

OPERATOR’S MANUAL

SETTING UP AND MAKING A FLUX-CORED WELD

A. ITEMS NEEDED FOR

FLUX CORED WELDING

1. 035 Contact Tip

.035

2. Knurled Drive Roll

3. .035 NR-211MP Flux-Cored Wire

.035 NR-211 MP

5. Welding Gun

7. Work Cable & Clamp

4. Black Flux Cored gun nozzle

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

Page 14

B-5

OPERATION

B-5

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 on the wire drive.

3. Make sure the gun connector end is seated fully into the wire drive and tighten the molded hand screw to secure the gun connector.

4. Plug the gun trigger lead connector into the 4 pin gun trigger receptacle on the machine front.

5. Wire Drive Polarity. Flux cored welding requires negative (-) polarity. Connect the short power cable from the wire drive to the negative (-) output terminal and tighten threaded knob.

6. Work Lead Connection. Slide the lugged end of the work cable through the hole in the machine front and place on the positive (+) output terminal and tighten threaded knob.

SLIDE C

ONNEC

END

ERE

TOR

(4 PIN) L

EAD CO

GUN AND CABLE

TERMINAL END (FITS ON STUD INSIDE SEE FIGURE BELOW)

NNECTOR

MOLDED HAND SCREW TO TIGHTEN CONNECTOR BUSHING

NNECTOR

END ATTACH

(4 PIN) TRIGGER RE PLUGGED IN

WORK CLAMP

CEPTACLE

FIGURE B.7

OPEN LATCH DOO

WORK CLAMP

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

SHORT POWER CABLE NEGATIVE "-" OUTPUT TERMINAL

WORK LEAD CONNECTION POSITIVE "+" OUTPUT TERMINAL

C. LOAD WIRE SPOOL

(See Figure B.8)

1. Locate the blue labeled 4" diameter spool of .035 NR-211MP flux-cored wire and place onto wire spool spindle. Orient the spool so that the wire feeds off the top of the spool.

2. Secure spool in place by tightening the wing nut against the against the spacer that holds the wire spool on the spindle.

3. Open the pivot arm assembly by rotating the tension arm assembly down and lift pivot arm assembly up.

4. Remove drive roll the drive roll on. Install the .030/.045 knurled drive roll.

5. Carefully unwind and straighten the first six inches of welding wire from the spool. Do not let the end of the wire go to prevent the wire from unspooling.

by turning the twist lock that holds

FIGURE B.8

PIVOT ARM ASSEMBLY

BEARING

OUTGOING GUIDE

TENSION ARM ASSEMBLY DOWN

LINER

TWIST LOCK

DRIVE ROLL

WIRE SPOOL .035" (0.9mm)

NR-211-MP

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

Page 15

B-6

OPERATION

(See Figure B.9)

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

7. Close the Pivot Arm Assembly and secure by pivoting the Tension Arm Assembly back to the up position.

(See Figure B.10)

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

PIVOT ARM ASSEMBLY WITH BEARING PRESSING AGAINST DRIVE ROLL

SLIDE WIRE INTO GUN CONNECTOR SIDE

FIGURE B.9

TENSION ARM ASSEMBLY LOCKED IN UP POSITION

BEARING

LINER

DRIVE ROLL

OUTGOING GUIDE

WIRE SPOOL .035" (0.9mm)

NR-211-MP

DIRECTION OF WIRE

B-6

9. Turn the machine power to on and depress the gun trigger to feed the wire through the gun liner until the wire comes out of the threaded end of the gun several inches. (See figure B.11)

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

WARNING

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

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

• Keep away from moving parts and pinch points.

• Keep all Doors, Covers, panels and guards securely in place.

DO NOT REMOVE OR CONCEAL WARNING LABELS.

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

11. Install the .035 contact tip

12. Install the black flux cored welding nozzle to the gun.

REMOVED NOZZLE

REMOVED CONTACT TIP

LAY CABLE AND GUN STRAIGHTEN IN THIS POSITION

FEED WIRE APPROXIMATELY 4.00" FROM THE GUN TUBE END

DEPRESS TRIGGER TO ACTIVATE WIRE, WHICH FEEDS THE WIRE THRU THE LINER.

FIGURE B.10

FIGURE B.11

ON/OFF SWITCH

WORK CLAMP AND CABLE

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

WIRE SPOOL

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

WIRE SPOOL

PLUG IN POWER INPUT CORD

ROTAT ION

OPERATOR’S MANUAL

13. Trim the wire stickout to 3/8” from the contact tip. (See Figure B.12)

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

15. Read "Learn to Weld" (LTW1) that is included with the machine or watch the "How to Weld" DVD included with the machine.

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

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

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

FIGURE B.12

INSTALL .035 CONTACT TIP

INSTALL BLACK FLUX-CORED NOZZLE

Page 16

B-7

OPERATION

SETTING UP AND MAKING A MIG WELD*

B-7

A. ITEMS NEEDED FOR MIG WELDING

1. 025 Contact Tip

.025

3. .025 Drive Roll

.025

4. .025 SuperArc L-56 Solid MIG Wire

L-56 MIG

7. Work Cable & Clamp

8. Gas Regulator & Gas Line

9. Bottle of 75/25 Ar/

CO2shielding gas (or 100% shielding gas) (note this requires a adapter which is sold separately.

CO2regulator

5. Brass gun nozzle

6. Welding Gun

WIRE

MALE END

100%

(REQUIRES ADAPTER SOLD SEPARATELY)

FEMALE END

75/25

MIXES

* 125 Amp Units can be upgraded for MIG welding

using KIT K2526-1 (See Accessory Section).

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

Page 17

B-8

B. INSTALL SHIELDING GAS

OPERATION

B-8

FIGURE B.13

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

100% CO

can be used refer to the following instruc-

tions to properly connect shielding gas to the machine.

WARNING

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

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

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

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

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

WARNING

BUILDUP OF SHIELDING GAS may harm health or kill.

• Shut off shielding gas supply when not in use.

MALE END

100%

FEMALE END

75/25

MIXES

REGULATOR ADAPTER

PLASTIC WASHER

S19298

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

regulator 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.

SHIELDING GAS

OPERATOR’S MANUAL

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

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

WARNING

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

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

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

1. For

CO2, open the cylinder very slowly. For argonmixed gas, open cylinder valve slowly a fraction of a turn. When the cylinder pressure gauge pointer stops moving, open the valve fully.

2. Set gas flow rate for 30 to 40 cubic feet per hour (14 to 18 I/min.) under normal conditions, increase to as high as 40 to 50 CFH (18 to 23.5 I/min.) under drafty (slightly windy) conditions.

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

Page 18

B-9

OPERATION

C. CONNECT LEADS AND CABLES ON

THE MACHINE

(See Figure B.14)

1. Open the case side door.

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

3. Make sure the gun connector end is seated fully into the wire drive and tighten the thumbscrew to secure the gun.

4. Plug the gun trigger lead connector into the 4 pin gun trigger receptacle on the machine front.

5. Wire Drive Polarity. MIG welding requires Positive (+) polarity. Connect the short power cable from the wire drive to the positive (+) output terminal and tighten the thumbscrew.

LOCATE COMPONENTS TO CONNECT TO THE FRONT OF MACHINE

SLIDE CONNECTOR END HERE

(4 PI

LEA

D CON

GUN A

FIGURE B.14

TERMINAL EN (FITS ON STUD S

EE FIGURE B

CTOR

ND CABLE

MOLDED HAND SCREW TO TIGHTEN CONNECTOR BUSHING

WORK CLAMP

OPEN LATCH DOOR

NSI

LOW)

B-9

CASE SIDE DOOR

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

WORK LEAD CONNECTION NEGATIVE "-" OUTPUT TERMINAL

6. Work Lead Connection. Slide the lugged end of the work cable through the hole in the machine front and place on the negative (-) output terminal and tighten thumbscrew.

D. LOAD WIRE SPOOL

(See Figure B.15)

1. Locate the green labeled 4" diameter spool of .025 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 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 the drive roll on. Install the grooved

drive roll.

by turning the twist lock that holds

.025-.035 smooth

CONNECTOR END ATTACH

(4 PIN) T

RIGGER RECEPTACL

PLUGGED IN

FIGURE B.15

PIVOT ARM ASSEMBLY

BEARING

OUTGOING GUIDE

TENSION ARM ASSEMBLY DOWN

LINER

TWIST LOCK

WORK CLAMP

WIRE SPOOL .025" (0.6mm)

SHORT POWER CABLE POSITIVE "+" OUTPUT TERMINAL

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.

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

DRIVE ROLL

Page 19

B-10

OPERATION

(See Figure B.16)

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

PIVOT ARM ASSEMBLY WITH BEARING PRESSING AGAINST DRIVE ROLL

B-10

FIGURE B.16

7. Close the Pivot Arm Assembly and secure by pivoting the Tension Arm Assembly back to the up position.

(See Figure B.17)

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

9. Turn the machine power to on and depress the gun trigger to feed the wire through the gun liner until the wire comes out of the threaded end of the gun several inches. (See Figure B.18)

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

WARNING

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

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

• Keep away from moving parts and pinch points.

• Keep all Doors, Covers, panels and guards securely in place.

DO NOT REMOVE OR CONCEAL WARNING LABELS.

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

11. Install the .025 contact tip.

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

13. Trim the wire stickout to 3/8 from the nozzle end. (See Figure B.19)

SLIDE WIRE INTO GUN CONNECTOR SIDE

REMOVED NOZZLE

REMOVED CONTACT TIP

LAY CABLE AND GUN STRAIGHTEN IN THIS POSITION

FEED WIRE APPROXIMATELY 4.00" FROM THE GUN TUBE END

DEPRESS TRIGGER TO ACTIVATE WIRE, WHICH FEEDS THE WIRE THRU THE LINER.

OUTGOING GUIDE

FIGURE B.17

FIGURE B.18

ON/OFF SWITCH

WORK CLAMP AND CABLE

TENSION ARM ASSEMBLY LOCKED IN UP POSITION

BEARING

LINER

DRIVE ROLL

WIRE SPOOL .025" (0.6mm)

ROTAT ION

DIRECTION OF WIRE

WIRE SPOOL .025" (0.6mm)

PLUG IN POWER INPUT CORD

OPERATOR’S MANUAL

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

15. Read "Learn to Weld" (LTW1) that is included with the machine or watch the "How to Weld" DVD included with the machine.

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

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

FIGURE B.19

INSTALL .025 CONTACT TIP

INSTALL BRASS NOZZLE

Page 20

B-11

OPERATION

SETTING UP AND MAKING A ALUMINUM WELD USING SPOOL GUN

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

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

3. Disconnect Magnum 100L Gun.

4. Install optional K2532-1 Magnum 100SG spool gun per instructions included with gun.

5. Set Gun selector toggle switch to Spool Gun position. (See Figure B.20)

FIGURE B.20

B-11

WARNING

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

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

Page 21

C-1

K2525-1 - Spot Timer Kit

Timer kit, when turned on, allows you to set a fixed weld time so that when the gun trigger is pulled the machine will weld for a fixed time period up to 10 seconds. Ideal for making consistent spot welds when welding on thin sheet metal

K2528-1 - 045 Innershield Kit (For 230V models)

Includes everything needed to weld with .045 diameter Innershield wire. Includes an .035/.045 Magnum™ 100L gun liner, .045 Contact Tip, gasless nozzle, knurled drive roll, .035-.045 inner wire guide, and a 10 lb. (4.5kg) spool of .045"(0.9mm) Innershield® NR®-212 wire.

K2532-1 - Magnum 100SG Spool Gun

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.

ACCESSORIES

C-1

OPERATOR’S MANUAL

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)

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

Page 22

C-2

ACCESSORIES

K520—Utility Cart

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

For mounting welding machines to K520 carts that do not have slotted mounting holes. Drill 9/32” holes (3 places) into the cart top as shown and attach the welding machine to the cart with the proper hardware shown.

C-2

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

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

8-1/16"

3-11/16"

3-3/4"

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

9/32" DRILL 3 PLACES

3-13/32"

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

16"

Page 23

C-3

ACCESSORIES

K2275-1 - Welding Cart

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

For mounting welding machines to K2275-1 carts that do not have slotted mounting holes. Drill 9/32” holes (3 places) into the cart top as shown and attach the welding machine to the cart with the proper hardware shown.

C-3

OPERATOR’S MANUAL

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 Flange Nut (2 Required)

7-9/16"

3-3/16"

1-1/4"

9/32" DRILL 3 PLACES

2-15/16"

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

1-1/2"

13-1/2"

Page 24

D-1

MAINTENANCE

D-1

MAINTENANCE SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Disconnect input power by removing plug from receptacle before working inside WIRE FEEDER WELDERS (125,140, 180 MODELS).

Use only grounded receptacle. Do not touch electrically “hot” parts inside WIRE FEEDER WELDERS (125,140, 180 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 (125,140, 180 MODELS). Take the unit to an authorized Lincoln Service Center if you experience problems. N O maintenance is required.

In extremely dusty locations, sages causing the welder to run hot with premature tripping of thermal protection. If so, blow dirt out of the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build-up on internal parts.

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.

dirt may clog the air pas-

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, cable liner from the gas diffuser end.

gently blow out the

CAUTION

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

Flex the cable over its entire length and again blow out the cable. Repeat this procedure until no further dirt comes out.

Contact Tips, Nozzles, and Gun Tubes

1. Dirt can accumulate in the contact tip hole and restrict wire feeding. After each 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. 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

3. Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required.

4. Be sure the gas nozzle is fully screwed onto the diffuser for gas shielded processes. For the Innershield®process, the gasless nozzle should screw

onto the diffuser.

5. To remove gun tube from gun, remove gas nozzle or gasless nozzle and remove diffuser from gun tube. Remove both collars from each end of the gun handle and separate the handle halves. Loosen the locking nut holding the gun tube in place

against the gun end cab le 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 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.

fuser. Replace the gas nozzle or gasless nozzle.

gas diffuser.

Replace the gun handle, trigger and dif-

spool of wire is

A variable

(no

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

Page 25

D-2

MAINTENANCE

OVERLOAD PROTECTION

Output Overload

The WIRE FEEDER WELDERS (125,140, 180 MODELS) is 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 ELS) has a rated output duty cycle as defined in the Technical Specification page. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools to a reasonable operating temperature. This is an automatic f FEEDER WELDERS (125,140, 180 MODELS) and does not require user intervention. The fan continues to run during cooling.

Electronic Wire Drive Motor Protection

The WIRE FEEDER WELDERS (125,140, 180 MODELS) has built-in protection for wire drive motor overload.

FEEDER WELDERS (125,140, 180 MOD-

unction of the WIRE

Set Screw Brass Cable

Connector

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

FIGURE D.2

Liner trim length

D-2

1-1/4”(31.8 mm) Liner Trim Length

Gas Diffuser

Gas Nozzle or Gasless Nozzle

OPERATOR’S MANUAL

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 ing counter-clockwise.

2. Remove the existing contact tip from the gun by unscrewing counter-clockwise.

3. Remove the gas diffuser from the gun tube by unscrewing counter-clockwise.

4. Lay the gun and cable out straight on a flat surface. Loosen the set screw located in the brass 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 At this time, the gas diffuser should not be installed onto the end of the gun tube.

the set screw on the brass cable connector.

the gun by unscrew-

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 collar reaches a stop. Then pull the collar off the gun handle. If the collars are difficult to turn, 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.

position the gun handle against a corner,

➣

Counter-clockwise

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.

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

FIGURE D.3

Page 26

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and

machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all sa

__________________________________________________________________________

fety notes and precautions detailed throughout this manual.

E-1

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing 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.

that

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service

Facility.

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.

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

CAUTION

Page 27

E-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-2

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

OUTPUT PROBLEMS

“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 dut

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

y cycle.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadj ustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

OPERATOR’S MANUAL

PROBLEMS (SYMPTOMS)

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

3. Gun trigger may be faulty.

POSSIBLE CAUSE

FEEDING PROBLEMS

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.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadj ustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

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.

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

CAUTION

Page 28

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

PROBLEMS (SYMPTOMS)

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

PROBLEMS (SYMPTOMS)

Arc is unstable – Poor starting

POSSIBLE CAUSE

GAS FLOW PROBLEMS

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

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

POSSIBLE CAUSE

WELDING PROBLEMS

1. Check for correct input voltage to machine.

RECOMMENDED COURSE OF ACTION

If all recommended possible areas of misadj ustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

RECOMMENDED COURSE OF ACTION

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

break

7. Check for proper drive roll orientation and alignment.

8. Check liner for proper size.

If all recommended possible areas of misadj ustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

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.

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

CAUTION

Page 29

F-1

DIAGRAMS

F-1

OPERATOR’S MANUAL

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.

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

Page 30

F-2

DIMENSION PRINT

F-2

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

Page 31

NOTES

OPERATOR’S MANUAL

WIRE FEEDER WELDERS (125, 140, 180 MODELS)

Page 32

ALIMENTADOR DE ALAMBRE

IMS891-C

SOLDADORA (MODELOS 125, 140, 180)

Enero, 2009

Para usarse con máquinas con Números de Código:

TABLA DE CONTENIDO

Instalación ...........................Sección A

Especificaciones Técnicas .................A-1,A-2

Precauciones de Seguridad ....................A-2

Selección de una Ubicación Adecuada .........A-2

Estibación ................................A-2

Inclinación................................A-2

Identificación y Ubicación de los Componentes

for180Ampand140AmpUnits...............A-3

Identificación y Ubicación de los Componentes

for125AmpFluxCoreUnit ..................A-3

Operación ...........................Sección B

Seguridad y Descripción del Producto ............B-1

Controles y Configuraciones ...............B-2,B-3

Rodillo Impulsor y Tabla de Guías de Alambre .....B-4

Preparación y Realización de una

Soldadura deAlambre Tubular ...........B-4 aB-6

Preparación y Realización de una Soldadura

MIGeInstalacióndelGasProtector ......B-7aB-10

Preparación y Realización de una Soldadura de Aluminio

. .B-11..

11173 por 11506, 11550

ISO 9001

ANSI RAB

QMS

Designed and Manufactured Under aI

Quality Program Certified byI ABS Quality Evaluations, Inc.I

to ISO 9001 Requirements.

CERTIFICATE NUMBER: 30273

Accesorios ..........................

Accesorios Opcionales .......................C-1

Carros Utilitarios ........................C-2,C-3

Mantenimiento .......................Sección

Precauciones de Seguridad ...................D-1

Compartimiento de Alimentación de Alambre,

Motor del Ventilador, Mantenimiento del Carrete de

Alambre ................................D-1

Mantenimiento de la Pistola y Cable .............D-2

Protección contra Sobrecarga ..................D-2

Procedimientos de Reemplazo de Componentes . . .D-2

LocalizacióndeAverías ................Sección E

Precauciones de Seguridad ....................E-1

Cómo Utilizar la Guía de Localización de Averías . . .E-1

Guía de Localización de Averías ...........E-2aE-3

iagrama de Cableado & Dibujo de Dimensi

Sección C

ón.

.Sección F

La Seguridad Depende de

El equipo de soldadura de arco y corte de Lincoln está diseñado y construido teniendo la seguridad en mente. Sin embargo, es posible aumentar su seguridad general a través de una instalación apropiada... y una operación cuidadosa de su parte. NO

INSTALE, OPERE O REPARE ESTE EQUIPO SIN LEER ESTE MANUAL Y LAS PRECAUCIONES DE SEGURIDAD CONTENIDAS EN EL MISMO. Y

lo más importante, piense antes de actuar y tenga cuidado.

Usted

MANUAL DE OPERACIÓN

• Ventas y Servicio a través de las Subsidiarias y Distribuidores en todo el Mundo •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

•Líder mundial en productos de soldadura y corte •

Page 33

i-SP

SEGURIDAD

ADVERTENCIA

ADVERTENCIA DE LA LEY 65 DE CALIFORNIA

En el estado de California, se considera a las emisiones del motor de diesel y algunos de sus componentes como dañinas para la salud, ya que provocan cáncer, defectos de nacimiento y otros daños reproductivos.

i-SP

Las emisiones de este tipo de productos contienen químicos que, para el estado de California, provocan cáncer, defectos de nacimiento y otros daños reproductivos.

Lo anterior aplica a los motores Diesel

Lo anterior aplica a los motores de gasolina

LA SOLDADURA AL ARCO PUEDE SER PELIGROSA. PROTEJASE USTED Y A LOS DEMAS CONTRA POSIBLES LESIONES DE DIFERENTE GRAVEDAD, INCLUSO MORTALES. NO PERMITA QUE LOS NIÑOS SE ACERQUEN AL EQUIPO. LAS PERSONAS CON MARCAPASOS DEBEN CONSULTAR A SU MEDICO ANTES DE USAR ESTE EQUIPO.

Lea y entienda los siguientes mensajes de seguridad. Para más información acerca de la seguridad, se recomienda comprar un ejemplar de "Safety in Welding & Cutting - ANIS Standard Z49.1" de la Sociedad Norteamericana de Soldadura, P.O. Box 351040, Miami, Florida 33135 ó CSA Norma W117.2-1974. Un ejemplar gratis del folleto "Arc Welding Safety" (Seguridad de la soldadura al arco) E205 está disponible de Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

ASEGURESE QUE TODOS LOS TRABAJOS DE INSTALACION, FUNCIONAMIENTO, MANTENIMIENTO Y REPARACION SEAN HECHOS POR PERSONAS CAPACITADAS PARA ELLO.

Para equipos accionados por MOTOR.

1.a.

Apagar el motor antes de hacer trabajos de localización de averías y de mantenimiento, salvo en el caso que el trabajo de mantenimiento requiera que el motor esté funcionando.

____________________________________________________

1.b.L os motores deben abiertos bien ventilados, o expulsar los gases de escape del motor al exterior.

funcionar en lugares

1.h. Para evitar quemarse con agua caliente, no quitar la tapa a presión del radiador mientras el motor está caliente.

LOS CAMPOS ELECTRICOS Y MAGNETICOS pueden

____________________________________________________

1.d. Mantener seguridad del equipo en su lugar y en buenas condiciones. No acercar las manos, cabello, ropa y herramientas a las correas en V, engranajes, ventiladores y todas las demás piezas móviles durante el arranque, funcionamiento o reparación del equipo.

____________________________________________________

1.e. En algunos casos puede ser necesario quitar los protectores

para hacer algún trabajo de mantenimiento requerido. Quitarlos solamente cuando sea necesario y volver a colocarlos después de terminado el trabajo de mantenimiento. Tener siempre el máximo cuidado cuando se trabaje cerca de piezas en movimiento.

___________________________________________________

1.g. Para

gasolina mientras se hace girar el motor o generador de la soldadura durante el trabajo de mantenimiento, desconectar los cables de las bujías, tapa del distribuidor o cable del magneto, según corresponda.

1.c. No cargar combustible cerca de un arco de soldadura Apagar el motor y dejar que se enfríe antes de rellenar de combustible para impedir que el combustible derramado se vaporice al quedar en contacto con las piezas del motor caliente. No derramar combustible al llenar el tanque. Si se derrama, limpiarlo con un trapo y no arrancar el motor hasta que los vapores se hayan eliminado.

todos los protectores, cubiertas y dispositivos de

1.f. No poner las manos cerca del ventilador del motor. lador de velocidad en vacío empujando las varillas de control del acelerador mientras el motor está funcionando.

impedir el arranque accidental de los motores de

cuando el motor esté funcionando.

No tratar de sobrecontrolar el regu-

SOLDADORAS DE ALIMENTACION DE ALAMBRE (125, 140, 180 MODELOS)

2.a. La corriente eléctrica que circula a través de un conductor origina campos eléctricos y magnéticos (EMF) localizados. La corriente de soldadura crea campos EMF alrededor de los cables y los equipos de soldadura.

2.b. Los campos EMF pueden interferir con los marcapasos y en otros equipos médicos individuales, de manera que los operarios que utilicen estos aparatos deben consultar a su médico antes de trabajar con una máquina de soldar.

2.c. La exposición a los campos EMF en soldadura puede tener otros efectos sobre la salud que se desconocen.

2.d. Todo soldador debe emplear los procedimientos siguientes para reducir al mínimo la exposición a los campos EMF del circuito de soldadura:

2.d.1. Pasar los cables de pinza y de trabajo juntos -

2.d.2. Nunca enrollarse el cable de electrodo alrededor del

2.d.3. No colocar el cuerpo entre los cables de electrodo y

2.d.4. Conectar el cable de trabajo a la pieza de trabajo lo más

2.d.5. No trabajar al lado de la fuente de corriente.

Mar ‘95

ser peligrosos

Encintarlos juntos siempre que sea posible.

cuerpo.

trabajo. Si el cable del electrodo está en el lado derecho, el cable de trabajotambién debe estar en el lado derecho.

cerca posible del área que se va a soldar.

Page 34

ii-SP

SEGURIDAD

ii-SP

La DESCARGA ELÉCTRICA puede causar la muerte.

3.a.

Los circuitos del electrodo y de trabajo están eléctricamente con tensión cuando el equipo de soldadura está encendido. No tocar esas piezas con tensión con la piel desnuda o con ropa mojada. Usar guantes secos sin agujeros para aislar las manos.

3.b. Aislarse del circuito de trabajo y de tierra con la ayuda de material aislante seco. Asegurarse de que el aislante es suficiente para protegerle completamente de todo contacto físico con el circuito de trabajo y tierra.

Además de las medidas de seguridad normales, si es necesario soldar en condiciones eléctricamente peligrosas (en lugares húmedos o mientras se está usando ropa mojada; en las estructuras metálicas tales como suelos, emparrillados o andamios; estando en posiciones apretujadas tales como sentado, arrodillado o acostado, si existe un gran riesgo de que ocurra contacto inevitable o accidental con la pieza de trabajo o con tierra, usar el equipo siguiente:

• Equipo de soldadura semiautomática de C.C. a tensión constante.

• Equipo de soldadura manual C.C.

• Equipo de soldadura de C.A. con control de voltaje reducido.

3.c. En la soldadura semiautomática o automática con alambre continuo, el electrodo, carrete de alambre, cabezal de soldadura, boquilla o pistola para soldar semiautomática también están eléctricamente con tensión.

3.d. Asegurar siempre que el cable de trabajo tenga una buena conexión eléctrica con el metal que se está soldando. La conexión debe ser lo más cercana posible al área donde se va a soldar.

3.e. Conectar el trabajo o metal que se va a soldar a una buena toma de tierra eléctrica.

3.f. Mantener el portaelectrodo, pinza de trabajo, cable de soldadura y equipo de soldadura en unas condiciones de trabajo buenas y seguras. Cambiar el aislante si está dañado.

3.g. Nunca sumergir el electrodo en agua para enfriarlo.

3.h. Nunca tocar simultáneamente la piezas con tensión de los portaelectrodos conectados a dos equipos de soldadura porque el voltaje entre los dos puede ser el total de la tensión en vacío de ambos equipos.

3.i. Cuando se trabaje en alturas, usar un cinturón de seguridad para protegerse de una caída si hubiera descarga eléctrica.

3.j. Ver también 6.c. y 8.

SOLDADORAS DE ALIMENTACION DE ALAMBRE (125, 140, 180 MODELOS)

Los RAYOS DEL ARCO pueden quemar.

4.a.

Colocarse una pantalla de protección con el filtro adecuado para protegerse los ojos de las chispas y rayos del arco cuando se suelde o se observe un soldadura por arco abierto. Cristal y pantalla han de satisfacer las normas ANSI Z87.I.

4.b. Usar ropa adecuada hecha de material resistente a la flama durable para protegerse la piel propia y la de los ayudantes de los rayos del arco.

4.c. Proteger a otras personas que se encuentren cerca del arco, y/o advertirles que no miren directamente al arco ni se expongan a los rayos del arco o a las salpicaduras.

Los HUMOS Y GASES pueden ser peligrosos.

5.a. La soldadura puede producir humos y gases peligrosos para la salud. Evite respirarlos. Durantela soldadura, mantener la cabeza alejada de loshumos. Utilice ventilación y/o

mantener los humos y gases alejados de la zona de respiración. Cuando se suelda con electrodos de acero

inoxidable o recubrimiento duro que requieren ventilación especial (Ver instrucciones en el contenedor o la MSDS) o cuando se suelda chapa galvanizada, chapa recubierta de Plomo y Cadmio, u otros metales que producen humos tóxicos, se deben tomar precauciones suplementarias. Mantenga la exposición lo más baja posible, por debajo de los valores límites umbrales (TLV), utilizando un sistema de extracción local o una ventilación mecánica. En espacios confinados o en algunas situaciones, a la intemperie, puede ser necesario el uso de respiración asistida.

5.b. La operación de equipo de control de humos de soldadura se ve afectada por diversos factores incluyendo el uso adecuado y el posicionamiento del equipo así como el procedimiento de soldadura específico y la aplicación utilizada. El nivel de exposición del trabajador deberá ser verificado durante la instalación y despuees periodicamente a fin de asegurar que está dentro de los límites OSHA PEL y ACGIH TLV ppermisibles.s.

5.c No soldar en lugares cerca de una fuente de vapores de hidrocarburos clorados provenientes de las operaciones de desengrase, limpieza o pulverización. El calor y los rayos del arco puede reaccionar con los vapores de solventes para formar fosgeno, un gas altamente tóxico, y otros productos irritantes.

5.c. Los gases protectores usados para la soldadura por arco pueden desplazar el aire y causar lesiones graves, incluso la muerte. Tenga siempre suficiente ventilación, especialmente en las áreas confinadas, para tener la seguridad de que se respira aire fresco.

5.d. Lea atentamente las instrucciones del fabricante de este equipo y el material consumible que se va a usar, incluyendo la hoja de datos de seguridad del material (MSDS) y siga las reglas de seguridad del empleado, distribuidor de material de soldadura o del fabricante.

5.e. Ver también 1.b.

AGO ‘06

extracción de humos junto al arco para

MANUAL DE OPERACIÓN

Page 35

iii-SP

SEGURIDAD

iii-SP

Las CHISPAS DE SOLDADURA pueden provocar un incendio o una explosión.

6.a.

Quitar todas las cosas que presenten riesgo de incendio del lugar de soldadura. Si esto no es posible, taparlas para impedir que las chispas de la soldadura inicien un incendio. Recordar que las chispas y los materiales calientes de la soldadura puede pasar fácilmente por las grietas pequeñas y aberturas adyacentes al área. No soldar cerca de tuberías hidráulicas. Tener un extintor de incendios a mano.

6.b. En los lugares donde se van a usar gases comprimidos, se deben tomar precauciones especiales para prevenir situaciones de riesgo. Consultar “Seguridad en Soldadura y Corte“ (ANSI Estándar Z49.1) y la información de operación para el equipo que se esté utilizando.

6.c Cuando no esté soldando, asegúrese de que ninguna parte del circuito del electrodo haga contacto con el trabajo o tierra. El contacto accidental podría ocasionar sobrecalentamiento de la máquina y riesgo de incendio.

6.d. No calentar, cortar o soldar tanques, tambores o contenedores hasta haber tomado los pasos necesarios para asegurar que tales procedimientos no van a causar vapores inflamables o tóxicos de las sustancias en su interior. Pueden causar una explosión incluso después de haberse “limpiado”. Para más información, consultar “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 de la American Welding Society .

6.e. Ventilar las piezas fundidas huecas o contenedores antes de calentar, cortar o soldar. Pueden explotar.

6.f. Las chispas y salpicaduras son lanzadas por el arco de soldadura. Usar ropa adecuada que proteja, libre de aceites, como guantes de cuero, camisa gruesa, pantalones sin bastillas, zapatos de caña alta y una gorra. Ponerse tapones en los oídos cuando se suelde fuera de posición o en lugares confinados. Siempre usar gafas protectoras con protecciones laterales cuando se esté en un área de soldadura.

6.g. Conectar el cable de trabajo a la pieza tan cerca del área de soldadura como sea posible. Los cables de la pieza de trabajo conectados a la estructura del edificio o a otros lugares alejados del área de soldadura aumentan la posibilidad de que la corriente para soldar traspase a otros circuitos alternativos como cadenas y cables de elevación. Esto puede crear riesgos de incendio o sobrecalentar estas cadenas o cables de izar hasta hacer que fallen.

6.h. Ver también 1.c.

6.I. Lea y siga NFPA 51B "estándar para la prevención contra los incendios durante la soldadura, el corte y el otro trabajo caliente", disponibles de NFPA, 1 parque de Batterymarch, caja 9101, Quincy, mA 022690-9101 del PO.

6.j. No utilice una fuente de energía de la soldadura para la pipa que deshiela.

La BOTELLA de gas puede explotar si está dañada.

7.a.

Emplear únicamente botellas que contengan el gas de protección adecuado

en buenas condiciones de funcionamiento diseñados para el tipo de gas y la presión utilizados. Todas las mangueras, rácores, etc. deben ser adecuados para la aplicación y estar en buenas condiciones.

7.b. Mantener siempre las botellas en posición vertical sujetas firmemente con una cadena a la parte inferior del carrooaun soporte fijo.

7.c. Las botellas de gas deben estar ubicadas:

• Lejos de las áreas donde puedan ser golpeados o estén

sujetos a daño físico.

• A una distancia segura de las operaciones de corte o

soldadura por arco y de cualquier fuente de calor, chispas o llamas.

7.d. Nunca permitir que el electrodo, portaelectrodo o cualquier otra pieza con tensión toque la botella de gas.

7.e. Mantener la cabeza y la cara lejos de la salida de la válvula de la botella de gas cuando se abra.

7.f. Los capuchones de protección de la válvula siempre deben estar colocados y apretados a mano, excepto cuando la botella está en uso o conectada para uso.

7.g. Leer y seguir las instrucciones de manipulación en las botellas de gas y el equipamiento asociado, y la publicación P-I de CGA, “Precauciones para un Manejo Seguro de los Gases Comprimidos en los Cilindros“, publicado por Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA

22202.

para el proceso utilizado, y reguladores

PARA equipos

ELÉCTRICOS

8.a. Cortar la electricidad entrante usando el interruptor de desconexión en la caja de fusibles antes de trabajar en el equipo.

8.b. Conectar el equipo a la red de acuerdo con U.S. National Electrical Code, todos los códigos y las recomendaciones del fabricante.

8.c. Conectar el equipo a tierra de acuerdo con U.S. National Electrical Code, todos los códigos y las recomendaciones del fabricante.

Enero de 07

SOLDADORAS DE ALIMENTACION DE ALAMBRE (125, 140, 180 MODELOS)

Page 36

iv-SP

SEGURIDAD

iv-SP

PRÉCAUTIONS DE SÛRETÉ

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.