Lincoln Electric IM890 User Manual

Operator’s Manual

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POWER MIG ®(140, 180 MODELS)

For use with machines having Code Numbers:

11254, 11255, 11256, 11257 and
11444

LINCOLN

ELECTRIC

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM890-A | Issue D ate Nov- 13

© Lincoln Global, Inc. All Rights Reserved.

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THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIAL SITUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY

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

SAFETY DEPENDS ON YOU

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

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

act and be careful.

WARNING

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

CAUTION

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

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

corrective lenses if necessary to
stay a reasonable distance away
from the arc.

READ and obey the 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.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate
(See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

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.

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

SECTION A:

Diesel Engines

Gasoline Engines

WARNINGS

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

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.

SAFETY

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

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.

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.

ii

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.

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

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.

between the

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 within applicable OSHA PEL and
ACGIH TLV limits 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.

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.

3.j. Also see It ems 6.c. and 8.

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

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.

iii

cause

SAFETY

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.

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.

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.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety
Interactive Web Guide
for mobile devices

iv

SAFETY

ELECTROMAGNETIC

COMPATIBILITY (EMC)

CONFORMANCE

Products displaying the CE mark are in conformity with European
Community Council Directive of 3 May 1989 on the approximation of
the laws of the Member States relating to electromagnetic compat­ibility (89/336/EEC). It was manufactured in conformity with a national
standard that implements a harmonized standard: EN 60974-10
Electromagnetic Compatibility (EMC) Product Standard for Arc Welding
Equipment. It is for use with other Lincoln Electric equipment. It is
designed for industrial and professional use.

INTRODUCTION

All electrical equipment generates small amounts of electromagnetic
emission. Electrical emission may be transmitted through power lines
or radiated through space, similar to a radio transmitter. When
emissions are received by other equipment, electrical interference
may result. Electrical emissions may affect many kinds of electrical
equipment; other nearby welding equipment, radio and TV reception,
numerical controlled machines, telephone systems, computers, etc.
Be aware that interference may result and extra precautions may be
required when a welding power source is used in a domestic estab­lishment.

INSTALLATION AND USE

The user is responsible for installing and using the welding equipment
according to the manufacturer’s instructions. If electromagnetic
disturbances are detected then it shall be the responsibility of the
user of the welding equipment to resolve the situation with the
technical assistance of the manufacturer. In some cases this remedial
action may be as simple as earthing (grounding) the welding circuit,
see Note. In other cases it could involve construction of an electro­magnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances
must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons

according to national codes. Changing the earthing arrangements should
only be authorized by a person who is competent to access whether the
changes will increase the risk of injury, e.g., by allowing parallel welding
current return paths which may damage the earth circuits of other equip­ment.

ASSESSMENT OF AREA

Before installing welding equipment the user shall make an
assessment of potential electromagnetic problems in the surrounding
area. The following shall be taken into account:

a. other supply cables, control cables, signaling and telephone cables;

above, below and adjacent to the welding equipment;

b. radio and television transmitters and receivers;

c. computer and other control equipment;

d. safety critical equipment, e.g., guarding of industrial equipment;

e. the health of the people around, e.g., the use of pacemakers and

hearing aids;

f. equipment used for calibration or measurement

g. the immunity of other equipment in the environment. The user shall

ensure that other equipment being used in the environment is
compatible. This may require additional protection measures;

h. the time of day that welding or other activities are to be carried out.

The size of the surrounding area to be considered will depend on the
structure of the building and other activities that are taking place. The
surrounding area may extend beyond the boundaries of the premises.

METHODS OF REDUCING EMISSIONS

Mains Supply

Welding equipment should be connected to the mains supply
according to the manufacturer’s recommendations. If interference
occurs, it may be necessary to take additional precautions such as
filtering of the mains supply. Consideration should be given to
shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be
electrically continuous throughout its length. The shielding should be
connected to the welding power source so that good electrical contact
is maintained between the conduit and the welding power source
enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to
the manufacturer’s recommendations. All access and service doors
and covers should be closed and properly fastened when the welding
equipment is in operation. The welding equipment should not be
modified in any way except for those changes and adjustments
covered in the manufacturers instructio ns. In particular, the spark
gaps of arc striking and stabilizing devices should be adjusted and
maintained according to the manufacturer’s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should be
positioned close together, running at or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and
adjacent to it should be considered. However, metallic components
bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the
electrode at the same time. The operator should be insulated from all
such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not
connected to earth because of its size and position, e.g., ships hull or
building steelwork, a connection bonding the workpiece to earth may
reduce emissions in some, but not all instances. Care should be taken
to prevent the earthing of the work piece increasing the risk of injury
to users, or damage to other electrical equipment. Where necessary,
the connection of the workpiece to earth should be made by a direct
connection to the work piece, but in some countries where direct
connection is not permitted, the bonding should be achieved by
suitable capacitance, selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in
the surrounding area may alleviate problems of interference.
Screening of the entire welding installation may be considered for
special applications.

1

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic

Compatibility (EMC) product standard for arc welding equipment.”

viii

TABLE OF CONTENTS

Page

––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

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

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

Safety Precautions.................................................................................................A-3

Location...........................................................................................................A-3

Stacking ..........................................................................................................A-3

Tilting...............................................................................................................A-3

Identify and Locate Components...........................................................................A-4

________________________________________________________________________________

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

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

Controls and Settings.....................................................................................B-2, B-3

Drive Roll and Wire Guides Table .........................................................................B-4

Setting Up and Making a Flux-Cored Weld.............................................B-5 thru B-7

Setting Up and Making a MIG Weld and Install Shielding Gas..............B-8 thru B-11

Setting Up and Making a Aluminum Weld...........................................................B-12

________________________________________________________________________

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

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

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

________________________________________________________________________

viii

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

Safety Precautions ................................................................................................D-1

Wire Feed Compartment, Fan Motor, Wire Reel Maintenance .............................D-1

Gun And Cable Maintenance ................................................................................D-2

Overload Protection...............................................................................................D-2

Component Replacement Procedures ..................................................................D-3

________________________________________________________________________

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

Safety Precautions.................................................................................................E-1

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

Troubleshooting Guide.............................................................................E-2 thru E-4

________________________________________________________________________

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

________________________________________________________________________

Parts Lists................................................................................................P-533, P-202-E

________________________________________________________________________

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS

180 Amp units

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

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 Open Circuit Voltage Wire Speed Range

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

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,

1

Input Amps Power Cord

Three Prong Plug

(NEMA Type 6-50P)

PHYSICAL DIMENSIONS

Height Width Depth Weight

14.0 in 10.15 in 18.6 in 66 Ibs
357 mm 258 mm 472 mm 30 kg

1

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

(1.3 - 12.7 m/min.)

140 Amp units

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

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 19.5

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

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

14.0 in 10.15 in 18.6 in 58 Ibs
357 mm 258 mm 472 mm 26.3 kg

1

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

(1.3 - 12.7 m/min.)

3 Conductor # 12 AWG

POWER MIG (140, 180 MODELS)

A-2

INSTALLATION

A-2

TECHNICAL SPECIFICATIONS

180 Amp units

(K2668-1 180C)

INPUT – SINGLE PHASE ONLY

Standard Voltage/Frequency Input Current

240 V 50 Hz

I

I

1 eff

1 max

20 Amps

10.7 Amps

RATED OUTPUT

Voltage/Duty

240 V 25% 131 Amps 20

Cycle Current Voltage at Rated Amperes

OUTPUT

Welding

Current Range Open Circuit Voltage Wire Speed Range

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

RECOMMENDED INPUT CABLE AND FUSE SIZES

Input Voltage/Frequency Fuse or Breaker Size

240 V 50 Hz 40 Amp Super Lag 20 15 Amp, 240 V,

1

Input Amps Power Cord

PHYSICAL DIMENSIONS

Height Width Depth Weight

14.0 in 10.15 in 18.6 in 66 Ibs
357 mm 258 mm 472 mm 30 kg

1

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

1.3 - 12.7 ( m/min.)

Three Pin Plug

2

Requirements For Maximum Output

In order to utilize the maximum output capability of
the machine, a branch circuit capable of 25 amps at
120 volts, 60 Hertz is required.

POWER MIG (140, 180 MODELS)

A-3

INSTALLATION

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.

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.

A-3

STACKING

POWER MIG (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.

POWER MIG (140, 180 MODELS)

A-4

INSTALLATION

A-4

IDENTIFY AND LOCA TE COMPONENTS

INCLUDED COMPONENTS

• Wire Feeder Welder.

• Work Cable & Clamp.

• Magnum 100L Welding Gun.

• .030” -.045” (0.8 - 1.1mm) Knurled Drive Roll
(Installed on Machine)

.030

.045

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

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

(Installed on Machine)

• Outer Wire Guide (Installed on Machine)

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

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

OUTER WIRE GUIDE

• Black Flux-cored Gasless Gun Nozzle (Installed on

Welding Gun)

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

• 3 .025” (0.6mm) Contact Tips.

.035

.035

.025

.025

.025

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

Innershield Flux-cored Wire.

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

NR-211 MP

• .025”-.030” (0.6 - 0.8mm)

• .035” (0.9mm)

Smooth Drive Roll

Smooth Drive Roll

L-56 MIG

WIRE

• Brass MIG Gas Gun Nozzle

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

• Regulator

• Gas Hose

• Learn to Weld (LTW1 Manual)

• DVD

REGULATOR

GAS HOSE

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

"LEARN TO WELD"

LTW1

DVD

POWER MIG (140, 180 MODELS)

B-1

OPERATION

B-1

Read entire operation section before
operating the POWER MIG.

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.

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. Flux-cored
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”(0.9mm)
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.

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

POWER MIG (140, 180 MODELS)

COMMON WELDING ABBREVIATIONS

GMAW (MIG)

• Gas Metal Arc Welding

FCAW (Innershield or Outershield)

• Flux Core Arc Welding

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.

FIGURE B.1

2

3

1

FIGURE B.2

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” (0.6mm to 0.9mm) wire. The 180A machine
can weld with .045”(1.1mm) wire if an optional
.045”(1.1mm) liner is installed in the gun.

b. Contact Tip – provides electrical contact to the

wire.

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.

5c

4

5b

5a

.035"(0.9mm)

5

6

7

NR-211-MP

WIRE SPOOL

POWER MIG (140, 180 MODELS)

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”(102mm) diameter spool. Use the 2”(51mm)
spindle adapter included with the machine to use
8”(203mm) diameter spools. The thumbscrew
sets the brake friction to prevent the spool from
over rotating when the trigger is released.

FIGURE B.3

8

9

FIGURE B.4

2"(51mm) SPINDLE ADAPTER (FOR 8"(20mm) REEL OF WIRE)

( 4"(102mm) REEL OF WIRE)

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. Top and Bottom 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. Inner & Outer Wire Guide – Guides the wire

between the Top and Bottom Drive Roll and
through the wire drive. The inner guide has a
groove to match a particular wire diameter.
Refer to Table B.1 for available wire guides.

c. Drive Roll Tension Thumbscrew – Turning

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

FIGURE B.5

TOP DRIVE ROLL PRESSURE ARM

TENSION ADJUSTOR DOWN

INNER WIRE GUIDE REMOVED

LOWER DRIVE ROLL REMOVED

WIRE SPOOL
.035" (0.9mm)

NR-211-MP

OUTER WIRE GUIDE REMOVED

POWER MIG (140, 180 MODELS)

B-4

OPERATION

TABLE B.1

DRIVE ROLL AND WIRE GUIDES

B-4

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
.045”(1.1mm) flux-cored

12. CIRCUIT BREAKER – If the rated input current of
the machine is exceeded this circuit breaker will
trip. Press to reset.

.025”/.030” (0.6mm/0.8mm)

.035”(0.9mm) Smooth Drive Roll

.030”/.045” (0.8mm/1.1mm)

.030”/.045” (0.8mm/1.1mm)

See Figure B.6

Drive Roll

Smooth Drive Roll

Knurled Drive Roll

Knurled Drive Roll

Drive Roll Part

Number

KP2529-1

KP2529-2

KP2529-3

KP2529-3

12

Inner Wire Guide

.025”-.035”

(0.6mm-0.9mm)

Steel Wire Guide

.045”(1.1mm)

Wire Guide

Steel

FIGURE B.6

13

Inner Wire Guide

Part Number

KP2531-1

KP2531-2

13. GAS INLET – Shielding gas connects to this inlet.

POWER MIG (140, 180 MODELS)

B-5

OPERATION

SETTING UP AND MAKING A FLUX-CORED WELD

A. ITEMS NEEDED FOR FLUX CORED

WELDING

1. 035”(0.9mm) Contact Tip

.035

2. .025”-.035”(0.6mm-0.9mm) wire guide

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

B-5

7. Work Cable & Clamp

3. Knurled Drive Roll

.030

.045

4. .035”(0.9mm) NR-211MP Flux-Cored Wire

.035 NR-211 MP

E

R

F

L

I

W

E

U

R

X

O

-

C

5. Black Flux Cored gun nozzle

6. Welding Gun

POWER MIG (140, 180 MODELS)

B-6

OPERATION

B. CONNECT LEADS AND CABLES ON

THE MACHINE

(See Figure B.7)

1. Open the case side door

LOCATE COMPONENTS
TO CONNECT TO THE
FRONT OF MACHINE

B-6

FIGURE B.7

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 thumbscrew 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 the thumbscrew.

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 thumbscrew.

C. LOAD WIRE SPOOL

(See Figure B.8)

1. Locate the blue labeled 4"(102mm) diameter
spool of .035”(0.9mm) NR-211MP flux-cored wire
and place onto wire spool spindle. Orient the
spool so that the wire feeds off the top of the
spool.

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

SLIDE
CONNECTOR
END HERE

(4 PIN)
LEAD CONNECTOR

GUN AND CABLE

OPEN LATCH DOOR

TERMINAL END
(FITS ON STUD INSIDE
SEE FIGURE BELOW)

WORK CLAMP

THUMB SCREW TO
TIGHTEN CONNECTOR
BUSHING

CONNECTOR
END ATTACH

(4 PIN)
TRIGGER RECEPTACLE

PLUGGED IN

FIGURE B.8

TOP DRIVE ROLL PRESSURE ARM

TENSION ADJUSTOR DOWN

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

WORK CLAMP

WIRE SPOOL
.035" (0.9mm)

SHORT POWER
CABLE NEGATIVE "-"
OUTPUT TERMINAL

WORK LEAD
CONNECTION
POSITIVE "+"
OUTPUT TERMINAL

3. Open the top drive roll pressure arm by rotating
the tension adjustor arm down and pivoting the
drive roll pressure arm up.

4. Remove the outer wire guide.

4a. Slide gun out of drive slightly.

5. Remove the lower drive roll and inner wire guide.
Install the .025”-.035”(0.6mm-0.9mm) inner wire guide.

6.

7. Install the .030”/.045”(0.8mm/1.1mm) knurled lower drive roll.

8. 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.

POWER MIG (140, 180 MODELS)

NR-211-MP

INNER WIRE GUIDE REMOVED

LOWER DRIVE ROLL REMOVED

OUTER WIRE
GUIDE REMOVED

B-7

R

(

See Figure B.9)

OPERATION

9. Feed the wire through the wire drive inlet along the
inner wire guide groove and into the wire drive outlet
on the gun side.

10. Close the top drive roll pressure arm and secure by
pivoting the tension adjustor back to the up position.

11. Re-install the outer wire guide.

SLIDE WIRE
INTO GUN
CONNECTOR
SIDE

TOP DRIVE ROLL
PRESSED AGAINST
LOWER DRIVE ROLL

FIGURE B.9

TENSION ADJUSTOR
LOCKED IN POSITION

WIRE SPOOL
.035" (0.9mm)

NR-211-MP

DIRECTION
OF WIRE

B-7

(See Figure B.10)

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

13. 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)

14. 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.

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

15. Install the .035”(0.9mm) contact tip

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

LOWER DRIVE ROLL
BE SURE WIRE
IS IN GROOVE

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

WIRE SPOOL

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

WIRE SPOOL

PLUG IN POWE
INPUT CORD

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

17. Trim the wire stickout to 3/8”(9.5mm) from the con­tact tip. (See Figure B.12)

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

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

20. 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.

POWER MIG (140, 180 MODELS)

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

ROTATION

WORK CLAMP AND CABLE

FIGURE B.12

INSTALL .035 CONTACT TIP

INSTALL BLACK FLUX-CORED NOZZLE

B-8

OPERATION

SETTING UP AND MAKING A MIG WELD

A. ITEMS NEEDED FOR MIG WELDING

1. 025”(0.6mm) Contact Tip

.025

2. 025”-035”(0.6mm-0.9mm) Inner wire guide

INNER WIRE GUIDE
.025-.035

B-8

7. Work Cable & Clamp

8. Gas Regulator & Gas Line

.025-.035

3. .025”(0.6mm) Drive Roll

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

L-56 MIG

WIRE

9. Bottle of 75/25 Ar/

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

MALE END

CO

100%

2

FEMALE END

CO2regulator

75/25

MIXES

CO

2

5. Brass gun nozzle

6. Welding Gun

(REQUIRES ADAPTER
SOLD SEPARATELY)

POWER MIG (140, 180 MODELS)

B-9

B. INSTALL SHIELDING GAS

OPERATION

B-9

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-

2

or

2

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

CO

100%

FEMALE END

75/25

MIXES

2

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

CO

2

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

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.

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

POWER MIG (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.

B-10

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 PIN)
LEAD CONNECTOR

GUN AND CABLE

FIGURE B.14

OPEN LATCH DOOR

TERMINAL END
(FITS ON STUD INSIDE
SEE FIGURE BELOW)

WORK CLAMP

THUMB SCREW TO
TIGHTEN CONNECTOR
BUSHING

CASE SIDE DOOR

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

B-10

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"(102mm) diameter
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 against the spacer that holds the wire
spool on the spindle.

3. Open the top drive roll pressure arm by rotating the
tension adjustor arm down and pivoting the idle roll
pressure arm up.

4. Remove the outer wire guide.

4a. Slide gun out of drive slightly.

CONNECTOR
END ATTACH

(4 PIN)
TRIGGER RECEPTACLE
PLUGGED IN

FIGURE B.15

TOP DRIVE ROLL PRESSURE ARM

TENSION ADJUSTOR DOWN

WORK CLAMP

WIRE SPOOL
.025" (0.6mm)

L

-

5

6

SHORT POWER
CABLE POSITIVE "+"
OUTPUT TERMINAL

G

I

M

D

S

I

O

L

5. Remove the lower drive roll and inner wire guide.

6. Install the .025”-.035”(0.6mm-0.9mm) inner wire guide.

7. Install the .025”(0.6mm) smooth grooved lower drive roll.

8. 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.

POWER MIG (140, 180 MODELS)

INNER WIRE GUIDE REMOVED

LOWER DRIVE ROLL REMOVED

OUTER WIRE
GUIDE REMOVED

B-11

R

OPERATION

(See Figure B.16)

9. Feed the wire through the wire drive inlet along the

inner wire guide groove and into the wire drive out­let on the gun side.

TOP IDLER ROLL
PRESSED AGAINST
LOWER DRIVE ROLL

FIGURE B.16

TENSION ADJUSTOR
LOCKED IN POSITION

B-11

10. Close the top drive roll pressure arm and secure

by pivoting the tension adjustor back to the up
position.

11. Re-install the outer wire guide.

(See Figure B.17)

12. Remove the nozzle from the gun and contact tip

and straighten the gun out flat.

13. 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)

14. 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.

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

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

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.

FIGURE B.17

FIGURE B.18

ON/OFF
SWITCH

DRIVE ROLL
BE SURE WIRE
IS IN GROOVE

WIRE SPOOL
.025" (0.6mm)

L

-

5

6

S

O

L

M

I

D

WIRE SPOOL
.025" (0.6mm)

L

-

5

6

S

O

G

I

L

I

WIRE SPOOL
.025" (0.6mm)

L

I

M

D

-

5

6

S

O

G

DIRECTION
OF WIRE

G

I

M

D

L

I

PLUG IN POWE
INPUT CORD

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

17. Trim the wire stickout to 3/8”(9.5mm) from the nozzle
end. (See Figure B.19)

18. Close the case side door. The machine is now ready

to weld.

19. Read "Learn to Weld" (LTW1) that is included with

the machine or watch the "How to Weld" DVD includ­ed with the machine.

20. 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.

POWER MIG (140, 180 MODELS)

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

ROTATION

WORK CLAMP AND CABLE

FIGURE B.19

INSTALL .025 CONTACT TIP

INSTALL BRASS NOZZLE

B-12

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-12

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

POWER MIG (140, 180 MODELS)

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”(1.1mm)
diameter Innershield wire. Includes an
.035”/.045”(0.9mm/1.1mm) Magnum™ 100L gun liner,
.045”(1.1mm) Contact Tip, gasless nozzle, knurled
drive roll, .045”(1.1mm) inner wire guide, and a 10 lb.
(4.5kg) spool of .045"(1.1mm) Innershield® NR®-212
wire.

ACCESSORIES

C-1

K2532-1 - Magnum 100SG Spool Gun

Designed to easily feed small 4"(102mm0 diameter
(1lb.-.5kg spools of) .030”(0.8mm) or .035”(0.9mm)
aluminum wire. Includes gun, adapter kit, three extra
.035”(0.9mm) contact tips, gas nozzle, and spool of
Superglaze 4043 .035"(0.9mm) 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)

POWER MIG (140, 180 MODELS)

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.

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

C-2

8-1/16"

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

3-3/4" (95.3mm)

(204.8mm)

3-11/16"

(93.7mm)

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

9/32"(7.1mm) DRILL

3 PLACES

3-13/32"

(96.8mm)

4"(102mm)

16"(406.4mm)

POWER MIG (140, 180 MODELS)

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 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

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"(192.1mm)

3-3/16"(81mm)

1-1/4"(31.8mm)

9/32"(7.1mm) DR
3 PLACES

ILL

2-15/16"(74.6mm)

1-1/2"(38.1mm)

13-1/2"(342.9mm)

POWER MIG (140, 180 MODELS)

D-1

MAINTENANCE

MAINTENANCE
SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Disconnect input power by removing
plug from receptacle before working
inside POWER MIG (140, 180 MODELS).
Use only grounded receptacle. Do not
touch electrically “hot” parts inside
POWER MIG (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 POWER MIG
(140, 180 MODELS). Take the unit to an authorized Lincoln
Service Center if you experience problems. NO maintenance
is required.

D-1

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 wire guides and keep grooves
clean.

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.

POWER MIG (140, 180 MODELS)

D-2

MAINTENANCE

D-2

GUN AND CABLE
MAINTENANCE

FOR MAGNUM™ 100L GUN

Gun Cable Cleaning

Clean cable liner after using approximately 300 lbs
(136 kg) of solid wire or 50 lbs (23 kg) of flux-cored
wire. Remove the cable from the wire feeder and lay it
out straight on the floor. Remove the contact tip from
the gun. Using low pressure air, gently blow out the
cable liner from the gas diffuser end.

CAUTION

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

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

Contact Tips, Nozzles, and Gun Tubes

1. Dirt can accumulate in the contact tip hole and
restrict wire feeding. After each spool of wire is
used, remove the contact tip and clean it by push­ing a short piece of wire through the tip repeatedly.
Use the wire as a reamer to remove dirt that may
be adhering to the wall of the hole through the tip.

2. Replace worn contact tips as required. A variable
or “hunting” arc is a typical symptom of a worn con­tact tip. To install a new tip, choose the correct size
contact tip for the electrode being used (wire size is
stenciled on the side of the contact tip) and screw it
snugly into the gas diffuser.

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

4. Be sure the gas nozzle is fully screwed onto the
diffuser for gas shielded processes. For the
Innershield®process, the gasless nozzle should
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 cable connector.
Unscrew gun tube from cable connector. To install
gun tube, screw the locking nut on the gun tube as
far as possible. Then screw the gun tube into the
cable connector until it bottoms. Then unscrew (no
more than one turn) the gun tube until its axis is
perpendicular to the flat sides of the cable connec­tor and pointed in the direction of the trigger.
Tighten the locking nut so as to maintain the proper
relationship between the gun tube and the cable
connector. Replace the gun handle, trigger and dif­fuser. Replace the gas nozzle or gasless nozzle.

OVERLOAD PROTECTION

Output Overload

The POWER MIG (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 POWER MIG (140, 180 MODELS) 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 function of the POWER MIG
(140, 180 MODELS) and does not require user inter­vention. The fan continues to run during cooling.

Electronic Wire Drive Motor Protection

The POWER MIG (140, 180 MODELS) has built-in
protection for wire drive motor overload.

POWER MIG (140, 180 MODELS)

D-3

Set Screw Brass Cable

Connector

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

MAINTENANCE

1-1/4”(31.8 mm)
Liner Trim Length

Gas Diffuser

Gas Nozzle or
Gasless Nozzle

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 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.

D-3

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, 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.

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.

POWER MIG (140, 180 MODELS)

➣

Counter-clockwise

FIGURE D.3

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 safety 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 that
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

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

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

CAUTION

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

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

POWER MIG (140, 180 MODELS)

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 duty cycle.

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

RECOMMENDED
COURSE OF ACTION

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

Contact your local Lincoln
Authorized Field Service
Facility.

3. Gun trigger may be faulty.

CAUTION

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

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

POWER MIG (140, 180 MODELS)

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

PROBLEMS
(SYMPTOMS)

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

PROBLEMS
(SYMPTOMS)

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.

POSSIBLE
CAUSE

RECOMMENDED
COURSE OF ACTION

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

Contact your local Lincoln
Authorized Field Service
Facility.

RECOMMENDED
COURSE OF ACTION

GAS FLOW PROBLEMS

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

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

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

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

Contact your local Lincoln
Authorized Field Service
Facility.

CAUTION

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

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

POWER MIG (140, 180 MODELS)

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

PROBLEMS
(SYMPTOMS)

Arc is unstable – Poor starting

POSSIBLE
CAUSE

WELDING PROBLEMS

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.

RECOMMENDED
COURSE OF ACTION

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

Contact your local Lincoln
Authorized Field Service
Facility.

8. Check liner for proper size.

CAUTION

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

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

POWER MIG (140, 180 MODELS)

F-1

FOR CODES 11254, 11255, 11256, 11257

Enhanced Diagram

DIAGRAMS

F-1

FOR CODES 11254, 11255, 11256, 11257

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.

POWER MIG (140, 180 MODELS)

F-2

DIAGRAMS

F-2

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.

POWER MIG (180 MODELS)

F-3

DIMENSION PRINT

F-3

A

M21111-2

14.08

10.37

2.46

18.78

12.00

3.08

POWER MIG (140, 180 MODELS)

6.00 5.50

PARTS LIST FOR

®

POWER MIG

(140 & 180 Models)

P-533P-533

This parts list is provided as an informative guide only.

It was accurate at the time of printing. These pages are only updated on the
Service Navigator DVD and in Lincoln Electricʼs official Parts Book (BK-34).

When ordering parts, always refer to Lincoln Electricʼs official Parts Book
(BK-34) for the latest pages.

POWER MIG®(140, 180 MODELS)

ILLUSTRATION OF SUB-ASSEMBLIES

5

3

2

1

4

P-533-AP-533-A

POWER MIG

®

(140, 180 MODELS)

02-04-2010

P-533-A.1 P-533-A.1

POWER MIG®(140, 180 Models)

For Codes: 11254, 11255, 11256, 11257, 11444, 11804, 11819 & 11820

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any
code numbers not listed.

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and
column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

SUB ASSEMBLY

PAGE NAME

Optional Equipment Listing

PAGE NO.

CODE NO.

11254 (140 Amp) 1111111•

11255 (140 Amp) 1511121•

11256 (180 Amp) 2121111•

P-533-B.1

Miscellaneous Items

P-533-B.2

1

General Assembly

P-533-C

2

Power Module Assembly

P-533-D

3

Center Panel Assembly

P-533-E

4

Wire Drive Assembly

P-533-F

5

Wraparound & Door Assembly

P-533-G

Magnum 100 L Gun & Cable

(K530-6)

P-202-E2

Magnum Pro 100 L Gun &

Cable (K3080-1)

P-202-AJ

#

11257 (180 Amp) 2121121•

11444 (180 Amp) 3122131•

11804 (140 Amp) 443312• 1

11819 (140 Amp) 421312• 1

11820 (180 Amp) 5 32312• 1

POWER MIG

®

(140, 180 MODELS)

01-30-2012

OPTIONAL EQUIPMENT LISTING

Miscellaneous Options Available for your machine are listed below:

# Indicates a change this printing.

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PART NUMBER

Spot Timer Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2525-1

.045 Innershield Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2528-1

Deluxe Adjustable Gas Regulator & Hose Kit (Codes 11254,11255,11256 & 11257)

Welding Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2275-1

Utility Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K520-1

Spool Gun Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2532-1

.025 Smooth Drive Roll Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2529-1

.035 Smooth Drive Roll Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2529-2

.030/.045 Knurled Drive Roll Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2529-3

.025/.035 Steel Wire Guide Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2531-1

.045 Steel Wire Guide Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2531-2

. . . . . . .Order K586-1

P-533-B.1P-533-B.1

POWER MIG

®

(140, 180 MODELS)

02-04-2010

P-533-B.2

MISCELLANEOUS ITEMS

(THESE ITEMS ARE NOT ILLUSTRATED)

P-533-B.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

DESCRIPTION PART NO. QTY. 123456789

Plug & Lead Assembly S18250-908 1 X • • X •
Plug & Lead Assembly S18250-909 1 • X X • X
Plug & Lead Assembly (P301) S18250-916 1 X X • X •
Plug & Lead Assembly S18250-944 1 • • X • •
Plug & Lead Assembly (P1005) S18250-917 1 XXX• X
Work Cable S11609-29 1 X • • X •
Work Cable S11609-30 1 • X X • X
Work Clamp M12033 1 XXXXX
DVD (Arc Welding) S26375 1 XXXXX
Wire Reel Spindle Adapter M15445-1 1 XXXXX
Gas Regulator (Argon Mixed) S25805 * 1 XX•••
Gas Regulator S25183 1 • • X • •
Gas Regulator 3000290 1 •••XX
Gas Hose Assembly S19303 1 X X • X X
Gas Hose Assembly S19303-3 1 • • X • •

* Deluxe version available as K586-1.

Includes S19303 Gas Hose Asbly

POWER MIG

®

(140, 180 MODELS)

05-25-2011

General Assembly

1A

13

1B

7A

7B

4

6

1B

12A

11B

9A

8

10

9B

9C

5A

5B

3A

2

14

P-533-CP-533-C

7A

1A

7B

3A

1B

9A

5A

9B

9C

12A

5B

11B

1B

14

13

10

POWER MIG

®

(140, 180 MODELS)

02-04-2010

P-533-C.1

P-533-C.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Case Front G4812-1 1 XXXXX
1B Thread Forming Screw S9225-63 4 XXXXX
2 Nameplate (Code 11254) L12398-2 1 X ••••
2 Nameplate (Code 11255) L12398-4 1 ••••X
2 Nameplate (Code 11256) L12398-3 1 X ••••
2 Nameplate (Codes 11257 & 11444) L12398-5 1 X ••••
2 Nameplate (Codes 11804 & 11819) L13921-1 1 • X • X •
2 Nameplate (Code 11820) L13921-2 1 • • X • •
3A Knob S18425-1 2 XXXXX

As Req

3B Nut (Not Shown) T10940-10

XXXXX
3C Self Tapping Screw (Not Shown) S8025-96 2 XXXXX
3D Lock Washer (Not Shown) T9695-5 2 • XXX•
4 Switch T10800-59 1 XXXXX
5A

Square Flange Female Receptacle (Part of Plug & Lead Asbly)

S18657 1 XXXXX
5B Self Tapping Screw S8025-96 2 XXXXX
6 Control P.C. Board (Code 11254 & 11256) L12450-[ ] 1 X •••X
6

Cntrl P.C. Bd (Codes 11255,11257,11444,11804,11819 &11820)

L12230-[ ] 1 XXXXX
7A Handle M20483 1 XXXXX
7B Thread Forming Screw S9225-63 2 XXXXX
8 Case Back & Bottom G4718 1 XXXXX
9A Solenoid Assembly M17294-8 1 XXXXX
9B Plain Washer S9262-10 1 XXXXX
9C Lock Nut T14370-1 1 XXXXX
10 Circuit Breaker T12287-21 1 X • X • •
10 Circuit Breaker T12287-40 1 • X • X X

Power Cord (Not Shown) (Codes 11254, 11255 & 11819)

11A

Power Cord (Not Shown) (Codes 11256, 11257 & 11820)

11A

S25563-3 1 X X • • X

S15599-2 1 X • X • X
11A Power Cord (Not Shown) (Code 11444) S19836-7 1 X •••X
11A Power Cord (Not Shown) (Code 11804) S25563-1 1 •••X•

Lead Grommet (Codes 11254,11255,11256,11257,11804,11819 & 11820)

11B

T9274-11 1 XXXXX
11B Lead Grommet (Code 11444) S19999-2 1 X •••X
12A

Case Back (Codes 11254,11255,11256,11257,11804,11819&11820)

G4813 1 XXXXX
12A Case Back Panel (Code 11444) G4813-1 1 X •••X
12B Self Tapping Screw (Not Shown) S8025-101 4 XXXXX
13 Gas Hose T10642-217 1 XXXXX
14 Rating Decal (Codes 11254, 11255, 11804 & 11819) S26499-2 1 X X • X X
14 Rating Decal (Codes 11256, 11257 & 11820) S26499-3 1 X • X • •
14 Rating Decal (Code 11444) S26499-5 1 X ••••

Grounding Screw Mounting Hardware:
16A Thread Forming Screw (Not Shown) S9225-63 1 X •••X
16A Thread Forming Screw (Not Shown) S9225-76 1 • XXX•
16B #10-24 HN (Not Shown) CF000010 2 XXXXX
16C Lock Washer (Not Shown) T9695-1 1 XXXXX

Hardware to Secure Leads to Ground Screw:
17A #10-24 HN (Not Shown) CF000010 1 XXXXX
17B Lock Washer (Not Shown) E106A-1 1 XXXXX
17C Plain Washer (Not Shown) S9262-27 1 XXXXX

#

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along
with any necessary jumpers or adapters. The dash number brackets [ ] have purposely
been left blank so as to eliminate errors, confusion and updates.

®

POWER MIG

(140, 180 MODELS)

07-24-2012

Power Module Assembly

4

1

6

2

3

5

P-533-DP-533-D

POWER MIG

®

(140, 180 MODELS)

02-04-2010

P-533-D.1

P-533-D.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Power Module Assembly, Includes: G4716-2 1 X • •

Power Module Assembly, Includes: G4716-3 1 • X •

Power Module Assembly, Includes: G4716-7 1 • • X
1 Chassis G4715 2 X X X
2 Rectifier L12306 1 X • •
2 Rectifier L12307 1 • X •
2 Rectifier L12306-1 1 • • X
3 Capacitor S13490-218 1 X • •
3 Capacitor S13490-220 1 • X •
3 Capacitor S13490-109 1 • • X
4 Transformer & Choke Assembly G4808-2 1 X • X
4 Transformer & Choke Assembly G4808-3 1 • X •
5 Fan S18977-4 1 X • X
5 Fan S18977-5 1 • X •
6 Flange Bolt S9225-8 2 X X X

Hardware for Mounting Rectifier & Choke Leads to Capacitor:

10A 1/4-28 HN (Not Shown) CF000198 2 X X X
10B Plain Washer (Not Shown) S9262-98 2 X X X
10C Lock Washer (Not Shown) E106A-2 2 X X X

#

POWER MIG

®

(140, 180 MODELS)

Oct-13

Center Panel Assembly

1

10

10

2

3

4

5

6

11D

11B

15C

15G

16A

16B

17A

17A

12

13

7

8

9

11C

11A

P-533-EP-533-E

16A

16B

17A

13

11C

11A

17A

12

10

15G

15C

11B

11D

10

POWER MIG

®

(140, 180 MODELS)

05-25-2011

P-533-E.1

P-533-E.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Center Panel Assembly, Includes: L12322 1 X • X

Center Panel Assembly, Includes: L12322-2 1 • X •
1 Center Panel L12321 1 X • X
1 Center Panel L12321-1 1 • X •
2 Bow Washer T10781-10 1 X X X
3 Wear Plate S18423-1 1 X X X
4 Spindle Shaft S24227 1 X X X
5 Spindle Spacer S24226 1 X X X
6 Wing Nut T9968-5 1 X X X
7 Plain Washer S9262-120 1 X X X
8 Lock Washer E106A-16 1 X X X
9 3/8-16 x .625 HHCS CF000018 1 X X X
10

Self Tapping Screw (Secures Center Panel to Chassis)

S8025-101 6 X X X
11A Polarity Panel L12555-1 1 X X X
11B Output Stud S25937 2 X X X
11C 1/4-20 x .50 HHCS CF000012 2 X X X

Plain Washer (Not Shown) S9262-23 2 X X X

Lock Washer (Not Shown) E106A-2 2 X X X
11D Wing Nut T9968-6 2 X X X
12 Plug Button T10397-3 1 X X X
13 Plug Button T10397-19 1 X X X
15A By-Pass Assembly (Refer to Wiring Diagram) S22969-4 1 • X •
15B Ground Screw Asbly, Includes: S18922-8 1 • X •
15C Thread Forming Screw S9225-63 1 • X •
15D Plain Washer (Not Shown) S9262-27 2 • X •
15E #10-24 HN (Not Shown) CF000010 2 • X •
15F Lock Washer (Not Shown) E106A-1 1 • X •
15G Lock Washer T9695-1 1 • X •
16A By-Pass P.C. Board L10882-[ ] 1 • X •
16B Sems Screw T10082-27 2 • X •

Spot Timer & Spool Gun Decal (Not Shown) (Includes -A & -B)

17A
17A

Spot Timer & Spool Gun Decal (Not Shown) (Includes -A & -B)

T13086-200 1 X X •
T13086-213 1 • • X

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along
with any necessary jumpers or adapters. The dash number brackets [ ] have purposely
been left blank so as to eliminate errors, confusion and updates.

®

POWER MIG

(140, 180 MODELS)

05-25-2011

Wire Drive Assembly

1A

7

10

21A

20

22

17

6

5

4B

11

12

8

19

13

14

16

15A

15B

15C

18A

P-533-FP-533-F

10

1A

11

19

21A

20

22

4B

17

12

13

14

16

15A

15B

15C

18A

POWER MIG®(140, 180 MODELS)

01-07-2011

P-533-F.1

P-533-F.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Wire Drive Assembly, Includes: L12379-3 1 X
1A Motor Parts Order Sub Assembly, Includes: L13556 1 X

Motor NSS 1X
Metric Screw (Not Shown) NSS 2X
Base NSS 1X
Hose Nipple NSS 1X
Pinion NSS 1X
Bearing NSS 1X

4B Bearing M9300-141 1 X
5 Shaft S26311 1 X
6 Gear S26298 1 X
7 Pivot Arm Assembly S26296 1 X
8 Conductor Block S25931 1 X
9 Dowel Pin (Not Shown) T13942-15 1 X
10 Tension Arm Assembly M20593-2 1 X
11 Cover L12390 1 X
12 Inner Wire Guide S25932-2 1 X
13 Gear S26234-1 1 X
14 Hub M20860 1 X
15A Twist Lock S26238 1 X
15B Screw T14731-63 1 X
15C Lock Washer T9695-3 1 X
16 Drive Roll (Knurled) S26236-3 1 X
17 Molded Hand Screw T13858-4 1 X
18A Outer Wire Guide Assembly, Includes: S26899 1 X

Wire Guide Knob NSS 2X

19 Hose Nipple T13776-5 1 X
20 Insulating Washer S26452 3 X
21A 1/4-20 x .625 HHCS CF000013 1 X
21B Lock Washer (Not Shown) E106A-2 1 X
21C Plain Washer (Not Shown) S9262-98 1 X
22 Self Tapping Screw S8025-116 3 X

#

#

NSS - Not Sold Separately

POWER MIG

®

(140, 180 MODELS)

01-07-2011

Wraparound & Door Assembly

1

4

15

6

2

8

9

7

16

11

14

13

3A

3B

7A

12

11

P-533-GP-533-G

3B

3A

14

13

12

16

7A

15

POWER MIG

®

(140, 180 MODELS)

05-25-2011

P-533-G.1

P-533-G.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Wraparound & Door Asbly,

(M20452-3)

Includes: NSS 1 XXX

1 Door L12320-1 1 X X X
2 Case Side G4719-1 1 X X X
3A Hinge (Includes S25898-2) S25898-1 2 X X X
3B Self Tapping Screw S8025-92 4 X X X
4 Door Latch S21033 1 X X X
6 Warranty Decal S22127-1 1 X X X
7 Side Decal T13086-172 2 X • •
7A Logo Decal S27368-2 2 • X X
8 Wiring Diagram M20410 1 X X •
8 Wiring Diagram M20410-2 1 • • X
9 Warning Decal M16196 1 X X •
9 Warning Decal M16196-3 1 • • X
11 Plug Button T10397-19 1 X X X
12 Procedure Decal (Code 11254) L12603-2 1 X • •
12 Procedure Decal (Code 11255, 11804 & 11819) L12603-4 1 • X •
12 Procedure Decal (Code 11256) L12603-3 1 X • •
12 Procedure Decal (Codes 11257, 11444 & 11820) L12603-5 1 • X X
13 Self Tapping Screw S8025-92 8 X X X
14 Self Tapping Screw S8025-101 2 X X X
15 Family Name Decal S27369-1 2 • X X
16 Nascar Decal S27370-2 2 • X X

#

NSS - Not Sold Separately

POWER MIG

®

(140, 180 MODELS)

09-26-2011

GAS

DIFFUSER

CONTACT

TIP

NOZZLE

LINER

5

3

2

7

6A

6A

4A

4B

5

8

1

P-202-E.2 P-202-E.2

MAGNUM®100L Parts

100L

®

MAGNUM

6A

6A

4A

4B

LINER

GAS

DIFFUSER

MAGNUM

®

100L

CONTACT

TIP

NOZZLE

Item Description Part Number Qty.

New Complete Gun & Cable Assemblies:

Replacement Parts:

1 Cable Assembly M16318-2 1
2 Trigger Assembly S19725 1
3 Locking Nut S19580 1
4A Gun Tube Assembly KP2038-1 1
4B Gun Tube Assembly Cover T10642-162 1
5 Collar S19701 2
6A Gun Handle (Right & Left) G2209 1
7 O Ring T13483-8 2
8 Control Wire Cord S26388 1

Gun Consumable Parts:

Item Description Part Number Qty.
Item

Description Part Number Qty

®

Magnum

100L K530-6

Liners:

.025-.035” Liner KP1937-3
.030-.035” Liner (Aluminum) KP1959-1
.035-.045ʼ Liner KP45-40-15

Diffuser:

Gas Diffuser KP35-50

Item Description Part Number Qty.

Contact Tips:

.025” (0.5 mm)
.030” (0.8 mm) KP11-30
.035” (0.9 mm) KP11-35
.045” (1.2 mm) KP11-45

Tapered Contact Tips:

.025” (0.6 mm) KP11T-25
.030” (0.8 mm) KP11T-30
.035” (0.9 mm) KP11T-35
.045” (1.2 mm) KP11T-45

Nozzles:

Gas Nozzle 0.5 ID, Tip Flush KP21-50-F
Gas Nozzles, Tip Recessed

0.37” I.D. KP21T-37

0.50” I.D. KP21T-50

0.62” I.D. KP21T-62
Gasless Flux Cored Nozzle KP1939-1
Spot Welding Nozzle .625 ID KP21-62-FAS

KP11-25

#

#

MAGNUM®100L

01-20-2012

NOTES

MAGNUM®100L

NOTES

POWER MIG®(140, 180 MODELS)

NOTES

POWER MIG (140, 180 MODELS)

CUSTOMER ASSISTANCE POLICY

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

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

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