Lincoln Electric IMT10135 User Manual [en, de, es, fr]

WIRE FEEDER

RETURN TO MAIN MENU

WELDER (180 MODEL)

IMT10135

January 2013

For use with machines having Code Numbers:

TABLE OF CONTENTS
Safety

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

Technical Specifications . . . . . . . . . . . . . .A-1

Identify and Locate Components . . . . . . .A-2

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

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

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

Dual Track Drive Roll and Wire Guide Table

Setting Up and Making a Flux-Cored Weld . . .

. . . . . . . . . . . . . . . . . . . . . . . . .B-4 thru B-6

Setting Up and Making a MIG Weld . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . B-7 thru B-10

Setting Up and Making a Aluminum Weld

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

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

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

. .B-4

. . .B-11

11937, 11938, 11939, 11940

OPERATORʼS MANUAL

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

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

Wire Feed Compartment, Fan Motor, Wire

Reel

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

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

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

Component Replacement Procedures . . .D-2

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

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

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

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

Wiring Diagram and Dimension Print . Section F

Parts Pages . . . . . . . . . . . . . .P-717, P-202-E

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 DEL OPERADOR

MANUEL DE LʼOPÉRATEUR

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

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

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

____________________________________________________

1.c. Do n ot add the fuel near a n open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

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

____________________________________________________

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

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

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

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

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

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

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

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

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

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

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

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

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

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.

ii

SAFETY

ii

ELECTRIC SHOCK can
kill.

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

gloves to insulate hands.

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

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

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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

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

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

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

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

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

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

fumes and gases away from the breathing zone. 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
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.

vapors

OPERATORʼS MANUAL

to

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

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. 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 ke ep cyl inder s 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 fo llow the in structi on s on compre ss ed 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.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

NOTES

OPERATORʼS MANUAL

WIRE FEEDER WELDER (180 MODEL)

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

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

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

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

Your Product”. 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 “Support” and then “Register

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.

INSTALLATION

A-1A-1

TECHNICAL SPECIFICATIONS

180 Amp units (K2481-1, K2515-1, K2659-1, 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 17.6

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

230/208 V 60 Hz 40 Amp Super Lag 20 14 AWG

1

Input Amps Minimum Input Cable

PHYSICAL DIMENSIONS

Height Width Depth Weight

13.7 in 10.15 in 18.2 in 56 Ibs
347 mm 258 mm 462 mm 25.4 kg

1

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

(1.3 - 12.7 m/min.)

OPERATORʼS MANUAL

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 WIRE FEEDER
WELDER 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 WIRE FEEDER WELDER power switch is
to be in the OFF (“O”) position when installing
work cable and gun and when connecting
power cord to input power.

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

SELECT SUITABLE LOCATION

Locate the welder in a dry location where there is free
circulation of clean air into the louvers in the back and
out the front of the unit. A location that minimizes the
amount of smoke and dirt drawn into the rear louvers
reduces the chance of dirt accumulation that can
block air passages and cause overheating.

STACKING

WIRE FEEDER WELDER(180 MODEL) 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.

WIRE FEEDER WELDER (180 MODEL)

A-2

INSTALLATION

IDENTIFY AND LOCATE COMPONENTS

A-2

INCLUDED COMPONENTS

• Wire Feeder Welder.

• Work Cable & Clamp.

• Magnum 100L Welding Gun.

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

.025 GROOVE

5

2

0

.035 GROOVE

.

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

• Brass MIG Gas Gun Nozzle.

• 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”(0.9mm) diameter NR-211MP

Innershield Flux-cored Wire.

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

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

• Regulator

• Gas Hose

• Learn-to-Weld DVD

• Instruction Manual

REGULATOR

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

GAS HOSE

"INSTRUCTION
MANUAL"

IMXXXXX

DVD

WIRE FEEDER WELDER (180 MODEL)

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)

The portable 180Amp Wire Feeder Model is capable
of MIG welding on steel, stainless steel, and alu­minum, in addition to flux-core welding on mild steel.

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

OPERATORʼS MANUAL

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

Your 180Amp machine includes the necessary items
to weld with either the flux-cored welding or MIG weld­ing process on steel. To weld on stainless steel, an
optional stainless steel welding wire can be purchased
separately. The 180Amp machine is spool gun ready
and the machine can weld aluminum using
.035”(0.9mm) diameter 4043 aluminum welding wire.
Since aluminum welding wire is soft, an optional spool
gun is recommended for best results. A welding
Procedure Decal on the wire drive compartment door
provides suggested settings for welding.

Observe all safety information throughout
this manual.

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

WIRE FEEDER WELDER (180 MODEL)

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

3. WIRE FEED SPEED CONTROL (WFS) – This

knob sets the speed that the machine feeds wire.
Along with arc voltage, this control sets a weld pro­cedure. Refer to the procedure decal on the wire
drive compartment door to set a welding procedure
based on the type of material and thickness being
welded.

See Figure B.2

4. GUN TRIGGER – Pressing the trigger activates the

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

FIGURE B.1

2

3

1

FIGURE B.2

5c

5. WELDING GUN – Delivers wire and welding cur-

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

the wire drive. The gun liner will feed .025” to
.035”(0.6mm to 0.9mm) wire.

b. Contact Tip – provides electrical contact to the

wire.

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

5b

.035"(0.9mm)

5a

5

4

6

7

NR-211-MP

WIRE SPOOL

WIRE FEEDER WELDER (180 MODEL)

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 Cover and Side
Door have been removed for clarity of Items 8 and

9).

9. OUTPUT TERMINALS - Connections to these ter-

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

See Figure B.4

10. WIRE SPOOL SPINDLE AND BRAKE – Holds a

4”(102mm) diameter spool. Use the 2”(51mm)
spindle adapter included with the machine for
8”(203mm) diameter spools. The wing nut sets
the brake friction to prevent the spool from over
rotating when the trigger is released. Tightening
the wing nut will prevent the spool from rotating
when the trigger is released.

FIGURE B.3

8

FIGURE B.4

9

OPERATORʼS MANUAL

See Figure B.5

11. WIRE DRIVE & COMPONENTS – Feeds wire

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

a. Drive Roll – Drives the wire through the drive

system. The drive roll has grooves to match the
specific wire type and diameter. Refer to Table

B.1 for available drive rolls.

b. Incoming & Outgoing Guide – The wire is fed

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

c. Tension Arm Assembly – Turning clockwise

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

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

Magnum 100SG Spool Gun can be purchased at
authorized retailers. The part number is K2532-1.

FIGURE B.5

PIVOT ARM ASSEMBLY

BEARING

OUTGOING GUIDE

INCOMING GUIDE

FIGURE B.5a

SWITCH

TENSION ARM ASSEMBL

WIRE SPOOL
.035" (0.9mm)

NR-211-MP

DRIVE ROLL

Y

WIRE FEEDER WELDER (180 MODEL)

MAGNUM 100SG

MAGNUM 100L

B-4

OPERATION

B-4

TABLE B.1

DRIVE ROLLS

Wire Diameter & Type

.035 GROOVE*

5

2

0

.

.025 GROOVE*

.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

*KP3285-1 May also be used to feed

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.

Smooth Drive Roll

(Dual Grooves)

Drive Roll

Part Number

Use .025”(0.6mm) Drive Roll Groove

KP2948-1

Use .035”(0.9mm) Drive Roll Groove

Use .045”(1.1mm) Drive Roll Groove

KP3285-1*

.030”(0.8mm) and .035”(0.9mm) flux-cored wire.

FIGURE B.6

12

13

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

SETTING UP AND MAKING A FLUX-CORED WELD

A. ITEMS NEEDED FOR

FLUX CORED WELDING

3. .035”(0.9mm) NR-211MP Flux-

1. .035”(0.9mm) Contact Tip

.035

2. Dual Groove Drive Roll.

Cored Wire

.035 NR-211 MP

F

4. Black Flux Cored gun nozzle

5. Welding Gun

E

R

L

U

I

W

D

X

E

-

C

R

O

6. Work Cable & Clamp

WIRE FEEDER WELDER (180 MODEL)

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. Tighten thumb screw to
connector bushing.

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

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

5. Wire Drive Polarity. NR-211 MP requires negative
(-) polarity. Connect the short power cable from
the wire drive to the negative (-) output terminal
and tighten wing nut.

6. Work Lead Connection. Slide the end of the work
cable through the hole in the machine front. Place
lug on the positive (+) output terminal and tighten
wing nut.

SLIDE
CONNECTOR
END HERE

(4 PIN)
LEAD CONNECTOR

GUN AND CABLE

TIGHTEN THUMB SCREW TO
CONNECTOR BUSHING

TERMINAL END
(FITS ON STUD INSIDE
SEE FIGURE BELOW)

(4 PIN)
TRIGGER RECEPTACLE
PLUGGED IN

WORK CLAMP

FIGURE B.7

OPEN LATCH DOOR

ALL COMPONENTS SHOWN CONNECTED

(FRONT AND SIDE DOOR IS REMOVED

SHORT POWER
CABLE NEGATIVE "-"
OUTPUT TERMINAL

WORK CLAMP

FOR CLARITY)

WORK LEAD
CONNECTION
POSITIVE "+"
OUTPUT TERMINAL

OPERATORʼS MANUAL

C. LOAD WIRE SPOOL

(See Figure B.8)

1. Locate the sample spool of .035”(0.9mm) NR­211MP flux-cored wire and place onto wire spool
spindle. Orient the spool so that the wire feeds off
the top of the spool.

2. Secure spool by tightening the wing nut against
the spacer that holds the wire spool on the spin­dle. Do not over tighten the spool.

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

4. Remove drive roll
that holds the drive roll on. Install the Dual Groove
drive roll with the .035”(0.9mm) mark facing outward
which will allow feeding of
flux-cored wire

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

by un-screwing the black knob

.035”

(0.9mm)

NR-211MP

.

FIGURE B.8

PIVOT ARM ASSEMBLY

BEARING

OUTGOING GUIDE

INCOMING GUIDE

TENSION ARM ASSEMBL

WIRE SPOOL
.035" (0.9mm)

NR-211-MP

DRIVE ROLL

Y

WIRE FEEDER WELDER (180 MODEL)

B-6

OPERATION

(See Figure B.9)

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

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

(See Figure B.10)

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

SLIDE WIRE
INTO GUN
CONNECTOR
SIDE

FIGURE B.9

PIVOT ARM ASSEMBLY
WITH BEARING PRESSING
AGAINST DRIVE ROLL

TENSION ARM ASSEMBL
LOCKED IN UP POSITION

BEARING

INCOMING
GUIDE

DRIVE ROLL

OUTGOING GUIDE

Y

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”

12. Install the black welding nozzle to the gun.

13. Trim the wire stickout to 3/8”

contact tip. (See Figure B.12)

(0.9mm)

contact tip

(9.5mm)

from the

REMOVED NOZZLE

REMOVED CONT

CABLE AND GUN STRAIGH

LAY

FEED WIRE

Y 4.00"

TEL

APPROXIMA
FROM THE GUN

DEPRESS

ACTIVATE WIRE,

TO

WHICH FEEDS

THRU THE LINER.

TUBE END

TRIGGER

THE WIRE

FIGURE B.10

TIP

ACT

FIGURE B.11

ON/OFF
SWITCH

WORK CLAMP AND CABLE

WIRE SPOOL BRAKE

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

WIRE SPOOL

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

WIRE SPOOL

PLUG IN POWER
INPUT CORD

ROTATION

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

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

16. Based on the thickness of the material you are
going to weld and the type and diameter of the
welding wire set the voltage and the wire feed
speed per the procedure decal attached to the
inside of the wire drive compartment door. The
settings listed on the procedure decal are sug­gestions. The dials may need to be adjusted to
accommodate the application, input voltage or
user preference.

WIRE FEEDER WELDER (180 MODEL)

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

FIGURE B.12

INSTALL .035”(0.9mm) CONTACT TIP

INSTALL BLACK NOZZLE

B-7

OPERATION

SETTING UP AND MAKING A MIG WELD

B-7

A. ITEMS NEEDED FOR MIG WELDING

1. .025”(0.6mm) Contact Tip

.025

3. .025”(0.6mm) Dual Groove drive roll is used with L­56 Solid Mig wire

4. .025”(0.6mm) 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).

CO

CO2regulator

OPERATORʼS MANUAL

2

WIRE

5. Brass gun nozzle

6. Welding Gun

MALE END

CO

2

100%

(REQUIRES ADAPTER
SOLD SEPARATELY)

FEMALE END

75/25

MIXES

WIRE FEEDER WELDER (180 MODEL)

B-8

B. INSTALL SHIELDING GAS

OPERATION

B-8

FIGURE B.13

MIG welding requires an appropriate bottle of shielding
gas. For mild steel a cylinder of Ar/CO2or 100% CO

2

can be used; refer to the following instructions to prop­erly connect shielding gas to the machine.

WARNING

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

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

• Never lift welder with cylinder
attached.

• Never allow welding electrode to
touch cylinder.

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

WARNING

BUILDUP OF SHIELDING GAS may
harm health or kill.

• Shut off shielding gas supply
when not in use.

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.

5. Ensure the black adjustment knob is installed into the

center of the gas regulator. This knob is used to set
the gas flow rate.

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 WELDER (180 MODEL)

SHIELDING GAS

1. For

2. Set gas flow rate for 30 to 40 cubic feet per hour (14

3. Keep the cylinder valve closed, except when using

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.

to 18 I/min.) under normal conditions. Increase to as
high as 40 to 50 CFH (18 to 23.5 I/min.) for out of
position welding.

the machine.

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. Tighten
thumbscrew to connector bushing.

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

LOCATE COMPONENTS
TO CONNECT TO THE
FRONT OF MACHINE

SLIDE
CONNECTOR
END HERE

(4 PIN)
LEAD CONNECTOR

FIGURE B.14

TERMINAL END
(FITS ON STUD INSIDE
SEE FIGURE BELOW)

WORK CLAMP

OPEN LATCH DOOR

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

B-9

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

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

6. Work Lead Connection. Slide the lugged end of the
work cable through the hole in the machine front
and route cable through the strain relief as shown in
figure B.14. Place lug on the negative (-) output ter­minal and tighten wing nut.

D. LOAD WIRE SPOOL

(See Figure B.15)

1. Locate the sample spool of .025”(0.6mm) L-56 solid
MIG wire and place onto wire spool spindle. Orient
the spool so that the wire feeds off the top of the
spool.

GUN AND CABLE

GAS LINE

TIGHTEN THUMB SCREW TO
CONNECTOR BUSHING

TRIGGER RECEPTACLE

(4 PIN)

PLUGGED IN

SHORT POWER
CABLE POSITIVE
OUTPUT TERMINAL

FIGURE B.15

"+"

WORK CLAMP

WORK LEAD
CONNECTION
NEGATIVE "-"
OUTPUT TERMINAL

OPERATORʼS MANUAL

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

by un-screwing the black knob that
holds the drive roll on. Install the Dual Track drive roll
with the .025”(0.6mm) mark facing outward which will
allow feeding of

.025”

(0.6mm)

L-56 Solid MIG wire

.

5. Carefully unwind and straighten the first six inches
of welding wire from the spool. Hold onto the wire
until the the Pivot Arm assembly and Tension Arm
are locked in place. This will prevent the wire from
unspooling.

WIRE FEEDER WELDER (180 MODEL)

PIVOT ARM ASSEMBLY

BEARING

OUTGOING GUIDE

TENSION ARM ASSEMBL

INCOMING GUIDE

DRIVE ROLL

WIRE SPOOL
.025" (0.6mm)

L-56 SOLID
MIG WIRE

Y

B-10

OPERATION

(See Figure B.16)

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

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

(See Figure B.17)

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

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

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

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”(0.6mm) contact tip.

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

SLIDE WIRE
INTO GUN
CONNECTOR
SIDE

REMOVED NOZZLE

REMOVED CONTACTTIP

LAY CABLE
IN THIS POSITION

FEED WIRE

APPROXIMATELY

THE GUN

FROM

DEPRESS

TO
WHICH FEEDS THE WIRE
THRU

AND GUN STRAIGHTEN

4.00"

TUBE END

TRIGGER
TE WIRE,

ACTIVA

THE LINER.

FIGURE B.16

PIVOT ARM ASSEMBLY
WITH BEARING PRESSING

FIGURE B.17

FIGURE B.18

ON/OFF
SWITCH

AGAINST DRIVE ROLL

TENSION ARM ASSEMBL
LOCKED IN UP POSITION

BEARING

INCOMING
GUIDE

DRIVE ROLL

OUTGOING GUIDE

Y

WIRE SPOOL
.025" (0.6mm)

L-56 Solid
MIG WIRE

WIRE SPOOL
.025" (0.6mm)

L

-

5

6

S

WIRE SPOOL
.025" (0.6mm)

L

-

5

6

S

O

L

DIRECTION

OF WIRE

G

I

M

O

D

I

L

PLUG IN POWER
INPUT CORD

G

I

M

D

I

B-10

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

1

nozzle end. (See Figure B.19)

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

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

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. The
settings listed on the procedure decal are sugges­tions. The dials may need to be adjusted to
accommodate the application, input voltage or
user preference.

WIRE FEEDER WELDER (180 MODEL)

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

WIRE SPOOL BRAKE

WORK CLAMP AND CABLE

FIGURE B.19

INSTALL .025(0.6mm) CONTACT TIP

INSTALL BRASS NOZZLE

ROTATION

B-11

OPERATION

SETTING UP AND MAKING A ALUMINUM WELD USING SPOOL GUN

1. Loosen the THUMB SCREW Disconnect Magnum

100L Gun.

B-11

2. Insert K2532-1 Magnum 100SG spool gun into the

brass block and tighten the THUMB SCREW.

3. Depress Gun selector SWITCH to Spool Gun posi­tion. (See Figure B.20 and B.21)

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

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

FIGURE B.20

6. Turn machine on and make weld per recommended
settings on Procedure Decal inside machine door.
The settings listed on the procedure decal are sug­gestions. The dials may need to be adjusted to
accommodate the application, input voltage or user
preference.

FIGURE B.21

(Location of Selector Switch and Thumb Screw)

SWITCH

MAGNUM 100SG

THUMB SCREW FOR
CONNECTING THE

MAGNUM 100L GUN OR
MAGNUM 100SG SPOOL GUN.

MAGNUM 100L

OPERATORʼS MANUAL

WIRE FEEDER WELDER (180 MODEL)

C-1

K3281-1 - 045 Innershield Kit (For 230V models
Code 11937 and above.)

Includes everything needed to weld with .045” diame­ter Innershield wire. Includes an .035”/.045”
Magnum™ 100L gun liner, .045” Contact Tip, gasless
nozzle, drive roll, and a 10 lb. (4.5kg) spool of

®NR®

.045"(0.9mm) Innershield

K2532-1 - Magnum 100SG Spool Gun

(0nly available on 140 Models K2480-1, K2514-1,
K2658-1 and K2697-1).
Designed to easily feed small 4" diameter (1lb. spools
of) .030” or .035” aluminum wire. Includes gun,
adapter kit, three extra .035” contact tips, gas nozzle,
and spool of Superglaze 4043 .035" diameter welding
wire. Packaged in a convenient carry case.

-212 wire.

ACCESSORIES

C-1

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 WELDER (180 MODEL)

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 (2 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)

OPERATORʼS MANUAL

3-11/16"

1/4"-20
(2 Require

9/32" DRILL
2 PLACES

4"

16"

WIRE FEEDER WELDER (180 MODEL)

Flange Nuts

d)

3-13/32"

C-3

K2275-3 - Welding Cart

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

ACCESSORIES

C-3

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

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

(2 Required)

WIRE FEEDER WELDER (180 MODEL)

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
WELDER (180 MODEL).

Use only grounded receptacle. Do not touch elec­trically “hot” parts inside WIRE FEEDER WELDER
(180 MODEL).

• 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 WELDER (180 MODEL). Take the
unit to an authorized Lincoln Service Center if you
experience problems. NO maintenance is required.

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

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.

OPERATORʼS MANUAL

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.

WIRE FEEDER WELDER (180 MODEL)

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

5. To remove gun tube from gun, remove gas nozzle
or gasless nozzle and remove diffuser from gun
tube. Remove both collars from each end of the
gun handle and separate the handle halves.
Loosen the locking nut holding the gun tube in
place against the gun end cable connector.
Unscrew gun tube from cable connector. To install
gun tube, screw the locking nut on the gun tube as
far as possible. Then screw the gun tube into the
cable connector until it bottoms. Then unscrew (no
more than one turn) the gun tube until its axis is
perpendicular to the flat sides of the cable connec­tor and pointed in the direction of the trigger.
Tighten the locking nut so as to maintain the proper
relationship between the gun tube and the cable
connector. Replace the gun handle, trigger and dif­fuser. Replace the gas nozzle or gasless nozzle.

D-2

OVERLOAD PROTECTION

MAINTENANCE

D-2

FIGURE D.2

Liner trim length

Output Overload

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

Thermal Protection

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

Electronic Wire Drive Motor Protection

The WIRE FEEDER WELDERS have built-in protection
for wire drive motor overload.

CHANGING LINER

NOTE: 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.

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.

1-1/4”(31.8 mm)
Liner Trim Length

Gas Diffuser

Set Screw Brass Cable

Connector

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

Gas Nozzle or
Gasless 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.

FIGURE D.3

5. Insert a new untrimmed liner into the connector end
of the cable. Be sure the liner bushing is stenciled
appropriately for the wire size being used.

6. Fully seat the liner bushing into the connector.
Tighten the set screw on the brass cable connector.
At this time, the gas diffuser should not be installed
onto the end of the gun tube.

7. With the gas nozzle and diffuser removed from the
gun tube, be sure the cable is straight, and then
trim the liner to the length shown in the Figure D.2.
Remove any burrs from the end of the liner.

8. Screw the gas diffuser onto the end of the gun tube
and securely tighten.

9. Replace the contact tip and nozzle.

WIRE FEEDER WELDER (180 MODEL)



Counter-clockwise

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.

OPERATORʼS MANUAL

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.

WIRE FEEDER WELDER (180 MODEL)

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.

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.

4. Check Magnum 100SG/Magnum

100L switch is properly switched
to activate proper gun.

RECOMMENDED
COURSE OF ACTION

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

Contact your local 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.

WIRE FEEDER WELDER (180 MODEL)

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 misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service
Facility.

OPERATORʼS MANUAL

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
breaks.

7. Check for proper drive roll orien­tation and alignment.

8. Check liner for proper size.

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

Contact your local Lincoln
Authorized Field Service
Facility.

CAUTION

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

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

WIRE FEEDER WELDER (180 MODEL)

F-1

WIRING DIAGRAM

DIAGRAMS

P4

WORK

MAGNUM 100L

PUSH GUN

MAGNUM 100SG

SPOOL GUN

(OPTIONAL)

1

23

J6

309

321

J3

CONTROL P.C. BOARD

J2

EITHER

MOTOR

4

315

13 14 15 16
1211

5678901
4
321

B2

B1

4
3

12

N.D.

317

SWITCH

SPOOL GUN

316
315
314
313
312
311
310
309
308
307
306
305
304
303
302
301

524

522

204
203
202

GND

522

N.B.

S2

306

520

N.C.

N.D.

P2

S1

203

521

12

ON/OFF SWITCH

523

SWITCH

SELECTOR

N.D.

A

A

B

45678

3

2

1

311

305

318

WIRE FEED MOTOR

45

LATCH

C

312

P3

8

16

7

15

6

1412

5

11 13

LATCH

10
9

1234

304

E

D

P4

304

314

313

320

RECTIFIER

CHOKE

OUTPUT

X1

T1

TRANSFORMER

H2

319

N.C.

8

7

6

5

4

3

ARROW

2

1

N.D.

R

301

302

303

307

X2

X4

H1

3

1

J6

2

R

C1

X3

LOCATED IN TRANSFORMER

A.05

4

ELECTRICAL SYMBOLS PER E1 537

310

316

321

N.A.

THERMOSTAT

F-1

M24682

308

GAS

12 VDC

204

CIRCUIT BREAKER

BLACK

TO GROUND

PER NATIONAL

Only qualified persons should install,

Do not operate with covers removed.

Disconnect input power by unplugging

WARNING

use or service this machine.

power cord before servicing.

Do not touch electrically li ve parts

WHITE

GND

can kill

HIGH VOLTAGE

ELECTRICAL

CODE.

230V FAN

202

SOLENOID

OF CONNECTORS.

COMPOUND (BURNDY PENETROX A1 3) WHEN REATTACHING.

NOTES:

N.A. BOLTED AL UMINUM CONNECTIONS REQUIRE E2 529 JOINT

N.D. COMPONENT VIEWED FROM REAR.

N.C. CAVIT Y NUMBERING SEQUENCE VIEWED FROM IN SERTION SIDE

N.B. WORK AND GUN C ONNECTIONS SHOWN FOR GMAW WELDING.

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 WELDER (180 MODEL)