Lincoln Electric POWER MIG 140, POWER MIG 180 User Manual

LINCOLN

ELECTRIC

POWER MIG (140, 180 MODELS)

RETURN TO MAIN MENU

IM890-A

May, 2007

For use with machines having Code Numbers:

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 o pe ration on you r par t. DO

NOT I NSTALL, OPERAT E OR
REP A I R THIS EQU I P MENT
WIT H O UT REA D I NG THI S
MAN U A L AND TH E SAFET Y
P R E CAUT IONS CONT AINE D
THR O U GHOU T . And , most

importantly, think before you act
and be careful.

11254, 11255, 11256, 11257 and
11444

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

OPERATOR’S MANUAL

Copyright © 2007 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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

The Above For Gasoline Engines

i

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 t he f uel ne ar 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 ho t engine par ts 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 s om e cases it may be necessary t o remove sa fety

gu a rds t o p e rfo r m r e qui r ed m ain t ena nce. Rem o ve
guards only when necessary and replace them when the
ma i nte n anc e re q uir i ng thei r r emov al i s c omp l ete .
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. Electr ic c urrent flowin g th rough any conduct or c auses
local ized Elec tric and Magn etic Fiel ds (EMF). Weldin g
curre nt create s EM F fields around weldin g cables and
welding machines

2.b. EMF fi el ds may interfe re w it h some pa ce ma ke rs , 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. Nev er coi l the electrode l ead ar ou nd you r body.

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

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

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

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

Mar ʻ95

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 clothin g. W ear 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
mu st b e perfo rmed un der electrically hazar dous
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,
elect rode reel, weld ing head, noz zle or s emiauto matic
welding gun are also electrically “hot”.

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

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

ARC RAYS can burn.

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

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

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

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and ga ses
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

we ldin g with e lect rode s which req uire s peci al
ve ntil ati on such as stain less or hard fa cing (see
instructions on con tainer or MSDS) or on lea d o r
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
us ing local exhaust or mechan ica l v ent ilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
al so r equi red when we ldin g on galva nized steel.

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. Neve r simul ta ne ously t ouch el ectricall y “hot” par ts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

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

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

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

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 in ju ry or deat h. Alw ay s use enough ve nt il at io n,
especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturerʼs instructions for this

equipment and the consumables to be used, including the
ma t eri a l sa fet y da t a sh eet (MS D S) a nd f o llo w yo u r
employerʼs safety practices. MSDS forms are available from
yo u r w eld i ng dis tri b uto r o r f rom th e m anuf actu rer .

5.f. Also see item 1.b.

vapors

AUG 06

to

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

Re m emb e r th a t wel din g spar ks an d hot
materials from welding can easily go through small cracks
an d o penin gs to ad jac ent a rea s. Avoi d w eldin g n ear
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
Standar d Z4 9.1) and the operating in formati on 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
Co n tai n ers an d P ipi n g Tha t H ave H e ld Haz ard o us
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
incre ase the possi bility of the weldin g cu rrent pas sing
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 we ld ing sp ar ks fro m st ar ti ng a fir e.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Us e only com p res s ed gas cy lind ers
containing the correct shielding gas for the
pr o ces s use d an d pro perl y op e rat i ng
re g ula t ors des igne d f or the g a s a nd

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always k ee p cylinders i n an up ri gh t position se cu re ly
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. Re ad and fo llo w the i nst ru ction s on compr essed 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. Ins tall equipment in accord ance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.

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

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Jan, 07

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

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

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tension

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

b. Faire trés attention de bien sʼisoler de la masse quand on

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

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

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

d.Ne jamais plonger le porte-électrode dans lʼeau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

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

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

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

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.

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

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

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. U n court-c ircui t ac ciden tal peut prov oquer un
échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.

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

10. Ne pas souder en présence de vapeurs de chlore provenant
dʼo pérations de dé graissage, ne ttoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

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

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. P rotéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de lait ier en fusion sont émis es de lʼarc d e
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

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

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

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

Mar. ʻ93

v

EN 60974-10

INSTALLATION

v

POWER MIG (140, 180 MODELS)

vi

EN 60974-10:

INSTALLATION

vi

POWER MIG (140, 180 MODELS)

TThhaannkk YYoouu

viivii

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

“Product Registration”. Please complete the form and submit your registration.

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

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

WARNING

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

CAUTION

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

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

INPUT – SINGLE PHASE ONLY

Standard Voltage/Frequency Input Current

240 V 50 Hz

I

1 eff

RATED OUTPUT

Voltage/Duty

240 V 25% 130 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”.

(K2668-1 180C)

I

20 Amps

1 max

10.7 Amps

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

A-3

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

STACKING

POWER MIG (140, 180 MODELS) cannot be stacked.

TILTING

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

POWER MIG (140, 180 MODELS)

A-4

.025

.025

.025

.035

.035

NR-211 MP

WIRE

L-56 MIG

OUTER WIRE GUIDE

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

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

.030

.045

LTW1

"LEARN TO WELD"

DVD

GAS HOSE

REGULATOR

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

INSTALLATION

A-4

IDENTIFY AND LOCATE 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)

• .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)

• 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.

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

Innershield Flux-cored Wire.

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

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

• .035” (0.9mm)
Smooth Drive Roll

• Brass MIG Gas Gun Nozzle

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

• Regulator

• Gas Hose

• Learn to Weld (LTW1 Manual)

• DVD

POWER MIG (140, 180 MODELS)