Lincoln Electric SVM189-B User Manual
COMPACT WIRE WELDERS
LINCOLN
ELECTRIC
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For use with machines having Code Numbers: 11173 Thru 11506
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.
SVM189-B
January, 2011
and
11646 Thru 11650
View Safety Info View Safety Info View Safety Info View Safety Info
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 888=935=3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i 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
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.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.
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.
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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.
COMPACT WIRE WELDERS
ii 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
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.
vapors
to
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5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
COMPACT WIRE WELDERS
iii iii
SAFETY
WELDING and CUTTING
SPARKS can cause fire or
explosion.
6.a.
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 adjcent 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.
Remove fire hazards from the welding area.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
If
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.
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
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.
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COMPACT WIRE WELDERS
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
COMPACT WIRE WELDERS
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
I I
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . .Please refer to Service Navigator Parts Section for correct machine parts info.
COMPACT WIRE WELDERS
A-1 A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Machines in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
TABLE OF CONTENTS - INSTALLATION SECTION
MACHINES COVERED BY THIS MANUAL
CODE K-NUMBER PRODUCT NAME
11173 K2480-1 PRO-MIG 140T
11175 K2481-1 PRO-MIG 180T
11254 K2470-1 POWER MIG 140T *
11255 K2471-1 POWER-MIG 140C
11256 K2472-1 POWER MIG 180T *
11257 K2473-1 POWER MIG 180C
11300 K2479-1 PRO-CORE 125T
11302 K2513-1 WELD-PAK 125HD
11303 K2514-1 WELD-PAK 140HD
11304 K2515-1 WELD-PAK 180HD
11440 K2658-1 MIG-PAK 140
11441 K2659-1 MIG-PAK180
11442
11444 K2668-1 POWER-MIG 180C
11501 K2688-1 SP140T
11502 K2689-1 SP180T
11503 K2696-1 EASY-CORE 125
11504 K2697-1 EASY-MIG 140
11505 K2698-1 EASY-MIG 180
11506 K2699-1 WORK-PAK 125
11646 K2481-1 PRO MIG 180
11647 K2515-1 WELD-PAK 180HD
11648 K2659-1 MIG PAK 180
11649 K2689-1 SP180T
11650 K2698-1 EASY-MIG180
K2661-1
POWER-MIG 180C
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* Discontinued Models
COMPACT WIRE WELDERS
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS
180 Amp units
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
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 Prong Plug
(NEMA Type 6-50P)
TECHNICAL SPECIFICATIONS 140 Amp units
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,
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”.
1,2
Input Amps Power Cord Extension Cord
Three Prong Plug (4mm2) or Larger
(NEMA Type 5-15P) up to 50 ft.(15.2m)
(1.3 - 12.7 m/min.)
3 Conductor # 12 AWG
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COMPACT WIRE WELDERS
A-3 A-3
INSTALLATION
TECHNICAL SPECIFICATIONS 125 Amp units
INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current
120 V / 60 Hz 20 Amps @ rated output
RATED OUTPUT
Duty
Cycle Current Voltage at Rated Amperes
20% Duty Cycle 90 Amps 19
OUTPUT
Welding Current Range Maximum-Open Circuit Voltage Wire Speed Range
30-125 Amps 33 V 50 - 500 in/min.
(1.3 - 12.7 m/min.)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Input Voltage / Frequency Fuse or Breaker Size
1,2
Input Amps Power Cord Extension Cord
120 V 60 Hz 20 Amp 20 15 Amp, 125 V,
AWG
PHYSICAL DIMENSIONS
Height Width Depth Weight
13.7 in 10.15 in 17.9 in 48 Ibs
347 mm 258 mm 454 mm 21.7 kg
1
If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.
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.
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 machine’s 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 Machine power switch is to be in the
OFF (“O”) position when installing work
cable and gun and when connecting
power cord to input power.
3 Conductor #12
Three Prong Plug (4mm2) or Larger
(NEMA Type 5-15P) up to 50 ft.(15.2m)
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
Compact Wire Welders 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.
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COMPACT WIRE WELDERS
A-4 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
LTW 1
" LE AR N T O W EL D "
DVD
GAS HOSE
REGULATOR
2" SPINDLE ADAPTER (FOR 8" REEL OF WIRE)
LINCOLN
ELECTRIC
®
INSTALLATION
IDENTIFY AND LOCATE COMPONENTS
NOTE: Not all components are in every model.
Check the Operator’s Manual for items
included with a specific machine.
• Wire Feeder Welder.
or
• Work Cable & Clamp.
• Handshield
• 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
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COMPACT WIRE WELDERS
B-1 B-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Product Description & Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Controls & Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3/B-4
Drive Roll & Wire Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Items Needed for Flux Core Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Connect Leads & Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Load Wire Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Items Needed for Mig Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10
TABLE OF CONTENTS - OPERATION SECTION
Connect Leads & Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11
Load Wire Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11
Setting up and making an Aluminum Weld using the optional Spool Gun . . . . . . . . . . . . . . . . . . . . . . . .B-13
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COMPACT WIRE WELDERS
B-2 B-2
Read entire operation section before operating the Compact Wire Welder.
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
OPERATION
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.
The term “MIG” 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.
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.
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.
Most machines include the necessary items to weld
with either the MIG or the flux-cored welding process
on steel. The 125 amp units will require the addition of
a ‘MIG Conversion Kit’ (K2526-1) for welding gas
shielded processes. 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.
------------------------------------------
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Observe all safety information throughout this manual.
------------------------------------------------------------
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COMMON WELDING ABBREVIATIONS
GMAW (MIG)
• Gas Metal Arc Welding
FCAW (Innershield or Outershield)
• Flux Core Arc Welding
COMPACT WIRE WELDERS
B-3 B-3
1
3
2
.035"(0.9mm)
NR-211-MP
WIRE SPOOL
4
5a
5b
5
5c
6
7
OPERATION
CONTROLS AND SETTINGS
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.
NOTE: The Arc Voltage Control will be either a contin-
uous control or a multi-position switch depending on the model.
3. WIRE FEED SPEED CONTROL (WFS) – The knob
sets the speed that the machine feeds wire. Along
with arc voltage control 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
FIGURE B.1
FIGURE B.2
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4. GUN TRIGGER – Depress the trigger to activates
the wire drive to feed wire and energizes the output
of the machine. Depress the trigger to weld and
release the trigger to stop welding.
5. WELDING GUN – Delivers wire and welding current
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.
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COMPACT WIRE WELDERS
B-4 B-4
8
9
2"(51mm) SPINDLE ADAPTER (FOR 8"(20mm) REEL OF WIRE)
( 4"(102mm) REEL OF WIRE)
WIRE SPOOL
.035" (0.9mm)
NR-211-MP
INNER WIRE GUIDE REMOVED
LOWER DRIVE ROLL REMOVED
OUTER WIRE GUIDE REMOVED
TOP DRIVE ROLL PRESSURE ARM
TENS ION A DJUS TOR DOWN
OPERATION
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
for changing the output polarity of the machine
depending on whether you are MIG welding (+) or
flux-cored 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 wing nut sets the
brake friction to prevent the spool from over rotating when the trigger is released.
FIGURE B.3
FIGURE B.4
See Figure B.5
11. WIRE DRIVE & COMPONENTS (ALUMINUM
DRIVE HOUSING) – 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
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COMPACT WIRE WELDERS
B-5 B-5
12
13
WIRE SPOOL
.035" (0.9mm)
NR-211-MP
PIVOT ARM ASSEMBLY
TENSION ARM ASSEMBLY
LINER
DRIVE ROLL
OUTGOING GUIDE
BEARING
OPERATION
See Figure B.5a
11a. WIRE DRIVE & COMPONENTS (MOLDED
DRIVE HOUSING) – Feeds wire from the wire
spool through the drive and through the welding
gun to the weld.
a. Drive Roll – Drives the wire through the drive
system. The drive roll has a groove to match the
specific wire type and diameter. Refer to Table
B.1 for available drive rolls.
b. Liner & Outgoing Guide – The liner guides the
wire between the bearing on the Pivot Arm
Assembly and Drive Roll and through the outgoing guide.
c. Drive Roll Tension Thumbscrew – Turning
clockwise increases the force on the drive roll
and turning counterclockwise decreases the
force.
TABLE B.1
DRIVE ROLL AND WIRE GUIDES
Wire Diameter &
Drive Roll
Type
Drive Roll Part
Number
FIGURE B.5a
Inner Wire Guide
Inner Wire Guide
Part Number
.025”(0.6mm) MIG wire
.025”/.030” (0.6mm/0.8mm)
Smooth Drive Roll
.030”(0.8mm) MIG wire
.035”(0.9mm) MIG wire
.030”(0.8mm) flux-cored
.035”(0.9mm) Smooth Drive Roll
.030”/.045” (0.8mm/1.1mm)
Knurled Drive Roll
.035”(0.9mm) flux-cored
.045”(1.1mm) flux-cored
.030”/.045” (0.8mm/1.1mm)
Knurled Drive Roll
See Figure B.6
12. CIRCUIT BREAKER – If the rated input current of
the machine is exceeded this circuit breaker will
trip. Press to reset.
13. GAS INLET – Shielding gas connects to this inlet.
NOTE: Only on 125 amp machines that have added
the MIG Conversion Kit (K2525-1)
KP2529-1
KP2529-2
KP2529-3
KP2529-3
.025”-.035”
(0.6mm-0.9mm)
Steel Wire Guide
.045”(1.1mm)
Steel
Wire Guide
FIGURE B.6
KP2531-1
KP2531-2
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COMPACT WIRE WELDERS
B-6 B-6
INNER WIRE GUIDE
.025-.035 (.6-.9mm)
.035
.035 NR-211 MP
F
L
U
X
-
C
O
R
E
W
I
R
E
.030
.045
OPERATION
SETTING UP AND MAKING A FLUX-CORED WELD
A. ITEMS NEEDED FOR FLUX CORED
WELDING
1. 035”(0.9mm) Contact Tip
7. Work Cable & Clamp
2. .025”-.035”(0.6mm-0.9mm) wire guide
3. Knurled Drive Roll
4. .035”(0.9mm) NR-211MP Flux-Cored Wire
NOTE:125 amp units come set up for flux cored wire
welding.
5. Black Flux Cored gun nozzle
6. Welding Gun
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COMPACT WIRE WELDERS
B-7 B-7
GUN AND CABLE
WORK CLAMP
(4 PIN)
LEAD CONNECTOR
TERMINAL END
(FITS ON STUD INSIDE
SEE FIGURE BELOW)
SLIDE
CONNECTOR
END HERE
CASE SIDE DOOR
OPEN LATCH DOOR
WORK CLAMP
(4 PIN)
TRIGGER RECEPTACLE
PLUGGED IN
CONNECTOR
END ATTACH
ALL COMPONENTS SHOWN CONNECTED
(FRONT AND SIDE DOOR IS REMOVED
FOR CLARITY)
SHORT POWER
CABLE NEGATIVE "-"
OU TP U T T ER MI N AL
WORK LEAD
CONNECTION
POSITIVE "+"
OU TP U T T ER MI N AL
THUMB SCREW TO
TIGHTEN CONNECTOR
BUSHING
LOCATE COMPONENTS
TO CONNECT TO THE
FRONT OF MACHINE
WIRE SPOOL
.035" (0.9mm)
NR-211-MP
INNER WIRE GUIDE REMOVED
LOWER DRIVE ROLL REMOVED
OUTER WIRE
GUIDE REMOVED
TOP DRIVE ROLL PRESSURE ARM
TEN SION ADJU STOR DOWN
B. CONNECT LEADS AND CABLES ON
OPERATION
FIGURE B.7
THE MACHINE
(See Figure B.7)
1. Open the case side door
2. Slide the connector end of the gun and cable
through the hole in the machine front and into the
gun connector bushing on the wire drive.
3. Make sure the gun connector end is seated fully
into the wire drive and tighten the 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.
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.
FIGURE B.8
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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.
COMPACT WIRE WELDERS
B-8 B-8
.035"(0.9mm)
NR-211-MP
WIRE SPOOL
REMOVED NOZZLE
REMOVED CONTACT TIP
LAY CABLE AND GUN STRAIGHTEN
IN THIS POSITI ON
.035"(0.9mm)
NR-211-MP
WIRE SPOOL
DEPRESS TRIGG ER
TO AC TIVATE WIRE ,
WHICH FEEDS THE WIRE
THRU THE LINER .
FEED WIRE
APPROXIMATELY 4.00"
FROM THE GUN T UBE END
ROTATION
PLUG IN POWER
INPUT CORD
ON/OFF
SWITCH
WORK CLAMP AND CABLE
TENS ION A DJUS TOR
LOCKED IN POSITION
LOWER DRIVE ROLL
BE SURE WIRE
IS IN GROOVE
WIRE SPOOL
.035" (0.9mm)
SLIDE WIRE
INTO GUN
CONNECTOR
SIDE
TOP DRIVE ROLL
PRESS ED AG AINS T
LOWER DRIVE ROLL
DIRECTION
OF WIRE
NR-211-MP
INSTALL .035 CONTACT TIP
INSTALL BLACK FLUX-CORED NOZZLE
TRIM WIRE
STICKOUT
3/8"(9.5mm)
from the Contact Tip
(
See Figure B.9)
OPERATION
FIGURE B.9
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.
(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
FIGURE B.10
FIGURE B.11
16. Install the black flux cored welding nozzle to the gun.
17. Trim the wire stickout to 3/8”(9.5mm) from the con-
18.
19. Read "Learn to Weld" (LTW1) that is included with
20. Based on the thickness of the material you are going
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tact tip. (See Figure B.12)
Close the case side door. The machine is now ready
to weld.
the machine or watch the "How to Weld" DVD included with the machine.
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.
COMPACT WIRE WELDERS
FIGURE B.12
B-9 B-9
.025
WIRE
L-56 MIG
INNER WIRE GUIDE
.025-.035
.025-.035
75/25
FEMALE END
MIXES
MALE END
CO
100%
2
(REQUIRES ADAPTER
SOLD SEPARATELY)
OPERATION
SETTING UP AND MAKING A MIG WELD
A. ITEMS NEEDED FOR MIG WELDING
1. 025”(0.6mm) Contact Tip
7. Work Cable & Clamp
2. 025”-035”(0.6mm-0.9mm) Inner wire guide (140
180 amp machines)
8. Gas Regulator & Gas Line
3. .025”(0.6mm) Drive Roll
4. .025”(0.6mm) SuperArc L-56 Solid MIG Wire
5. Brass gun nozzle
9. Bottle of 75/25 Ar/
CO2shielding gas (or 100%
shielding gas) (note this requires a
adapter which is sold separately.
CO
CO2regulator
2
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6. Welding Gun
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NOTE:125 amp units must be upgraded with a
MIG Conversion Kit (K2526-1).
COMPACT WIRE WELDERS
B-10 B-10
75/25
FEMALE END
MALE END
CO
S19298
REGULATOR
ADAPTER
PLASTIC
WASH ER
MIXES
100%
2
OPERATION
FIGURE B.13
B. INSTALL SHIELDING GAS
MIG welding requires an appropriate bottle of shielding
gas. For mild steel either a cylinder bottle of Ar/CO2or
100% CO
can be used refer to the following instructions
2
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.
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
regulator adapter (S19298) is required and must be
purchased separately. When using the
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
2
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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.
------------------------------------------------------------------------
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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.
COMPACT WIRE WELDERS
B-11 B-11
GUN AND CABLE
WORK CLAMP
(4 PIN)
LEAD CONNECTOR
TERMINAL END
(FITS ON STUD INSIDE
SEE FIGURE BELOW)
SLIDE
CONNECTOR
END HERE
CASE SIDE DOOR
OPEN LATCH DOOR
WORK CLAMP
(4 PIN)
TRIGGER RECEPTACLE
PLUGGED IN
CONNECTOR
END ATTACH
ALL COMPONENTS SHOWN CONNECTED
(FRONT AND SIDE DOOR IS REMOVED
FOR CLARITY)
SHORT POWER
CABLE POSITIVE "+"
OU TP UT T ER MI NA L
WORK LEAD
CONNECTION
NEGATIVE "-"
OU TP UT T ER MI NA L
THUMB SCREW TO
TIGHTEN CONNECTOR
BUSHING
LOCATE COMPONENTS
TO CONNECT TO THE
FRONT OF MACHINE
WIRE SPOOL
.025" (0.6mm)
INNER WIRE GUIDE REMOVED
LOWER DRIVE ROLL REMOVED
OUTER WIRE
GUIDE REMOVED
TOP DRIVE ROLL PRESSURE ARM
TEN SION ADJU STOR DOWN
L
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5
6
S
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L
I
D
M
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C. CONNECT LEADS AND CABLES ON
OPERATION
FIGURE B.14
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.
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.
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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.
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.
COMPACT WIRE WELDERS
FIGURE B.15
B-12 B-12
TEN SION ADJU STOR
LOCKED IN POSITION
DRIVE ROLL
BE SURE WIRE
IS IN GROOVE
WIRE SPOOL
.025" (0.6mm)
SLIDE WIRE
INTO GUN
CONNECTOR
SIDE
TOP IDLER ROLL
PRES SED A GAIN ST
LOWER DRIVE ROLL
DIRECTION
OF WIRE
L
-
5
6
S
O
L
I
D
M
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REMOVED NOZZLE
REMOVED CONTACT TIP
LAY CABLE AND GUN STRAIGHTEN
IN THIS POSI TION
WIRE SPOOL
.025" (0.6mm)
L
-
5
6
S
O
L
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D
M
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DEPRESS TRIGGE R
TO AC TIVATE WIRE ,
WHICH FEEDS THE WIRE
THRU THE LINE R.
FEED WIRE
APPROXIMATELY 4.00"
FROM THE GUN TUBE END
ROTATION
PLUG IN POWER
INPUT CORD
ON/OFF
SWITCH
WORK CLAMP AND CABLE
WIRE SPOOL
.025" (0.6mm)
L
-
5
6
S
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L
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D
M
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INSTALL .025 CONTACT TIP
INSTALL BRASS NOZZLE
TRIM WIRE
STICKOUT
3/8"(9.5mm)
from the Brass Nozzle
(See Figure B.16)
OPERATION
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.
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 and contact tip from the gun
and straighten the gun cable 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 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.
-----------------------------------------------------------------------
15. Install the .025”(0.6mm) contact tip.
FIGURE B.17
FIGURE B.18
16. Install the brass gas MIG welding nozzle to the gun.
17. Trim the wire stickout to 3/8”(9.5mm) from the nozzle
18. Close the case side door. The machine is now ready
19. Read "Learn to Weld" (LTW1) that is included with the
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20. Based on the thickness of the material you are going
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end. (See Figure B.19)
to weld.
machine or watch the "How to Weld" DVD included
with the machine.
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.
COMPACT WIRE WELDERS
FIGURE B.19
B-13 B-13
OPERATION
SETTING UP AND MAKING AN ALUMINUM WELD USING
THE OPTIONAL 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
6. Turn machine on and make weld per recommended settings on the Procedure Decal inside machine
door.
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COMPACT WIRE WELDERS
B-14 B-14
NOTES
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COMPACT WIRE WELDERS
C-1 C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Utility Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3
Welding Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5
Locating Spool Gun Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6
Items Inside the Spool Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-8
Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-9
TABLE OF CONTENTS - ACCESSORIES SECTION
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-10/C-11
Mounting the Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-12
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-13
Loading Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-14/C-15
Connecting the Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-16
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COMPACT WIRE WELDERS
C-2 C-2
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
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)
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COMPACT WIRE WELDERS
C-3 C-3
3-3/4" (95.3mm)
4"(102mm)
16"(406.4mm)
3-11/16"
8-1/16"
3-13/32"
9/32"(7.1mm) DRILL
3 PLACES
1/4"-20 X 1/2" Hex Head Cap Screw
(2 Required)
1/4"-20 X 1"
Thread Forming Screw
(1 Required)
1/4"-20 X 1/2" Hex Head Cap Screw
(2 Required)
For mounting welding machines to K520 carts that do not have slotted mounting holes,
Drill 9/32” holes (3 places) into the cart top as shown and attach the welding machine to the cart
with the proper hardware shown.
(204.8mm)
(93.7mm)
(96.8mm)
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.
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COMPACT WIRE WELDERS
C-4 C-4
2-15/16"(74.6mm)
3-3/16"(81mm)
7-9/16"(192.1mm)
1-1/2"(38.1mm)
13-1/2"(342.9mm)
1-1/4"(31.8mm)
9/32"(7.1mm) DR
ILL
3 PLACES
1/4"-20 Flange Nut
(2 Required)
1/4"-20 X 1"
Thread Forming Screw
(1 Required)
1/4"-20 X 1/2" Hex Head Cap Screw
(2 Required)
For mounting welding machines to 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.
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.
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COMPACT WIRE WELDERS
C-5 C-5
ACCESSORIES
TECHNICAL SPECIFICATIONS - MAGNUM 100SG SPOOL GUN K2532-1
MODEL
WELDING PROCESS
WIRE ALLOYS
WIRE SIZES (DIAMETERS)
SPOOL SIZE
RATED WELDING CURRENT
AND DUTY CYCLE
OVERALL WEIGHT
CABLE LENGTH
OVERALL SIZE (BOUNDING BOX)
METHOD OF GUIDANCE
METHOD OF COOLING
K2532-1 Magnum 100SG Spool Gun
Aluminum GMAW (MIG), DC electrode positive polarity with
100% argon welding shielding gas.
Aluminum only: alloys 4043 or 5356
Solid wire 0.030 or 0.035 inches (0.8 or 0.9 mm)
1 lb. weight, nominal 4 inch diameter spool
130 amps at 30% for 10-minute basis
3.5 lbs. with cable but without case or spool
10.0±0.2 feet
In inches: 15.75 long x 10.50 high x 4.25 thick max.,
without case or gun cable.
Semiautomatic (manually-guided)
Air-cooled
UNPACKING THE SPOOL GUN
The spool gun is factory-assembled and tested, and
then packed in its own cushioned carrying case. It is
shipped fully-equipped to weld with 0.035 inch diameter aluminum wire. After opening the case, check that
it contains the following items:
1. One fully assembled K2532-1 spool gun with (1)
T11862-65 Conical Compression Spring for use
with alloy 5356 wire; wire spool not installed.
2. One spool of 0.035 aluminum alloy 4043 wire
3. Three S19726-3 contact tips
4. One instruction manual (IM913)
5. One M21182 electrical harness with toggle switch.
1
2
3
4
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5
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COMPACT WIRE WELDERS
C-6 C-6
ACCESSORIES
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the
welding power source before installation or changing drive rolls and/or
guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode and
drive mechanism are "hot" to work and ground
and could remain energized several seconds
after the gun trigger is released.
------------------------------------------------------------------------
LOCATING SPOOL GUN COMPONENTS
AND FEATURES
(See Figure C.1 for Items 1 thru 6)
1. Gas Cone Assembly and Contact Tip.
3
FIGURE C.1
5
6
2. Straightened Gun Tube Assembly.
3. 1/4-Turn Locking Collar.
4. Trigger Assembly.
5. Spool Cover: Provides easy, wide-open access to
spool and wire drive.
6. Locking Knob: Captive in spool cover.
(See Figure C.2 for these following items)
7. Integrated Single-Piece Cable: The Magnum design
provides neat and clean appearance; simplifies
cable management and reduces entanglements.
8. Standard Durable Strain Relief Clamp.
9. Three Captive Hex Nuts.
1
2
4
Left Side View
FIGURE C.2
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7 8
9
Right Side View
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COMPACT WIRE WELDERS
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