Lincoln Electric POWER MIG - 140 - 180 MODELS PDF

Operator’s Manual
®
POWER MIG (140, 180 MODELS)
For use with machines having Code Numbers:
11254, 11255, 11256, 11257 and
11444
LN
CO TRIC
LINLEC
E
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM890-A | Issue Date Nov- 13

© Lincoln Global, Inc. All Rights Reserved.
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES.
LINCOLN ELECTRIC. DON’T get too close to the arc. Use
corrective lenses if necessary to
stay a reasonable distance away
from the arc.
READ and obey the Material Safety
PLEASE EXAMINE CARTON AND EQUIPMENT FOR Data Sheet (MSDS) and the warning
DAMAGE IMMEDIATELY label that appears on all containers
When this equipment is shipped, title passes to the purchaser upon of welding materials.
receipt by the carrier. Consequently, Claims for material damaged in USE ENOUGH VENTILATION or
shipment must be made by the purchaser against the transportation exhaust at the arc, or both, to keep
company at the time the shipment is received. the fumes and gases from your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
SAFETY DEPENDS ON YOU USE NATURAL DRAFTS or fans to keep the fumes away from your
Lincoln arc welding and cutting equipment is designed and built with face.
safety in mind. However, your overall safety can be increased by If you develop unusual symptoms, see your supervisor. Perhaps the
proper installation ... and thoughtful operation on your part. welding atmosphere and ventilation system should be checked.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT. And, most importantly, think before you WEAR CORRECT EYE, EAR & BODY PROTECTION
act and be careful.
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
WARNING PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
This statement appears where the information must be followed clothing, flame-proof apron and gloves, leather
exactly to avoid serious personal injury or loss of life. leggings, and high boots.
PROTECT others from splatter, flash, and glare with
CAUTION protective screens or barriers.
IN SOME AREAS, protection from noise may be
This statement appears where the information must be followed to appropriate.
avoid minor personal injury or damage to this equipment.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area AT ALL
TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously had
been in contact with hazardous substances unless they are properly
cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release highly
toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat, mechanical
shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
SAFETY
SECTION A: 1.d. Keep all equipment safety guards, covers and

devices in position and in good repair.Keep
hands, hair, clothing and tools away from
WARNINGS V-belts, gears, fans and all other moving parts
when starting, operating or repairing
equipment.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel Engines 1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
Diesel engine exhaust and some of its constituents are known necessary and replace them when the maintenance requiring
to the State of California to cause cancer, birth defects, and other their removal is complete. Always use the greatest care when
reproductive harm. working near moving parts.
Gasoline Engines
1.f. Do not put your hands near the engine fan. Do not attempt to
The engine exhaust from this product contains chemicals known override the governor or idler by pushing on the throttle control
to the State of California to cause cancer, birth defects, or other rods while the engine is running.
reproductive harm.
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
ARC WELDING CAN BE HAZARDOUS. PROTECT as appropriate.
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY. PACE- 1.h. To avoid scalding, do not remove the radiator
MAKER WEARERS SHOULD CONSULT WITH THEIR pressure cap when the engine is hot.
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” ELECTRIC AND
booklet E205 is available from the Lincoln Electric Company, 22801 MAGNETIC FIELDS MAY
St. Clair Avenue, Cleveland, Ohio 44117-1199. BE DANGEROUS
BE SURE THAT ALL INSTALLATION, OPERATION,
2.a. Electric current flowing through any conductor
MAINTENANCE AND REPAIR PROCEDURES ARE
causes localized Electric and Magnetic Fields (EMF). Welding
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
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.
FOR ENGINE POWERED
EQUIPMENT. 2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the 2.d. All welders should use the following procedures in order to
maintenance work requires it to be running. minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
1.b. Operate engines in open, well-ventilated
them with tape when possible.
areas or vent the engine exhaust fumes outdoors.
2.d.2. Never coil the electrode lead around your body.
1.c. Do not add the fuel near an open flame 2.d.3. Do not place your body between the electrode and work
welding arc or when the engine is running. cables. If the electrode cable is on your right side, the
Stop the engine and allow it to cool before work cable should also be on your right side.
refueling to prevent spilled fuel from
2.d.4. Connect the work cable to the workpiece as close as pos-
vaporizing on contact with hot engine parts
sible to the area being welded.
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until 2.d.5. Do not work next to welding power source.
fumes have been eliminated.
ii
SAFETY
ELECTRIC SHOCK ARC RAYS CAN BURN.

CAN KILL.
3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your
electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or
not touch these “hot” parts with your bare skin observing open arc welding. Headshield and filter lens should
or wet clothing. Wear dry, hole-free gloves to insulate hands. conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant material
Make certain the insulation is large enough to cover your full area to protect your skin and that of your helpers from the arc rays.
of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if screening and/or warn them not to watch the arc nor expose
welding must be performed under electrically themselves to the arc rays or to hot spatter or metal.
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
FUMES AND GASES
positions such as sitting, kneeling or lying, if there
CAN BE DANGEROUS.
is a high risk of unavoidable or accidental contact 5.a. Welding may produce fumes and gases
with the workpiece or ground) use the following hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
equipment:
Use enough ventilation and/or exhaust at the arc to keep fumes
• Semiautomatic DC Constant Voltage (Wire) Welder.
and gases away from the breathing zone. When welding
• DC Manual (Stick) Welder.
with electrodes which require special ventilation
• AC Welder with Reduced Voltage Control. such as stainless or hard facing (see instructions
3.c. In semiautomatic or automatic wire welding, the electrode, on container or MSDS) or on lead or cadmium
electrode reel, welding head, nozzle or semiautomatic welding plated steel and other metals or coatings which
gun are also electrically “hot”.
produce highly toxic fumes, keep exposure as low
3.d. Always be sure the work cable makes a good electrical as possible and within applicable OSHA PEL and
connection with the metal being welded. The connection should ACGIH TLV limits using local exhaust or
be as close as possible to the area being welded. mechanical ventilation. In confined spaces or in
3.e. Ground the work or metal to be welded to a good electrical (earth) some circumstances, outdoors, a respirator may
ground. be required. Additional precautions are also
required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace 5. b. The operation of welding fume control equipment is affected by
damaged insulation. various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.g. Never dip the electrode in water for cooling. welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
3.h. Never simultaneously touch electrically “hot” parts of electrode thereafter to be certain it is within applicable OSHA PEL and
holders connected to two welders because voltage between the ACGIH TLV limits.
two can be the total of the open circuit voltage of both
welders. 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
3.i. When working above floor level, use a safety belt to protect heat and rays of the arc can react with solvent vapors to form
yourself from a fall should you get a shock. phosgene, a highly toxic gas, and other irritating products.
3.j. Also see Items 6.c. and 8. 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.
iii
SAFETY
WELDING AND CUTTING CYLINDER MAY EXPLODE IF

SPARKS CAN CAUSE DAMAGED.
FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing
6.a. Remove fire hazards from the welding area. If the correct shielding gas for the process used
this is not possible, cover them to prevent the and properly operating regulators designed for
welding sparks from starting a fire. Remember that welding the gas and pressure used. All hoses, fittings,
sparks and hot materials from welding can easily go through etc. should be suitable for the application and
small cracks and openings to adjacent areas. Avoid welding near maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely chained to
6.b. Where compressed gases are to be used at the job site, special an undercarriage or fixed support.
precautions should be used to prevent hazardous situations. 7.c. Cylinders should be located:
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used. • Away from areas where they may be struck or subjected
to physical damage.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause • A safe distance from arc welding or cutting operations
overheating and create a fire hazard. and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the electrically “hot” parts to touch a cylinder.
proper steps have been taken to insure that such procedures will
not cause flammable or toxic vapors from substances inside. 7.e. Keep your head and face away from the cylinder valve outlet
They can cause an explosion even though they have been when opening the cylinder valve.
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of 7.f. Valve protection caps should always be in place and hand tight
Containers and Piping That Have Held Hazardous Substances”, except when the cylinder is in use or connected for use.
AWS F4.1 from the American Welding Society (see address
7.g. Read and follow the instructions on compressed gas cylinders,
above).
associated equipment, and CGA publication P-l, “Precautions for
6.e. Vent hollow castings or containers before heating, cutting or Safe Handling of Compressed Gases in Cylinders,” available
welding. They may explode. from the Compressed Gas Association 1235 Jefferson Davis
Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
FOR ELECTRICALLY
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
POWERED EQUIPMENT.
other locations away from the welding area increase the 8.a. Turn off input power using the disconnect
possibility of the welding current passing through lifting chains, switch at the fuse box before working on the
crane cables or other alternate circuits. This can create fire equipment.
hazards or overheat lifting chains or cables until they fail.
8.b. Install equipment in accordance with the U.S. National Electrical
6.h. Also see item 1.c. Code, all local codes and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During 8.c. Ground the equipment in accordance with the U.S. National
Welding, Cutting and Other Hot Work”, available from NFPA, 1 Electrical Code and the manufacturer’s recommendations.
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.
Welding Safety
Interactive Web Guide
for mobile devices
iv
SAFETY
ELECTROMAGNETIC The size of the surrounding area to be considered will depend on the
structure of the building and other activities that are taking place. The
surrounding area may extend beyond the boundaries of the premises.
COMPATIBILITY (EMC)
CONFORMANCE METHODS OF REDUCING EMISSIONS
Products displaying the CE mark are in conformity with European Mains Supply
Community Council Directive of 3 May 1989 on the approximation of
the laws of the Member States relating to electromagnetic compat- Welding equipment should be connected to the mains supply
ibility (89/336/EEC). It was manufactured in conformity with a national according to the manufacturer’s recommendations. If interference
standard that implements a harmonized standard: EN 60974-10 occurs, it may be necessary to take additional precautions such as
Electromagnetic Compatibility (EMC) Product Standard for Arc Welding filtering of the mains supply. Consideration should be given to
Equipment. It is for use with other Lincoln Electric equipment. It is shielding the supply cable of permanently installed welding
designed for industrial and professional use. equipment, in metallic conduit or equivalent. Shielding should be
electrically continuous throughout its length. The shielding should be
connected to the welding power source so that good electrical contact
INTRODUCTION is maintained between the conduit and the welding power source
All electrical equipment generates small amounts of electromagnetic enclosure.
emission. Electrical emission may be transmitted through power lines Maintenance of the Welding Equipment
or radiated through space, similar to a radio transmitter. When
emissions are received by other equipment, electrical interference The welding equipment should be routinely maintained according to
may result. Electrical emissions may affect many kinds of electrical the manufacturer’s recommendations. All access and service doors
equipment; other nearby welding equipment, radio and TV reception, and covers should be closed and properly fastened when the welding
numerical controlled machines, telephone systems, computers, etc. equipment is in operation. The welding equipment should not be
Be aware that interference may result and extra precautions may be modified in any way except for those changes and adjustments
required when a welding power source is used in a domestic estab- covered in the manufacturers instructions. In particular, the spark
lishment. gaps of arc striking and stabilizing devices should be adjusted and
maintained according to the manufacturer’s recommendations.
INSTALLATION AND USE Welding Cables

The user is responsible for installing and using the welding equipment The welding cables should be kept as short as possible and should be
according to the manufacturer’s instructions. If electromagnetic positioned close together, running at or close to floor level.
disturbances are detected then it shall be the responsibility of the Equipotential Bonding
user of the welding equipment to resolve the situation with the
technical assistance of the manufacturer. In some cases this remedial Bonding of all metallic components in the welding installation and
action may be as simple as earthing (grounding) the welding circuit, adjacent to it should be considered. However, metallic components
see Note. In other cases it could involve construction of an electro- bonded to the work piece will increase the risk that the operator could
magnetic screen enclosing the power source and the work complete receive a shock by touching these metallic components and the
with associated input filters. In all cases electromagnetic disturbances electrode at the same time. The operator should be insulated from all
must be reduced to the point where they are no longer troublesome. such bonded metallic components.
Note: The welding circuit may or may not be earthed for safety reasons Earthing of the Workpiece
according to national codes. Changing the earthing arrangements should
only be authorized by a person who is competent to access whether the Where the workpiece is not bonded to earth for electrical safety, not
changes will increase the risk of injury, e.g., by allowing parallel welding connected to earth because of its size and position, e.g., ships hull or
current return paths which may damage the earth circuits of other equip-
ment. building steelwork, a connection bonding the workpiece to earth may
reduce emissions in some, but not all instances. Care should be taken
to prevent the earthing of the work piece increasing the risk of injury
ASSESSMENT OF AREA to users, or damage to other electrical equipment. Where necessary,
Before installing welding equipment the user shall make an the connection of the workpiece to earth should be made by a direct
assessment of potential electromagnetic problems in the surrounding connection to the work piece, but in some countries where direct
area. The following shall be taken into account: connection is not permitted, the bonding should be achieved by
a. other supply cables, control cables, signaling and telephone cables; suitable capacitance, selected according to national regulations.
above, below and adjacent to the welding equipment;
Screening and Shielding
b. radio and television transmitters and receivers;
Selective screening and shielding of other cables and equipment in
c. computer and other control equipment; the surrounding area may alleviate problems of interference.
d. safety critical equipment, e.g., guarding of industrial equipment; Screening of the entire welding installation may be considered for
special applications.
e. the health of the people around, e.g., the use of pacemakers and
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic
hearing aids;
Compatibility (EMC) product standard for arc welding equipment.”
f. equipment used for calibration or measurement
g. the immunity of other equipment in the environment. The user shall
ensure that other equipment being used in the environment is
compatible. This may require additional protection measures;
h. the time of day that welding or other activities are to be carried out.
viii TABLE OF CONTENTS viii
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
________________________________________________________________________
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 Cycle Current Voltage at Rated Amperes
230 V 30% 130 Amps 20
208 V 30% 130 Amps 17
OUTPUT
Welding Current Range Open Circuit Voltage Wire Speed Range
30-180 Amps 34 V 50 - 500 in/min.
(1.3 - 12.7 m/min.)
RECOMMENDED INPUT CABLE AND FUSE SIZES

Input Voltage/Frequency Fuse or Breaker Size1 Input Amps Power Cord
230 V 60 Hz 40 Amp Super Lag 20 50 Amp, 250 V,

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”.
140 Amp units (K2470-1 140T, K2471-1 140C)

120 V / 60 Hz 20 Amps @ rated output
RATED OUTPUT
Duty Cycle Current Voltage at Rated Amperes
20% Duty Cycle 90 Amps 19.5
OUTPUT
30-140 Amps 33 V 50 - 500 in/min.
(1.3 - 12.7 m/min.)
Input Voltage/Frequency Fuse or Breaker Size1,2 Input Amps Power Cord Extension Cord
120 V 60 Hz 20 Amp 20 15 Amp, 125 V, 3 Conductor # 12 AWG

Three Prong Plug (4mm2) or Larger
(NEMA Type 5-15P) up to 50 ft.(15.2m)
PHYSICAL DIMENSIONS
14.0 in 10.15 in 18.6 in 58 Ibs
357 mm 258 mm 472 mm 26.3 kg
1If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.

TECHNICAL SPECIFICATIONS 180 Amp units (K2668-1 180C)

240 V 50 Hz I1 max 20 Amps
I1 eff 10.7 Amps
RATED OUTPUT
Voltage/Duty Cycle Current Voltage at Rated Amperes
240 V 25% 131 Amps 20
OUTPUT
30 - 180 Amps 34 V 50 - 500 in/min.
1.3 - 12.7 ( m/min.)

Input Voltage/Frequency Fuse or Breaker Size1 Input Amps Power Cord
240 V 50 Hz 40 Amp Super Lag 20 15 Amp, 240 V,

Three Pin Plug
PHYSICAL DIMENSIONS
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”.
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 under-
stood the POWER MIG Operating Manual
should install and operate this equipment.
• Machine must be plugged into a receptacle
which is grounded per any national, local
or other applicable electrical codes.
• The POWER MIG power switch is to be in
the OFF (“O”) position when installing
work cable and gun and when connecting
power cord to input power.
SELECT SUITABLE LOCATION

Locate the welder in a dry location where there is free
circulation of clean air into the louvers in the back and
out the front of the unit. A location that minimizes the
amount of smoke and dirt drawn into the rear louvers
reduces the chance of dirt accumulation that can
block air passages and cause overheating.
STACKING
POWER MIG (140, 180 MODELS) cannot be stacked.
TILTING
Each machine must be placed on a secure, level sur-

face, directly or on recommended cart. The machine
may topple over if this procedure is not followed.

IDENTIFY AND LOCATE COMPONENTS • .030” -.045” (0.8 - 1.1mm) Knurled Drive Roll
(Installed on Machine)
INCLUDED COMPONENTS
• Wire Feeder Welder.
.030
.045
• .025” -.035” (0.6 - 0.9mm) Inner Wire guide
• .035” -.045” (0.9 - 1.1mm) Inner Wire Guide
(Installed on Machine)
• Outer Wire Guide (Installed on Machine)
INNER WIRE GUIDE INNER WIRE GUIDE
.025-.035 (.6-.9mm) .035-.045 (.9-1.1mm) OUTER WIRE GUIDE
• Work Cable & Clamp.
• Black Flux-cored Gasless Gun Nozzle (Installed on

• Magnum 100L Welding Gun. Welding Gun)
• 3 .035” (0.9mm) Contact Tips • Brass MIG Gas Gun Nozzle

(1 installed on the welding gun).
• 3 .025” (0.6mm) Contact Tips.
.025
.035
.035
.025
.025
• 2”(51mm) Spindle Adapter (For 8”(203mm) Reel of

wire)
• Spool of .035” (0.9 mm) diameter NR-211MP • Regulator
Innershield Flux-cored Wire. • Gas Hose
• Spool of .025” (0.6 mm) diameter L-56 MIG Wire. • Learn to Weld (LTW1 Manual)
• DVD
NR-211 MP L-56 MIG
REGULATOR
2" SPINDLE ADAPTER (FOR 8" REEL OF WIRE)
WIRE
GAS HOSE
• .025”-.030” (0.6 - 0.8mm) • .035” (0.9mm)
Smooth Drive Roll Smooth Drive Roll LTW1
"LEARN TO WELD"
DVD

B-1 OPERATION B-1
Read entire operation section before PRODUCT DESCRIPTION (PRODUCT

operating the POWER MIG. CAPABILITIES)
These small portable wire feed welders are capable of

WARNING MIG welding on steel, stainless steel, and aluminum.
They are also capable of flux-cored welding on mild
ELECTRIC SHOCK can kill. steel.
• Do not touch electrically live MIG welding stands for Metal Inert Gas welding and
parts or electrode with skin or requires a separate bottle of shielding gas to protect
wet clothing. Insulate yourself the weld until it cools. Appropriate shielding gas
from work and ground. based on the type of material you are welding can be
• Always wear dry insulating purchased separately from your local welding gas dis-
gloves. tributor. MIG welding is ideal for welding on thinner
and clean materials when a very clean excellent cos-
metic looking weld is required. An example would be
FUMES AND GASES can be automotive body panels.
dangerous.
Flux-cored Welding does not require separate shield-
• Keep your head out of fumes. ing gas to protect the weld since the welding wire has
• Use ventilation or exhaust to special additives known as flux to protect the weld
remove fumes from breathing until it cools. Flux-cored welding is ideal for medium
zone. 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
WELDING SPARKS can MIG shielding gas away from the weld. Flux-cored
cause fire or explosion. welding produces a good looking weld but does not
produce an excellent weld appearance as MIG weld-
• Keep flammable material away. ing does.
• Do not weld on closed contain-
ers. Your machine includes the necessary items to weld
with either the MIG or the flux-cored welding process
on steel. To weld on stainless steel optional stainless
steel welding wire can be purchased separately. This
machine can weld aluminum using .035”(0.9mm)
diameter 4043 aluminum welding wire. Since alu-
ARC RAYS can burn eyes
minum welding wire is soft an optional aluminum
and skin. spool gun is recommended for best results. A welding
• Wear eye, ear and body protec- Procedure Decal is located inside machine door to
tion. help provide suggested settings for welding.
COMMON WELDING ABBREVIATIONS

Observe all safety information throughout
this manual. GMAW (MIG)
------------------------------------------------------------ • Gas Metal Arc Welding
FCAW (Innershield or Outershield)

• Flux Core Arc Welding

B-2 OPERATION B-2
CONTROLS AND SETTINGS

This machine has the following controls:
See Figure B.1 FIGURE B.1
1. POWER SWITCH – Turns power on and off to the 2

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 3
procedure based on type of material and thickness
being welded.
3. WIRE FEED SPEED CONTROL (WFS) – The knob

1
sets the speed that the machine feeds wire. Along
with arc voltage this control sets a weld procedure.
Refer to the procedure decal on the inside wire
drive compartment door to set a correct welding
procedure based on type of material and thickness
being welded.
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.
5c
5. WELDING GUN – Delivers wire and welding cur-
rent to the weld.
a. Gun Liner – wire travels through the liner from 5b
the wire drive. The gun liner will feed .025” to
.035” (0.6mm to 0.9mm) wire. The 180A machine 5a
can weld with .045”(1.1mm) wire if an optional
.035"(0.9mm)
.045”(1.1mm) liner is installed in the gun. NR-211-MP
5 WIRE SPOOL
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. 4
When MIG welding the brass nozzle funnels the
shielding gas to the weld. 6 7
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 recep-
tacle.

B-3 OPERATION 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 8

to change the welding polarity of the machine
depending on whether you are MIG welding or flux-
cored welding.
9
2"(51mm) SPINDLE ADAPTER (FOR 8"(20mm) REEL OF WIRE)

10. WIRE SPOOL SPINDLE AND BRAKE – Holds a
4”(102mm) diameter spool. Use the 2”(51mm)
spindle adapter included with the machine to use
8”(203mm) diameter spools. The thumbscrew
sets the brake friction to prevent the spool from
over rotating when the trigger is released.
( 4"(102mm) REEL OF WIRE)
11. WIRE DRIVE & COMPONENTS – Feeds wire

from the wire spool through the drive and through
the welding gun to the weld.
TOP DRIVE ROLL PRESSURE ARM
TENSION ADJUSTOR DOWN
a. Top and Bottom Drive Roll – Drives the wire
through the drive system. The drive roll has a WIRE SPOOL
.035" (0.9mm)
groove to match the specific wire type and diam-

eter. Refer to Table B.1 for available drive rolls. NR-211-MP
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 INNER WIRE GUIDE REMOVED
clockwise increases the force on the drive rolls
LOWER DRIVE ROLL REMOVED
and turning counterclockwise decreases the
OUTER WIRE GUIDE REMOVED
force.

B-4 OPERATION B-4
TABLE B.1
DRIVE ROLL AND WIRE GUIDES
Wire Diameter & Drive Roll Drive Roll Part Inner Wire Guide Inner Wire Guide
Type Number Part Number
.025”(0.6mm) MIG wire .025”/.030” (0.6mm/0.8mm)

Smooth Drive Roll KP2529-1
.030”(0.8mm) MIG wire
.025”-.035”
.035”(0.9mm) MIG wire .035”(0.9mm) Smooth Drive Roll KP2529-2 (0.6mm-0.9mm) KP2531-1
Steel Wire Guide
.030”(0.8mm) flux-cored .030”/.045” (0.8mm/1.1mm)
Knurled Drive Roll KP2529-3
.035”(0.9mm) flux-cored
.045”(1.1mm) flux-cored .030”/.045” (0.8mm/1.1mm) KP2529-3 .045”(1.1mm) Steel KP2531-2

Wire Guide
Knurled Drive Roll
FIGURE B.6
See Figure B.6
12 13
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.

B-5 OPERATION B-5
SETTING UP AND MAKING A FLUX-CORED WELD
A. ITEMS NEEDED FOR FLUX CORED

WELDING
7. Work Cable & Clamp
1. 035”(0.9mm) Contact Tip
.035
2. .025”-.035”(0.6mm-0.9mm) wire guide
INNER WIRE GUIDE

.025-.035 (.6-.9mm)
3. Knurled Drive Roll

.030
.045
4. .035”(0.9mm) NR-211MP Flux-Cored Wire
11 MP
.035 NR-2
E
FLUX-CORE WIR
5. Black Flux Cored gun nozzle
6. Welding Gun

B-6 OPERATION B-6
B. CONNECT LEADS AND CABLES ON LOCATE COMPONENTS
TO CONNECT TO THE
FIGURE B.7
THE MACHINE FRONT OF MACHINE
CASE SIDE DOOR
(See Figure B.7)

1. Open the case side door
2. Slide the connector end of the gun and cable SLIDE

CONNECTOR
OPEN LATCH DOOR
through the hole in the machine front and into the END HERE
TERMINAL END
gun connector bushing on the wire drive. (FITS ON STUD INSIDE
SEE FIGURE BELOW)
(4 PIN)
3. Make sure the gun connector end is seated fully LEAD CONNECTOR
into the wire drive and tighten the thumbscrew to WORK CLAMP
secure the gun connector. ALL COMPONENTS SHOWN CONNECTED

(FRONT AND SIDE DOOR IS REMOVED
GUN AND CABLE FOR CLARITY)
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 THUMB SCREW TO SHORT POWER
TIGHTEN CONNECTOR CABLE NEGATIVE "-"
negative (-) polarity. Connect the short power BUSHING OUTPUT TERMINAL
cable from the wire drive to the negative (-) output

terminal and tighten the thumbscrew. CONNECTOR
END ATTACH
6. Work Lead Connection. Slide the lugged end of WORK LEAD

CONNECTION
the work cable through the hole in the machine POSITIVE "+"
front and place on the positive (+) output terminal (4 PIN)
OUTPUT TERMINAL
and tighten thumbscrew. TRIGGER RECEPTACLE

PLUGGED IN
WORK CLAMP
C. LOAD WIRE SPOOL

FIGURE B.8
(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.
TOP DRIVE ROLL PRESSURE ARM
2. Secure spool in place by tightening the wing nut
WIRE SPOOL
against the against the spacer that holds the wire .035" (0.9mm)
spool on the spindle.
NR-211-MP
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.
INNER WIRE GUIDE REMOVED

4a. Slide gun out of drive slightly.
5. Remove the lower drive roll and inner wire guide.
OUTER WIRE
GUIDE REMOVED
6. Install the .025”-.035”(0.6mm-0.9mm) inner wire guide.
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.

B-7 OPERATION B-7
(See Figure B.9) FIGURE B.9
TOP DRIVE ROLL
9. Feed the wire through the wire drive inlet along the PRESSED AGAINST
LOWER DRIVE ROLL
TENSION ADJUSTOR
inner wire guide groove and into the wire drive outlet LOCKED IN POSITION
on the gun side.

DIRECTION
10. Close the top drive roll pressure arm and secure by SLIDE WIRE WIRE SPOOL
OF WIRE
.035" (0.9mm)
pivoting the tension adjustor back to the up position. INTO GUN
CONNECTOR
SIDE
NR-211-MP
11. Re-install the outer wire guide.
(See Figure B.10)

12. Remove the nozzle from the gun and contact tip LOWER DRIVE ROLL
BE SURE WIRE
and straighten the gun out flat. IS IN GROOVE
FIGURE B.10
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)
REMOVED NOZZLE .035"(0.9mm)
NR-211-MP
14. When trigger is released spool of wire should not REMOVED CONTACT TIP
WIRE SPOOL
unwind. Adjust wire spool brake accordingly. LAY CABLE AND GUN STRAIGHTEN
IN THIS POSITION
WARNING
MOVING PARTS AND ELECTRICAL
CONTACT CAN CAUSE INJURY OR BE
FATAL. PLUG IN POWER
•When the gun trigger is depressed drive INPUT CORD
rolls, spool of wire and electrode are FIGURE B.11

ELECTRICALLY LIVE (HOT).
• Keep away from moving parts and
ON/OFF
pinch points. SWITCH
• Keep all Doors, Covers, panels and

guards securely in place. FEED WIRE
DO NOT REMOVE OR CONCEAL WARN- APPROXIMATELY 4.00"

FROM THE GUN TUBE END .035"(0.9mm)
NR-211-MP
ING LABELS. DEPRESS TRIGGER
TO ACTIVATE WIRE,
WHICH FEEDS THE WIRE WIRE SPOOL
---------------------------------------------------------------------------- THRU THE LINER.
15. Install the .035”(0.9mm) contact tip

ROTATION
16. Install the black flux cored welding nozzle to the
gun.
WORK CLAMP AND CABLE
17. Trim the wire stickout to 3/8”(9.5mm) from the con-

tact tip. (See Figure B.12)
18. Close the case side door. The machine is now FIGURE B.12
TRIM WIRE
ready to weld. STICKOUT INSTALL .035 CONTACT TIP
3/8"(9.5mm)
from the Contact Tip
19. Read "Learn to Weld" (LTW1) that is included with
INSTALL BLACK FLUX-CORED NOZZLE
the machine or watch the "How to Weld" DVD
included with the machine.
20. Based on the thickness of the material you are

going to weld and the type and diameter of the
welding wire set the voltage and the wire feed
speed per the procedure decal attached to the
inside of the wire drive compartment door.

B-8 OPERATION B-8
SETTING UP AND MAKING A MIG WELD
A. ITEMS NEEDED FOR MIG WELDING
1. 025”(0.6mm) Contact Tip
.025
7. Work Cable & Clamp
2. 025”-035”(0.6mm-0.9mm) Inner wire guide
INNER WIRE GUIDE

.025-.035
8. Gas Regulator & Gas Line
5
5-.03
.02
3. .025”(0.6mm) Drive Roll
9. Bottle of 75/25 Ar/CO2 shielding gas (or 100% CO2

shielding gas) (note this requires a CO2 regulator
adapter which is sold separately.
4. .025”(0.6mm) SuperArc L-56 Solid MIG Wire
L-56 MIG MALE END FEMALE END
WIRE
CO2
100%
75/25
MIXES
5. Brass gun nozzle
(REQUIRES ADAPTER
SOLD SEPARATELY)
6. Welding Gun

B-9 OPERATION B-9
FIGURE B.13
B. INSTALL SHIELDING GAS
MIG welding requires an appropriate bottle of shielding MALE END

REGULATOR
ADAPTER
gas. For mild steel either a cylinder bottle of Ar/CO2 or S19298
PLASTIC
100% CO2 can be used refer to the following instruc- CO2
100%
WASHER
tions to properly connect shielding gas to the machine. FEMALE END
WARNING 75/25
MIXES
CYLINDER may explode if dam-

aged. Keep cylinder upright and
chained to support
• Keep cylinder away from areas
where it may be damaged.
3. Attach the flow regulator to the cylinder valve and
• Never lift welder with cylinder tighten the union nut securely with a wrench.
attached.
• Never allow welding electrode to NOTE: If connecting to 100% CO2 cylinder, a CO2
touch cylinder. regulator adapter is required. Purchase separately
S19298 CO2 adapter be sure to install plastic washer
• Keep cylinder away from welding
included in the fitting on the bottle side.(See Figure
or other live electrical circuits.
B.13 )
-----------------------------------------------------------------------
4. Refer to Figure B.13. Attach one end of inlet gas hose
WARNING to the outlet fitting of the flow regulator and tighten the
union nut securely with a wrench. Connect the other
BUILDUP OF SHIELDING GAS may end to the machine Solenoid Inlet Fitting (5/8-18
harm health or kill. female threads — for CGA — 032 fitting). Make cer-
tain the gas hose is not kinked or twisted.
• Shut off shielding gas supply
when not in use.
SHIELDING GAS
1. Secure the cylinder to a wall or other stationary 1. For CO2, open the cylinder very slowly. For argon-
support to prevent the cylinder from falling over. mixed gas, open cylinder valve slowly a fraction of a
Insulate the cylinder from the work circuit and earth turn. When the cylinder pressure gauge pointer stops
ground. Refer to Figure B.13. moving, open the valve fully.
2. With the cylinder securely installed, remove the 2. Set gas flow rate for 30 to 40 cubic feet per hour (14
cylinder cap. Stand to one side away from the out- to 18 I/min.) under normal conditions, increase to as
let and open the cylinder valve very slightly for an high as 40 to 50 CFH (18 to 23.5 I/min.) under drafty
instant. This blows away any dust or dirt which may (slightly windy) conditions.
have accumulated in the valve outlet.
3. Keep the cylinder valve closed, except when using
WARNING the machine.
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.
------------------------------------------------------------------------

B-10 OPERATION B-10
C. CONNECT LEADS AND CABLES ON FIGURE B.14
THE MACHINE LOCATE COMPONENTS
TO CONNECT TO THE
FRONT OF MACHINE
(See Figure B.14)
1. Open the case side door. CASE SIDE DOOR
2. Slide the connector end of the gun and cable

through the hole of the machine front and into the
SLIDE
gun connector bushing on the wire drive. CONNECTOR
OPEN LATCH DOOR
END HERE
TERMINAL END
3. Make sure the gun connector end is seated fully (FITS ON STUD INSIDE
SEE FIGURE BELOW)
into the wire drive and tighten the thumbscrew to (4 PIN)
secure the gun. LEAD CONNECTOR
WORK CLAMP
4. Plug the gun trigger lead connector into the 4 pin ALL COMPONENTS SHOWN CONNECTED
(FRONT AND SIDE DOOR IS REMOVED
GUN AND CABLE FOR CLARITY)
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 THUMB SCREW TO
TIGHTEN CONNECTOR
WORK LEAD
CONNECTION
NEGATIVE "-"
tighten the thumbscrew. BUSHING
OUTPUT TERMINAL
CONNECTOR
6. Work Lead Connection. Slide the lugged end of the END ATTACH
work cable through the hole in the machine front

and place on the negative (-) output terminal and
tighten thumbscrew. SHORT POWER
CABLE POSITIVE "+"
(4 PIN)
TRIGGER RECEPTACLE OUTPUT TERMINAL
PLUGGED IN
WORK CLAMP
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 FIGURE B.15
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. TOP DRIVE ROLL PRESSURE ARM
3. Open the top drive roll pressure arm by rotating the WIRE SPOOL
.025" (0.6mm)
tension adjustor arm down and pivoting the idle roll
pressure arm up.
L- G
56 MI
S O LID
4. Remove the outer wire guide.
4a. Slide gun out of drive slightly.
5. Remove the lower drive roll and inner wire guide.

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

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

OUTER WIRE
GUIDE REMOVED
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.

B-11 OPERATION B-11
(See Figure B.16) FIGURE B.16
TOP IDLER ROLL
9. Feed the wire through the wire drive inlet along the PRESSED AGAINST
LOWER DRIVE ROLL
TENSION ADJUSTOR
inner wire guide groove and into the wire drive out- LOCKED IN POSITION
let on the gun side.
10. Close the top drive roll pressure arm and secure DIRECTION
OF WIRE
by pivoting the tension adjustor back to the up SLIDE WIRE WIRE SPOOL
.025" (0.6mm)
INTO GUN
position. CONNECTOR
SIDE
11. Re-install the outer wire guide.
L-
56
S OLI I G
D M
(See Figure B.17)

12. Remove the nozzle from the gun and contact tip
DRIVE ROLL
and straighten the gun out flat. BE SURE WIRE
IS IN GROOVE
13. Turn the machine power to on and depress the FIGURE B.17
gun trigger to feed the wire through the gun liner
until the wire comes out of the threaded end of the
gun several inches. (See Figure B.18)
14. When trigger is released spool of wire should not REMOVED NOZZLE
WIRE SPOOL
.025" (0.6mm)
unwind. Adjust wire spool brake accordingly. REMOVED CONTACT TIP

L-5
G
6 S O D MI
LI
LAY CABLE AND GUN STRAIGHTEN
WARNING IN THIS POSITION
MOVING PARTS AND ELECTRICAL

CONTACT CAN CAUSE INJURY OR BE
FATAL.
•When the gun trigger is depressed
FIGURE B.18
drive rolls, spool of wire and elec- PLUG IN POWER
INPUT CORD
trode are ELECTRICALLY LIVE (HOT).

• Keep away from moving parts and
pinch points.
• Keep all Doors, Covers, panels and ON/OFF
SWITCH
guards securely in place.
DO NOT REMOVE OR CONCEAL
WARNING LABELS. FEED WIRE
APPROXIMATELY 4.00"
WIRE SPOOL
FROM THE GUN TUBE END
.025" (0.6mm)
DEPRESS TRIGGER
TO ACTIVATE WIRE,
----------------------------------------------------------------------- WHICH FEEDS THE WIRE L-5
G
THRU THE LINER. 6 S O D MI
LI
15. Install the .025”(0.6mm) contact tip.
16. Install the brass gas MIG welding nozzle to the gun. ROTATION
17. Trim the wire stickout to 3/8”(9.5mm) from the nozzle WORK CLAMP AND CABLE
end. (See Figure B.19)

FIGURE B.19
18. Close the case side door. The machine is now ready TRIM WIRE
to weld. STICKOUT INSTALL .025 CONTACT TIP
3/8"(9.5mm)
from the Brass Nozzle
19. Read "Learn to Weld" (LTW1) that is included with
the machine or watch the "How to Weld" DVD includ- INSTALL BRASS NOZZLE
ed with the machine.
20. Based on the thickness of the material you are going

to weld and the type and diameter of the welding
wire set the voltage and the wire feed speed per the
procedure decal attached to the inside of the wire
drive compartment door.
B-12 OPERATION B-12
SETTING UP AND MAKING A ALUMINUM WELD USING SPOOL GUN
1. Follow the MIG welding steps in the previous sec-
tion.
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 posi-

tion. (See Figure B.20)
FIGURE B.20
6. Turn machine on and make weld per recommended

settings on Procedure Decal inside machine door.

C-1 ACCESSORIES C-1
K2525-1 - Spot Timer Kit

Timer kit, when turned on, allows you to set a fixed
weld time so that when the gun trigger is pulled the
machine will weld for a fixed time period up to 10 sec-
onds. 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.
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)

C-2 ACCESSORIES C-2
K520—Utility Cart
Heavy duty cart stores and transports welder, 150
cubic foot shielding gas cylinder, welding cables and
accessories. Includes stable platforms for welder and
gas bottle platform, lower tray for added storage
capacity and adjustable height handle.
For mounting welding machines to K520 carts that do not have slotted mounting holes,
Drill 9/32” holes (3 places) into the cart top as shown and attach the welding machine to the cart
with the proper hardware shown.
1/4"-20 X 1/2" Hex Head Cap Screw

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

(2 Required)
3-3/4" (95.3mm) 9/32"(7.1mm) DRILL

3 PLACES
8-1/16" (204.8mm)
3-11/16"(93.7mm) 3-13/32" (96.8mm)
4"(102mm)
16"(406.4mm)
C-3 ACCESSORIES C-3
K2275-1 - Welding Cart
Lightweight cart stores and transports welder, 80
cubic foot shielding gas cylinder, welding cables and
accessories. Includes an angled top shelf for easy
access to controls, lower tray for added storage
capacity, a sturdy fixed handle and convenient cable
wrap hanger.
For mounting welding machines to K2275 carts that do not have slotted mounting holes,
Drill 9/32” holes (3 places) into the cart top as shown and attach the welding machine to the cart
with the proper hardware shown.

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

(2 Required)
9/32"(7.1mm) DRILL
3 PLACES
1-1/4"(31.8mm)
7-9/16"(192.1mm)
3-3/16"(81mm) 2-15/16"(74.6mm)
1-1/2"(38.1mm)
13-1/2"(342.9mm)

D-1 MAINTENANCE D-1
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Disconnect input power by removing

plug from receptacle before working
inside POWER MIG (140, 180 MODELS).
Use only grounded receptacle. Do not
touch electrically “hot” parts inside
POWER MIG (140, 180 MODELS).
• Have qualified personnel do the mainte-

nance and trouble shooting work.
---------------------------------------------------------------------------------
ROUTINE MAINTENANCE
POWER SOURCE COMPARTMENT
No user serviceable parts inside! Do not attempt to perform
service in the power source (fixed) side of the POWER MIG
(140, 180 MODELS). Take the unit to an authorized Lincoln
Service Center if you experience problems. NO maintenance
is required.
In extremely dusty locations, dirt may clog the air passages

causing the welder to run hot with premature tripping of ther-
mal protection. If so, blow dirt out of the welder with low pres-
sure air at regular intervals to eliminate excessive dirt and dust
build-up on internal parts.
WIRE FEED COMPARTMENT

1. When necessary, vacuum accumulated dirt from gearbox
and wire feed section.
2. Occasionally inspect the wire guides and keep grooves

clean.
3. Motor and gearbox have lifetime lubrication and require no

maintenance.
FAN MOTOR
Has lifetime lubrication — requires no maintenance.
WIRE REEL SPINDLE

Requires no maintenance. Do not lubricate shaft.

D-2 MAINTENANCE D-2
GUN AND CABLE

MAINTENANCE 5. To remove gun tube from gun, remove gas nozzle
or gasless nozzle and remove diffuser from gun
FOR MAGNUM™ 100L GUN tube. Remove both collars from each end of the
gun handle and separate the handle halves.
Gun Cable Cleaning Loosen the locking nut holding the gun tube in
Clean cable liner after using approximately 300 lbs place against the gun end cable connector.
(136 kg) of solid wire or 50 lbs (23 kg) of flux-cored Unscrew gun tube from cable connector. To install
wire. Remove the cable from the wire feeder and lay it gun tube, screw the locking nut on the gun tube as
out straight on the floor. Remove the contact tip from far as possible. Then screw the gun tube into the
the gun. Using low pressure air, gently blow out the cable connector until it bottoms. Then unscrew (no
cable liner from the gas diffuser end. more than one turn) the gun tube until its axis is
perpendicular to the flat sides of the cable connec-
tor and pointed in the direction of the trigger.
CAUTION Tighten the locking nut so as to maintain the proper
Excessive pressure at the start may cause the dirt relationship between the gun tube and the cable
to form a plug. connector. Replace the gun handle, trigger and dif-
fuser. Replace the gas nozzle or gasless nozzle.
Flex the cable over its entire length and again blow OVERLOAD PROTECTION
out the cable. Repeat this procedure until no further
dirt comes out. Output Overload
The POWER MIG (140, 180 MODELS) is equipped
with a circuit breaker and a thermostat which protects
Contact Tips, Nozzles, and Gun Tubes the machine from damage if maximum output is
1. Dirt can accumulate in the contact tip hole and exceeded. The circuit breaker button will extend out
restrict wire feeding. After each spool of wire is when tripped. The circuit breaker must be manually
used, remove the contact tip and clean it by push- reset.
ing 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. Thermal Protection
The POWER MIG (140, 180 MODELS) has a rated
2. Replace worn contact tips as required. A variable output duty cycle as defined in the Technical
or “hunting” arc is a typical symptom of a worn con- Specification page. If the duty cycle is exceeded, a
tact tip. To install a new tip, choose the correct size thermal protector will shut off the output until the
contact tip for the electrode being used (wire size is machine cools to a reasonable operating temperature.
stenciled on the side of the contact tip) and screw it This is an automatic function of the POWER MIG
snugly into the gas diffuser. (140, 180 MODELS) and does not require user inter-
vention. The fan continues to run during cooling.
3. Remove spatter from inside of gas nozzle and from
tip after each 10 minutes of arc time or as required.
Electronic Wire Drive Motor Protection
4. Be sure the gas nozzle is fully screwed onto the The POWER MIG (140, 180 MODELS) has built-in
diffuser for gas shielded processes. For the protection for wire drive motor overload.
Innershield® process, the gasless nozzle should
screw onto the diffuser.

D-3 MAINTENANCE D-3
1-1/4”(31.8 mm)
Liner Trim Length
Gas Diffuser
Gas Nozzle or
Set Screw Brass Cable Gasless Nozzle
Connector
Liner Assembly
(Liner bushing to be sealed tight
against brass cable connector)
FIGURE D.2 8. Screw the gas diffuser onto the end of the gun tube
Liner trim length and securely tighten.
CHANGING LINER
9. Replace the contact tip and nozzle.
NOTICE: The variation in cable lengths prevents the
interchangeability of liners. Once a liner has been cut
for a particular gun, it should not be installed in anoth-
GUN HANDLE PARTS
er gun unless it can meet the liner cutoff length
The gun handle consists of two halves that are held
requirement. Refer to Figure D.2.
together with a collar on each end. To open up the
handle, turn the collars approximately 60 degrees
1. Remove the gas nozzle from the gun by unscrew-
counter-clockwise until the collar reaches a stop. Then
ing counter-clockwise.
pull the collar off the gun handle. If the collars are diffi-
cult to turn, position the gun handle against a corner,
2. Remove the existing contact tip from the gun by
place a screwdriver against the tab on the collar and
unscrewing counter-clockwise.
give the screwdriver a sharp blow to turn the collar
past an internal locking rib. See Figure D-3.
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 connec-
tor at the wire feeder end of the cable. Pull the liner
out of the cable.
5. Insert a new untrimmed liner into the connector end

of the cable. Be sure the liner bushing is stenciled
➣
Counter-clockwise
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.
FIGURE D.3
Remove any burrs from the end of the liner.

E-1 TROUBLESHOOTING E-1
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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
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.
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.

Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED

(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage “Do not Plug in machine or turn it on”.
is evident. Contact your local Authorized Field
Service Facility.
No wire feed, weld output or gas 1. Make sure correct voltage is

flow when gun trigger is pulled. Fan applied to the machine.
does NOT operate.
2. Make certain that power switch
is in the ON position.
3. Make sure circuit breaker is

reset. If all recommended possible areas
of misadjustment have been
No wire feed, weld output or gas 1. The thermostat may be tripped checked and the problem persists,
flow when gun trigger is pulled. due to overheating. Let machine Contact your local Lincoln
Fan operates normally. cool. Weld at lower duty cycle. Authorized Field Service
Facility.
2. Check for obstructions in air
flow. Check Gun Trigger connec-
tions. See Installation section.
3. Gun trigger may be faulty.
CAUTION

FEEDING PROBLEMS
No wire feed when gun trigger is 1. If the wire drive motor is running
pulled. Fan runs, gas flows and make sure that the correct drive
machine has correct open circuit rolls are installed in the machine.
voltage (33V) – weld output. If all recommended possible areas
2. Check for clogged cable liner or of misadjustment have been
contact tip. checked and the problem persists,
Contact your local Lincoln
3. Check for proper size cable liner Authorized Field Service
and contact tip. Facility.

GAS FLOW PROBLEMS
Low or no gas flow when gun 1. Check gas supply, flow regulator
trigger is pulled. Wire feed, weld and gas hoses.
output and fan operate normally.
2. Check gun connection to If all recommended possible areas
machine for obstruction or leaky of misadjustment have been
seals. checked and the problem persists,
Authorized Field Service
Facility.
CAUTION

WELDING PROBLEMS
Arc is unstable – Poor starting 1. Check for correct input voltage
to machine.
2. Check for proper electrode

polarity for process.
3. Check gun tip for wear or dam-

age and proper size – Replace.
If all recommended possible areas
4. Check for proper gas and flow of misadjustment have been
rate for process. (For MIG only.) checked and the problem persists,
5. Check work cable for loose or Authorized Field Service
faulty connections. Facility.
6. Check gun for damage or

breaks.
7. Check for proper drive roll orien-

tation and alignment.
8. Check liner for proper size.
CAUTION
F-1 DIAGRAMS Enhanced Diagram F-1
FOR CODES 11254, 11255, 11256, 11257
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
F-2 DIAGRAMS F-2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
POWER MIG (180 MODELS)

F-3 DIMENSION PRINT F-3
M21111-2
A
14.08
10.37
2.46
5.50
18.78
12.00
3.08
6.00

P-533 P-533
PARTS LIST FOR
POWER MIG®
(140 & 180 Models)
This parts list is provided as an informative guide only.

It was accurate at the time of printing. These pages are only updated on the
Service Navigator DVD and in Lincoln Electricʼs official Parts Book (BK-34).
When ordering parts, always refer to Lincoln Electricʼs official Parts Book
(BK-34) for the latest pages.
POWER MIG® (140, 180 MODELS)

P-533-A P-533-A
ILLUSTRATION OF SUB-ASSEMBLIES
1
2
POWER MIG® (140, 180 MODELS) 02-04-2010

P-533-A.1 P-533-A.1
POWER MIG® (140, 180 Models)
For Codes: 11254, 11255, 11256, 11257, 11444, 11804, 11819 & 11820
Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any
code numbers not listed.
Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and
column the desired part is located on for your particular code machine.
Sub Assembly Item 1 2 3 4 5

No.
Wraparound & Door Assembly
Magnum 100 L Gun & Cable

Optional Equipment Listing
Magnum Pro 100 L Gun &

Power Module Assembly
Center Panel Assembly
Wire Drive Assembly

Miscellaneous Items
General Assembly
Cable (K3080-1)
SUB ASSEMBLY
PAGE NAME
(K530-6)
PAGE NO. P-533-B.1 P-533-B.2 P-533-C P-533-D P-533-E P-533-F P-533-G P-202-E2 P-202-AJ
CODE NO.
11254 (140 Amp) 1 1 1 1 1 1 1 •
11255 (140 Amp) 1 5 1 1 1 2 1 • #
11256 (180 Amp) 2 1 2 1 1 1 1 •
11257 (180 Amp) 2 1 2 1 1 2 1 •
11444 (180 Amp) 3 1 2 2 1 3 1 •
11804 (140 Amp) 4 4 3 3 1 2 • 1
11819 (140 Amp) 4 2 1 3 1 2 • 1
11820 (180 Amp) 5 3 2 3 1 2 • 1
POWER MIG® (140, 180 MODELS) 01-30-2012

P-533-B.1 P-533-B.1
OPTIONAL EQUIPMENT LISTING
Miscellaneous Options Available for your machine are listed below:
# Indicates a change this printing.
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PART NUMBER
Spot Timer Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2525-1

.045 Innershield Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2528-1
Deluxe Adjustable Gas Regulator & Hose Kit (Codes 11254,11255,11256 & 11257) . . . . . . .Order K586-1
Welding Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2275-1
Utility Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K520-1
Spool Gun Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2532-1
.025 Smooth Drive Roll Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2529-1
.035 Smooth Drive Roll Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2529-2
.030/.045 Knurled Drive Roll Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2529-3
.025/.035 Steel Wire Guide Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2531-1
.045 Steel Wire Guide Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order KP2531-2
POWER MIG® (140, 180 MODELS) 02-04-2010

MISCELLANEOUS ITEMS
P-533-B.2 (THESE ITEMS ARE NOT ILLUSTRATED) P-533-B.2
# Indicates a change this printing. Use only the parts marked “x” in the column under the
heading number called for in the model index page.
DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9
Plug & Lead Assembly S18250-908 1 X • • X •

Plug & Lead Assembly S18250-909 1 • X X • X
Plug & Lead Assembly (P301) S18250-916 1 X X • X •
Plug & Lead Assembly S18250-944 1 • • X • •
Plug & Lead Assembly (P1005) S18250-917 1 X X X • X
Work Cable S11609-29 1 X • • X •
Work Cable S11609-30 1 • X X • X
Work Clamp M12033 1 X X X X X
DVD (Arc Welding) S26375 1 X X X X X
Wire Reel Spindle Adapter M15445-1 1 X X X X X
Gas Regulator (Argon Mixed) S25805 * 1 X X • • •
Gas Regulator S25183 1 • • X • •
Gas Regulator 3000290 1 • • • X X
Gas Hose Assembly S19303 1 X X • X X
Gas Hose Assembly S19303-3 1 • • X • •
* Deluxe version available as K586-1. POWER MIG® (140, 180 MODELS) 05-25-2011
Includes S19303 Gas Hose Asbly
P-533-C P-533-C
General Assembly
7A
1A
6
2
7B
3A 5A
1B
9A 9B 9C
12A
5B
11B
1B
14
4
13
10
POWER MIG® (140, 180 MODELS) 02-04-2010

P-533-C.1 P-533-C.1
ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9
1A Case Front G4812-1 1 X X X X X

1B Thread Forming Screw S9225-63 4 X X X X X
2 Nameplate (Code 11254) L12398-2 1 X • • • •
2 Nameplate (Code 11255) L12398-4 1 • • • • X
2 Nameplate (Code 11256) L12398-3 1 X • • • •
2 Nameplate (Codes 11257 & 11444) L12398-5 1 X • • • •
2 Nameplate (Codes 11804 & 11819) L13921-1 1 • X • X •
2 Nameplate (Code 11820) L13921-2 1 • • X • •
3A Knob S18425-1 2 X X X X X
3B Nut (Not Shown) T10940-10 As Req X X X X X
3C Self Tapping Screw (Not Shown) S8025-96 2 X X X X X
3D Lock Washer (Not Shown) T9695-5 2 • X X X •
4 Switch T10800-59 1 X X X X X
5A Square Flange Female Receptacle (Part of Plug & Lead Asbly) S18657 1 X X X X X
5B Self Tapping Screw S8025-96 2 X X X X X
6 Control P.C. Board (Code 11254 & 11256) L12450-[ ] 1 X • • • X
6 Cntrl P.C. Bd (Codes 11255,11257,11444,11804,11819 &11820) L12230-[ ] 1 X X X X X
7A Handle M20483 1 X X X X X
7B Thread Forming Screw S9225-63 2 X X X X X
8 Case Back & Bottom G4718 1 X X X X X
9A Solenoid Assembly M17294-8 1 X X X X X
9B Plain Washer S9262-10 1 X X X X X
9C Lock Nut T14370-1 1 X X X X X #
10 Circuit Breaker T12287-21 1 X • X • •
10 Circuit Breaker T12287-40 1 • X • X X
11A Power Cord (Not Shown) (Codes 11254, 11255 & 11819) S25563-3 1 X X • • X
11A Power Cord (Not Shown) (Codes 11256, 11257 & 11820) S15599-2 1 X • X • X
11A Power Cord (Not Shown) (Code 11444) S19836-7 1 X • • • X
11A Power Cord (Not Shown) (Code 11804) S25563-1 1 • • • X •
11B Lead Grommet (Codes 11254,11255,11256,11257,11804,11819 & 11820) T9274-11 1 X X X X X
11B Lead Grommet (Code 11444) S19999-2 1 X • • • X
12A Case Back (Codes 11254,11255,11256,11257,11804,11819&11820) G4813 1 X X X X X
12A Case Back Panel (Code 11444) G4813-1 1 X • • • X
12B Self Tapping Screw (Not Shown) S8025-101 4 X X X X X
13 Gas Hose T10642-217 1 X X X X X
14 Rating Decal (Codes 11254, 11255, 11804 & 11819) S26499-2 1 X X • X X
14 Rating Decal (Codes 11256, 11257 & 11820) S26499-3 1 X • X • •
14 Rating Decal (Code 11444) S26499-5 1 X • • • •
Grounding Screw Mounting Hardware:
16A Thread Forming Screw (Not Shown) S9225-63 1 X • • • X
16A Thread Forming Screw (Not Shown) S9225-76 1 • X X X •
16B #10-24 HN (Not Shown) CF000010 2 X X X X X
16C Lock Washer (Not Shown) T9695-1 1 X X X X X
Hardware to Secure Leads to Ground Screw:
17A #10-24 HN (Not Shown) CF000010 1 X X X X X
17B Lock Washer (Not Shown) E106A-1 1 X X X X X
17C Plain Washer (Not Shown) S9262-27 1 X X X X X
Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board
that is to be replaced. This will aid Lincoln in supplying the correct and latest board along
with any necessary jumpers or adapters. The dash number brackets [ ] have purposely
been left blank so as to eliminate errors, confusion and updates.
POWER MIG® (140, 180 MODELS) 07-24-2012
P-533-D P-533-D
Power Module Assembly
5
6
2
4
3
POWER MIG® (140, 180 MODELS) 02-04-2010

P-533-D.1 P-533-D.1
Power Module Assembly, Includes: G4716-2 1 X • •

Power Module Assembly, Includes: G4716-3 1 • X •
Power Module Assembly, Includes: G4716-7 1 • • X
1 Chassis G4715 2 X X X
2 Rectifier L12306 1 X • •
2 Rectifier L12307 1 • X • #
2 Rectifier L12306-1 1 • • X
3 Capacitor S13490-218 1 X • •
3 Capacitor S13490-220 1 • X •
3 Capacitor S13490-109 1 • • X
4 Transformer & Choke Assembly G4808-2 1 X • X
4 Transformer & Choke Assembly G4808-3 1 • X •
5 Fan S18977-4 1 X • X
5 Fan S18977-5 1 • X •
6 Flange Bolt S9225-8 2 X X X
Hardware for Mounting Rectifier & Choke Leads to Capacitor:
10A 1/4-28 HN (Not Shown) CF000198 2 X X X
10B Plain Washer (Not Shown) S9262-98 2 X X X
10C Lock Washer (Not Shown) E106A-2 2 X X X
POWER MIG® (140, 180 MODELS) Oct-13

P-533-E P-533-E
Center Panel Assembly
16A
16B
1
9 8
7
17A
13
11C 11A 12 10
17A 2
3
4
5
15G
15C15G
15C
11B 10
11D
POWER MIG® (140, 180 MODELS) 05-25-2011

P-533-E.1 P-533-E.1
Center Panel Assembly, Includes: L12322 1 X • X

Center Panel Assembly, Includes: L12322-2 1 • X •
1 Center Panel L12321 1 X • X
1 Center Panel L12321-1 1 • X •
2 Bow Washer T10781-10 1 X X X
3 Wear Plate S18423-1 1 X X X
4 Spindle Shaft S24227 1 X X X
5 Spindle Spacer S24226 1 X X X
6 Wing Nut T9968-5 1 X X X
7 Plain Washer S9262-120 1 X X X
8 Lock Washer E106A-16 1 X X X
9 3/8-16 x .625 HHCS CF000018 1 X X X
10 Self Tapping Screw (Secures Center Panel to Chassis) S8025-101 6 X X X
11A Polarity Panel L12555-1 1 X X X
11B Output Stud S25937 2 X X X
11C 1/4-20 x .50 HHCS CF000012 2 X X X
Plain Washer (Not Shown) S9262-23 2 X X X
Lock Washer (Not Shown) E106A-2 2 X X X
11D Wing Nut T9968-6 2 X X X
12 Plug Button T10397-3 1 X X X
15A By-Pass Assembly (Refer to Wiring Diagram) S22969-4 1 • X •
15B Ground Screw Asbly, Includes: S18922-8 1 • X •
15C Thread Forming Screw S9225-63 1 • X •
15D Plain Washer (Not Shown) S9262-27 2 • X •
15E #10-24 HN (Not Shown) CF000010 2 • X •
15F Lock Washer (Not Shown) E106A-1 1 • X •
15G Lock Washer T9695-1 1 • X •
16A By-Pass P.C. Board L10882-[ ] 1 • X •
16B Sems Screw T10082-27 2 • X •
17A Spot Timer & Spool Gun Decal (Not Shown) (Includes -A & -B) T13086-200 1 X X •
17A Spot Timer & Spool Gun Decal (Not Shown) (Includes -A & -B) T13086-213 1 • • X
Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board
that is to be replaced. This will aid Lincoln in supplying the correct and latest board along
with any necessary jumpers or adapters. The dash number brackets [ ] have purposely
been left blank so as to eliminate errors, confusion and updates.
POWER MIG® (140, 180 MODELS) 05-25-2011

P-533-F P-533-F
Wire Drive Assembly
10
1A 7
11
6
5
4B
19 12
21A
13
14
8 16
15A
15B 15C 18A
20
22
17
POWER MIG® (140, 180 MODELS) 01-07-2011

P-533-F.1 P-533-F.1
Wire Drive Assembly, Includes: L12379-3 1 X #

1A Motor Parts Order Sub Assembly, Includes: L13556 1 X
Motor NSS 1 X
Metric Screw (Not Shown) NSS 2 X
Base NSS 1 X
Hose Nipple NSS 1 X
Pinion NSS 1 X
Bearing NSS 1 X
4B Bearing M9300-141 1 X
5 Shaft S26311 1 X
6 Gear S26298 1 X
7 Pivot Arm Assembly S26296 1 X
8 Conductor Block S25931 1 X
9 Dowel Pin (Not Shown) T13942-15 1 X
10 Tension Arm Assembly M20593-2 1 X #
11 Cover L12390 1 X
12 Inner Wire Guide S25932-2 1 X
13 Gear S26234-1 1 X
14 Hub M20860 1 X
15A Twist Lock S26238 1 X
15B Screw T14731-63 1 X
15C Lock Washer T9695-3 1 X
16 Drive Roll (Knurled) S26236-3 1 X
17 Molded Hand Screw T13858-4 1 X
18A Outer Wire Guide Assembly, Includes: S26899 1 X
Wire Guide Knob NSS 2 X
19 Hose Nipple T13776-5 1 X
20 Insulating Washer S26452 3 X
21A 1/4-20 x .625 HHCS CF000013 1 X
21B Lock Washer (Not Shown) E106A-2 1 X
21C Plain Washer (Not Shown) S9262-98 1 X
22 Self Tapping Screw S8025-116 3 X
NSS - Not Sold Separately POWER MIG® (140, 180 MODELS) 01-07-2011
P-533-G P-533-G
Wraparound & Door Assembly
11
3B
3A
2 6
1
14
8
12
13
16
7A
15
POWER MIG® (140, 180 MODELS) 05-25-2011

P-533-G.1 P-533-G.1
Wraparound & Door Asbly, (M20452-3) Includes: NSS 1 X X X

1 Door L12320-1 1 X X X
2 Case Side G4719-1 1 X X X
3A Hinge (Includes S25898-2) S25898-1 2 X X X
3B Self Tapping Screw S8025-92 4 X X X
4 Door Latch S21033 1 X X X
6 Warranty Decal S22127-1 1 X X X
7 Side Decal T13086-172 2 X • •
7A Logo Decal S27368-2 2 • X X
8 Wiring Diagram M20410 1 X X •
8 Wiring Diagram M20410-2 1 • • X
9 Warning Decal M16196 1 X X •
9 Warning Decal M16196-3 1 • • X
12 Procedure Decal (Code 11254) L12603-2 1 X • •
12 Procedure Decal (Code 11255, 11804 & 11819) L12603-4 1 • X • #
12 Procedure Decal (Code 11256) L12603-3 1 X • •
12 Procedure Decal (Codes 11257, 11444 & 11820) L12603-5 1 • X X
13 Self Tapping Screw S8025-92 8 X X X
14 Self Tapping Screw S8025-101 2 X X X
15 Family Name Decal S27369-1 2 • X X
16 Nascar Decal S27370-2 2 • X X
NSS - Not Sold Separately POWER MIG® (140, 180 MODELS) 09-26-2011
P-202-E.2 P-202-E.2
MAGNUM® 100L
MAGNUM® 100L Parts
MAGNUM® 100L
6A
5
1
3
5
4B
4A
6A
2 7 LINER
GAS
DIFFUSER
CONTACT
TIP
8 NOZZLE
Item Description Part Number Qty. Item Description Part Number Qty.
New Complete Gun & Cable Assemblies: Contact Tips:

Magnum® 100L K530-6
.025” (0.5 mm) KP11-25 #
Replacement Parts: .030” (0.8 mm) KP11-30
1 Cable Assembly M16318-2 1 .035” (0.9 mm) KP11-35
2 Trigger Assembly S19725 1 .045” (1.2 mm) KP11-45
3 Locking Nut S19580 1 Tapered Contact Tips:
4A Gun Tube Assembly KP2038-1 1 .025” (0.6 mm) KP11T-25 #
4B Gun Tube Assembly Cover T10642-162 1 .030” (0.8 mm) KP11T-30
5 Collar S19701 2 .035” (0.9 mm) KP11T-35
6A Gun Handle (Right & Left) G2209 1 .045” (1.2 mm) KP11T-45
7 O Ring T13483-8 2 Nozzles:
8 Control Wire Cord S26388 1 Gas Nozzle 0.5 ID, Tip Flush KP21-50-F
Gun Consumable Parts: Gas Nozzles, Tip Recessed
Liners: 0.37” I.D. KP21T-37
.025-.035” Liner KP1937-3 0.50” I.D. KP21T-50
.030-.035” Liner (Aluminum) KP1959-1 0.62” I.D. KP21T-62
.035-.045ʼ Liner KP45-40-15 Gasless Flux Cored Nozzle KP1939-1
Diffuser: Spot Welding Nozzle .625 ID KP21-62-FAS
Gas Diffuser KP35-50
Item Description Part Number Qty.

Item Description Part Number Qty
MAGNUM® 100L 01-20-2012

NOTES
MAGNUM® 100L
NOTES
POWER MIG® (140, 180 MODELS)

NOTES

CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and
selling high quality welding equipment, consumables, and cutting
equipment. Our challenge is to meet the needs of our customers and
to exceed their expectations. On occasion, purchasers may ask
Lincoln Electric for advice or information about their use of our
products. We respond to our customers based on the best information
in our possession at that time. Lincoln Electric is not in a position to
warrant or guarantee such advice, and assumes no liability, with
respect to such information or advice. We expressly disclaim any
warranty of any kind, including any warranty of fitness for any
customer’s particular purpose, with respect to such information or
advice. As a matter of practical consideration, we also cannot assume
any responsibility for updating or correcting any such information or
advice once it has been given, nor does the provision of information
or advice create, expand or alter any warranty with respect to the sale
of our products.
Lincoln Electric is a responsive manufacturer, but the selection and
use of specific products sold by Lincoln Electric is solely within the
control of, and remains the sole responsibility of the customer. Many
variables beyond the control of Lincoln Electric affect the results
obtained in applying these types of fabrication methods and service
requirements.
Subject to Change – This information is accurate to the best of our
knowledge at the time of printing. Please refer to
www.lincolnelectric.com for any updated information.

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Operator’s Manual

Register your machine:

Save for future reference

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM890-A | Issue Date Nov- 13

SECTION A: 1.d. Keep all equipment safety guards, covers and

ELECTRIC SHOCK ARC RAYS CAN BURN.

WELDING AND CUTTING CYLINDER MAY EXPLODE IF

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

INSTALLATION AND USE Welding Cables

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

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

TECHNICAL SPECIFICATIONS 180 Amp units (K2472-1 180T, K2473-1 180C)

RECOMMENDED INPUT CABLE AND FUSE SIZES

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

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

120 V 60 Hz 20 Amp 20 15 Amp, 125 V, 3 Conductor # 12 AWG

POWER MIG (140, 180 MODELS)

TECHNICAL SPECIFICATIONS 180 Amp units (K2668-1 180C)

RECOMMENDED INPUT CABLE AND FUSE SIZES

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

2 Requirements For Maximum Output

POWER MIG (140, 180 MODELS)

Read entire installation section before starting

SELECT SUITABLE LOCATION

Each machine must be placed on a secure, level sur-

POWER MIG (140, 180 MODELS)

• Wire Feeder Welder.

• Black Flux-cored Gasless Gun Nozzle (Installed on

• 3 .035” (0.9mm) Contact Tips • Brass MIG Gas Gun Nozzle

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

POWER MIG (140, 180 MODELS)

Read entire operation section before PRODUCT DESCRIPTION (PRODUCT

These small portable wire feed welders are capable of

COMMON WELDING ABBREVIATIONS

FCAW (Innershield or Outershield)

POWER MIG (140, 180 MODELS)

CONTROLS AND SETTINGS

See Figure B.1 FIGURE B.1

1. POWER SWITCH – Turns power on and off to the 2

2. ARC VOLTAGE CONTROL – This knob sets the

3. WIRE FEED SPEED CONTROL (WFS) – The knob

See Figure B.2 FIGURE B.2

4. GUN TRIGGER – Depress the trigger to activates

b. Contact Tip – provides electrical contact to the

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

6. WORK CLAMP & CABLE – Clamps to the work

7. GUN TRIGGER CONNECTOR RECEPTACLE –

POWER MIG (140, 180 MODELS)

See Figure B.3 FIGURE B.3

8. WELDING GUN CONNECTOR BUSHING &

9. OUTPUT TERMINALS –These connections allow 8

See Figure B.4 FIGURE B.4

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

See Figure B.5 FIGURE B.5

11. WIRE DRIVE & COMPONENTS – Feeds wire

groove to match the specific wire type and diam-

POWER MIG (140, 180 MODELS)

.025”(0.6mm) MIG wire .025”/.030” (0.6mm/0.8mm)

.045”(1.1mm) flux-cored .030”/.045” (0.8mm/1.1mm) KP2529-3 .045”(1.1mm) Steel KP2531-2

12. CIRCUIT BREAKER – If the rated input current of

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