im10096 power mig 256 - lincoln...

Operator’s Manual

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IM10096 | Issue D ate Jan-18

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

11780, 11781

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

Power MIG ®256

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaserupon receipt by the carrier. Consequently, claims for materialdamaged in shipment must be made by the purchaser against thetransportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and builtwith safety in mind. However, your overall safety can be increasedby proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETYPRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,think before you act and be careful.

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

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

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.Use corrective lenses if necessaryto stay a reasonable distanceaway from the arc.

READ and obey the Safety DataSheet (SDS) and the warning labelthat appears on all containers ofwelding materials.

USE ENOUGH VENTILATION orexhaust at the arc, or both, tokeep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may beadequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmetproperly fitted and with proper grade of filter plate(See ANSI Z49.1).

PROTECT your body from welding spatter and arcflash with protective clothing including woolenclothing, flame-proof apron and gloves, leatherleggings, and high boots.

PROTECT others from splatter, flash, and glarewith protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work areaAT ALL TIMES.

SPECIAL SITUATIONSDO NOT WELD OR CUT containers or materials which previouslyhad been in contact with hazardous substances unless they areproperly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless specialprecautions with ventilation have been taken. They can releasehighly toxic fumes or gases.

Additional precautionary measuresPROTECT 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 FORIMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 06/15/2016

SECTION A:WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

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

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

ARC WELDING CAN BE HAZARDOUS. PROTECTYOURSELF AND OTHERS FROM POSSIBLE SERIOUSINJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITHTHEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. Foradditional 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 AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWEREDEQUIPMENT.

1.a. Turn the engine off before troubleshootingand maintenance work unless themaintenance work requires it to be running.

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

1.c. Do not add the fuel near an open flamewelding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel fromvaporizing on contact with hot engine partsand igniting. Do not spill fuel when fillingtank. If fuel is spilled, wipe it up and do not start engine untilfumes 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 orrepairing equipment.

1.e. In some cases it may be necessary to remove safety guards toperform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt tooverride the governor or idler by pushing on the throttle controlrods while the engine is running.

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

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

ELECTRIC ANDMAGNETIC FIELDS MAYBE DANGEROUS

2.a. Electric current flowing through any conductorcauses 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 physicianbefore welding.

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

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

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

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

2.d.3. Do not place your body between the electrode and workcables. If the electrode cable is on your right side, thework cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos-sible to the area being welded.

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

SAFETY

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ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot 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 areaof physical contact with work and ground.

In addition to the normal safety precautions, ifwelding must be performed under electricallyhazardous conditions (in damp locations or whilewearing wet clothing; on metal structures such asfloors, gratings or scaffolds; when in crampedpositions such as sitting, kneeling or lying, if thereis a high risk of unavoidable or accidental contactwith the workpiece or ground) use the followingequipment:

• 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 weldinggun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connection shouldbe 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.

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

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

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

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

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect youreyes from sparks and the rays of the arc when welding orobserving open arc welding. Headshield and filter lens shouldconform to ANSI Z87. I standards.

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

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

FUMES AND GASESCAN BE DANGEROUS.

5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enoughventilation and/or exhaust at the arc to keep fumes and gasesaway from the breathing zone. When welding hardfacing(see instructions on container or SDS) or on leador cadmium plated steel and other metals orcoatings which produce highly toxic fumes, keepexposure as low as possible and within applicableOSHA PEL and ACGIH TLV limits using localexhaust or mechanical ventilation unless exposureassessments indicate otherwise. In confinedspaces or in some circumstances, outdoors, arespirator may also be required. Additionalprecautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected byvarious factors including proper use and positioning of theequipment, maintenance of the equipment and the specificwelding procedure and application involved. Worker exposurelevel should be checked upon installation and periodicallythereafter to be certain it is within applicable OSHA PEL andACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations. Theheat and rays of the arc can react with solvent vapors to formphosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and causeinjury or death. Always use enough ventilation, especially inconfined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including theSafety Data Sheet (SDS) and follow your employer’s safetypractices. SDS forms are available from your weldingdistributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 06/15/2016

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the welding sparksfrom starting a fire. Remember that welding sparks and hotmaterials from welding can easily go through small cracks andopenings to adjacent areas. Avoid welding near hydraulic lines.Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, specialprecautions 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 istouching the work or ground. Accidental contact can causeoverheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside.They can cause an explosion even though they have been“cleaned”. For information, purchase “Recommended SafePractices for the Preparation for Welding and Cutting ofContainers 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 orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil freeprotective garments such as leather gloves, heavy shirt, cufflesstrousers, high shoes and a cap over your hair. Wear ear plugswhen welding out of position or in confined places. Always wearsafety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding areaas practical. Work cables connected to the building framework orother locations away from the welding area increase thepossibility of the welding current passing through lifting chains,crane cables or other alternate circuits. This can create firehazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

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

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

CYLINDER MAY EXPLODE IFDAMAGED.

7.a. Use only compressed gas cylinders containingthe correct shielding gas for the process usedand properly operating regulators designed forthe gas and pressure used. All hoses, fittings,etc. should be suitable for the application andmaintained in good condition.

7.b. Always keep cylinders in an upright position securely chained toan undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjectedto physical damage.

• A safe distance from arc welding or cutting operationsand any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tightexcept 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 forSafe Handling of Compressed Gases in Cylinders,” available fromthe Compressed Gas Association, 14501 George Carter WayChantilly, VA 20151.

FOR ELECTRICALLYPOWERED EQUIPMENT.

8.a. Turn off input power using the disconnectswitch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National ElectricalCode, all local codes and the manufacturer’s recommendations.

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

Refer tohttp://www.lincolnelectric.com/safetyfor additional safety information.

SAFETY

Safety 04 of 04 - 06/15/2016

ivSAFETyiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles 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 tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu 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” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

vi vi TABLE OF CONTENTS

Page

________________________________________________________________________

Installation....................................................................................................... Section A Technical Specifications........................................................................................ A-1 Safety Precautions.................................................................................................A-2 Uncrating the POWER MIG® 256.......................................................................... A-2 Location................................................................................................................. A-2 Input Power, Grounding and Connection Diagram........................................ A-2, A-3 Output Polarity Connections..................................................................................A-3 Gun and Cable Installation.................................................................................... A-3 Shielding Gas........................................................................................................ A-4 Auxiliary Power Receptacle...................................................................................A-4 Coil Claw™ Installation..........................................................................................A-4________________________________________________________________________

Operation......................................................................................................... Section B Safety Precautions.................................................................................................B-1 Product Description............................................................................................... B-2 Recommended Processes and Equipment........................................................... B-2 Welding Capability.................................................................................................B-2 Limitations..............................................................................................................B-2 Description of Controls.......................................................................................... B-2 Wire Size Conversion Parts...................................................................................B-3 Procedure for Changing Drive Roll........................................................................B-3 Wire Reel Loading................................................................................................. B-4 Mounting of 10 to 44 lb. Spools............................................................................. B-4 To Start the Welder................................................................................................B-4 Feeding Electrode..................................................................................................B-5 Idle Roll Pressure Setting...................................................................................... B-5 Wire Drive Configuration....................................................................................... B-6 Making a Weld.......................................................................................................B-7 Avoiding Wire Feeding Problems.......................................................................... B-7 Fan Control............................................................................................................B-7 Input Line Voltage Protection................................................................................ B-7 Wire Feed Overload Protection............................................................................. B-7 Welding Thermal Overload Protection...................................................................B-8 Overcurrent Protection...........................................................................................B-8 Welding Procedure Information............................................................................. B-8________________________________________________________________________ Accessories.....................................................................................................Section C Drive Roll Kits........................................................................................................C-1 Dual Cylinder Mounting Kit ...................................................................................C-1 Alternative Magnum GMAW Gun and Cable Assemblies..................................... C-1 Magnum Gun Connection Kit ............................................................................... C-1 Spool Gun..............................................................................................................C-1 Connecting the Spool Gun to the POWER MIG® 256.................................................... C-2 Making a Weld with the Spool Gun....................................................................... C-2 Making a Weld with the Magnum SG Spool Gun.................................................. C-3________________________________________________________________________

vii viiTABLE OF CONTENTS

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Maintenance.................................................................................................... Section D Safety Precautions................................................................................................ D-1 General Maintenance............................................................................................ D-1 Drive Rolls and Guide Plates.................................................................................D-1 Contact Tip and Gas Nozzle Installation............................................................... D-1 Gun Tubes and Nozzles........................................................................................D-1 Gun Cable Cleaning.............................................................................................. D-1 Liner Removal and Replacement.......................................................................... D-2 Liner Removal, Installation and Trimming Instructions for Magnum® PRO 250L..D-2 Gun Handle Disassembly......................................................................................D-3________________________________________________________________________

Troubleshooting.............................................................................................. Section E How to Use Troubleshooting Guide.......................................................................E-1 Troubleshooting Guide ........................................................................... E-2 thru E-4________________________________________________________________________

Wiring Diagram and Dimension Print............................................................Section F________________________________________________________________________

Parts Manual....................................................................................................Appendix POWER MIG® 256................................................................................................... P-680 Magnum® PRO 250L Gun ......................................................................... P-202-H.2________________________________________________________________________

A-1 A-1 INSTALLATION

Input Ampere

Input Voltage Fuse or Breaker Rating On Frequency (Hz) Size (Super Lag) Nameplate

208/60 60 56A 8230/60 60 52A 10

230/60 60 47A 10460/60 30 24A 14 575/60 25 19A 14

TECHNICAL SPECIFICATIONS – POWER MIG® 256INPUT – SINGLE PHASE ONLy

RATED OUTPUT

OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES

Height Width Depth Weight With Coil Claw™ Without Coil Claw™

220 lbs32.56 in. 20.12 in. 19.15 in. 39.9in. 100 kg. 827 mm 512 mm 487 mm 1014 mm

PHySICAL DIMENSIONS Wire Speed 50 – 700 IPM (1.27 – 17.8 m/minute)

WIRE SPEED RANGE

Standard Voltage/Phase/Frequency Input Current @ 200 Amp Rated Output Input Current @ 250 Amp Rated Output 208/230/1/60 Hz *47/44 Amps *56/52 Amps 230/460/575/1/60 Hz 41/20/16 Amps 47/24/19 Amps

Duty Cycle Amps Volts at Rated Amperes 40% 250 Amps 26 Volts 60% 200 Amps 28 Volts 100% 145 Amps 26 Volts

Welding Current Range (Continuous) Maximum Open Circuit Voltage Welding Voltage Range 30 – 300 Amps 40 Volts 10-28 Volts

POWER MIG® 256

TEMPERATURE RANGESSTORAGE TEMPERATURE RANGE

-40°F to 185°F(-40°C to +85°C)OPERATING TEMPERATURE RANGE

-4°F to 104°F(-20°C to +40°C)

* With 115V receptacle loaded to 15A.

Type S, SO, ST, STO or extrahard usage input cord

AWG (IEC) Sizes

FIGURE A.1 — Dual Voltage Machine InputConnections

A-2 A-2 INSTALLATIONRead entire installation section before startinginstallation.

SAFETy PRECAUTIONS

INPUT POWER, GROUNDING ANDCONNECTION DIAGRAM

1. Before starting the installation, check with the localpower company if there is any question aboutwhether your power supply is adequate for the volt-age, amperes, phase, and frequency specified onthe welder rating plate. Also be sure the plannedinstallation will meet the U.S. National ElectricalCode and local code requirements. This weldermay be operated from a single phase line or fromone phase of a two or three phase line.

2. Models that have multiple input voltages specifiedon the nameplate (e.g. 208/230) are shipped con-nected for the highest voltage. If the welder is to beoperated on lower voltage, it must be reconnectedaccording to the instructions in Figure A.1 for dualvoltage machines and Figure A.2 for triple voltagemachines.

Make certain that the input power is electricallydisconnected before removing the screw on thereconnect panel access cover.------------------------------------------------------------------------

UNCRATING THE POWER MIG® 256Cut banding and lift off cardboard carton. Cut bandingholding the machine to the skid. Remove foam andcorrugated packing material. Untape accessories fromGas Bottle Platform. Unscrew the two wood screws(at the Gas Bottle Platform) holding the machine tothe skid. Roll the machine off the skid assembly.

LOCATIONLocate the welder in a dry location where there is freecirculation of clean air into the louvers in the back andthe louvers out the front. A location that minimizes theamount of smoke and dirt drawn into the rear louversreduces the chance of dirt accumulation that canblock air passages and cause overheating.

ELECTRIC SHOCK can kill.• Only qualified personnel should

perform this installation.• Only personnel that have read

and understood the POWER MIG®

256 Operator’s Manual shouldinstall and operate this equip-ment.

• Machine must be grounded perany national, local or other applic-able electrical codes.

• The POWER MIG® 256 powerswitch is to be in the OFF posi-tion when installing work cableand gun and when connectingother equipment.

WARNING

WARNING

ELECTRIC SHOCK can kill.• Do not touch electrically live parts such as

output terminals or internal wiring.• All input power must be electrically dis-

connected before proceeding.

WARNING

POWER MIG® 256

Hand Screw

Male End Gun and Cable

Gun Adapter

Receptacle

Gun Trigger Connector

3. The 208/230 volt 60 Hz model POWER MIG isshipped with a 10 ft. input cable and plug connect-ed to the welder. Obtain a receptacle and mount itin a suitable location. Be sure it can be reached bythe plug on the input cable attached to the welder.Mount with the grounding terminal at the top toallow the power cable to hang down without bend-ing.The 230/460/575 volt 60 Hz model is not equippedwith a plug, an input cable or a receptacle.

FIGURE A.2 — Triple Voltage Machine InputConnection

4. Using the instructions in Figure A.3, have a quali-fied electrician connect the receptacle or cable tothe input power lines and the system ground per theU.S. National Electrical Code and any applicablelocal codes. See "Technical Specifications" at thebeginning of this chapter for proper wire sizes. Forlong runs over 100 feet, larger copper wires shouldbe used. Fuse the two hot lines with super lag typefuses as shown in the following diagram. The centercontact in the receptacle is for the groundingconnection. A green wire in the input cableconnects this contact to the frame of the welder.This ensures proper grounding of the welder framewhen the welder plug is inserted into the receptacle.

A-3 A-3 INSTALLATIONOUTPUT POLARITy CONNECTIONSThe welder, as shipped from the factory, is connectedfor electrode positive (+) polarity. This is the normalpolarity for GMAW.

If negative (–) polarity is required, interchange theconnection of the two cables located in the wire drivecompartment near the front panel. The electrodecable, which is attached to the wire drive, is to be con-nected to the negative (–) labeled terminal and thework lead, which is attached to the work clamp, is tobe connected to the positive (+) labeled terminal.

GUN AND CABLE INSTALLATIONThe Magnum® PRO 250L gun and cable provided with thePOWER MIG® 256 is factory installed with a liner for .035-.045" (0.9-1.1 mm) electrode and an .035" (0.9 mm) contacttip. Install the .045” tip (also provided) if this wire sizeis being used.

Turn the welder power switch off before installinggun and cable.

(See Figure A.4)1. Lay the cable out straight.2. Unscrew the Hand Screw on the drive unit front

end (inside wire feed compartment) until tip ofscrew no longer protrudes into Gun Adapter open-ing as seen from front of machine. (See Figure A.4)

3. Insert the male end of gun cable into the GunAdapter through the opening in front panel. Makesure connector is fully inserted and tighten HandScrew.

4. Connect the Gun Trigger Connector from the gunand cable to the mating Receptacle inside thecompartment located left just inside the opening onthe Front Panel. Make sure that the keyways are

POWER MIG® 256

FIGURE A.3 —Receptacle DiagramCONNECT TO A SYSTEMGROUNDING WIRE. SEE THEUNITED STATES NATIONALELECTRICAL CODE AND/ORLOCAL CODES FOR OTHERDETAILS AND MEANS FORPROPER GROUNDING.

CONNECT TO HOT WIRES OFA THREE-WIRE, SINGLEPHASE SYSTEM OR TO ONEPHASE OF A TWO ORTHREE PHASE SYSTEM.

WARNING

FIGURE A.4

SHIELDING GAS[For Gas Metal Arc Welding(GMAW) Processes]

Customer must provide cylinder of appropriate type shield-ing gas for the process being used.

A gas flow regulator, for Argon blend gas, an inlet gas hose,and a regulator adapter are factory provided with thePOWER MIG® 256. When using 100% CO2, the regulatoradapter will be required to connect the regulator to the gasbottle.

INSTALL SHIELDING GAS SUPPLy AS FOLLOWS:1. Set gas cylinder on rear platform of POWER MIG® 256.

Hook chain in place to secure cylinder to rear of welder.2. Remove the cylinder cap. Inspect the cylinder valves and

regulator for damaged threads, dirt, dust, oil or grease.Remove dust and dirt with a clean cloth.

DO NOT ATTACH THE REGULATOR IF OIL, GREASEOR DAMAGE IS PRESENT! Inform your gas supplier ofthis condition. Oil or grease in the presence of high pres-sure oxygen is explosive.

3. Stand to one side away from the outlet and open thecylinder valve for an instant. This blows away any dust ordirt which may have accumulated in the valve outlet.

Be sure to keep your face away from the valveoutlet when “cracking” the valve.--------------------------------------------------------------------------------4. Attach the flow regulator to the cylinder valve and tighten

the union nut(s) securely with a wrench. NOTE: If connecting to 100% CO2 cylinder, the regulator

adapter provided must be installed between the regulatorand cylinder valve.

5. Attach one end of the inlet gas hose to the outlet fitting ofthe flow regulator, the other end to the POWER MIG®

256 rear fitting marked “Feeder” and tighten the unionnuts securely with a wrench.

6. Before opening the cylinder valve, turn the regulatoradjusting knob counterclockwise until the adjustingspring pressure is released.

A-4A-4 INSTALLATION7. Standing to one side, open the cylinder valve slowly a

fraction of a turn. When the cylinder pressure gaugepointer stops moving, open the valve fully.

Never stand directly in front of or behind the flow regu-lator when opening the cylinder valve. Always stand toone side.--------------------------------------------------------------------------------8. The flow regulator is adjustable. Adjust it to the flow rate

recommended for the procedure and process being usedbefore making the weld.CyLINDER may explode if

damaged.• Gas under pressure is explosive.

Always keep gas cylinders in an uprightposition and always keep chained toundercarriage or stationary support.

See American National Standard Z49.1, “Safety inWelding and Cutting” published by the AmericanWelding Society.-----------------------------------------------------------------------

WARNING

WARNING

POWER MIG® 256

AUXILIARy POWER RECEPTACLES(For 208/230V Models only)

This machine is equipped with 15Amp 120V receptacle with15Amp Circuit Breaker. The receptacle is UL and CSAapproved.

COIL CLAW™ INSTALLATIONThe Coil Claw™ and mounting screws are providedas an optional accessory for the POWER MIG® 256.This user-install accessory provides cable manage-ment for the machine.

Turn the welder power switch OFFbefore installing Coil Claw™.

------------------------------------------------------------------------1. Unwrap Coil Claw™ from its protective paper andremove the bag of mounting screws from the backof the Coil Claw™.

2. Mount the Coil Claw™ using the provided mount-ing screws to the left side of the machine, whenviewed from the front. Make sure the Coil Claw™ isfirmly mounted. (See Figure A.5)

FIGURE A.5

MOUNTINGSCREWS

COIL CLAW™

WARNING

B-1 B-1 OPERATIONRead entire Operation section beforeoperating the POWER MIG® 256.

ELECTRIC SHOCK can kill.• Do not touch electrically live

parts or electrode with skin orwet clothing. Insulate yourselffrom work and ground.

• Always wear dry insulatinggloves.

FUMES AND GASES can bedangerous.• Keep your head out of fumes.• Use ventilation or exhaust to

remove fumes from breathingzone.

WELDING SPARKS cancause fire or explosion.• Keep flammable material away.• Do not weld on closed contain-

ers.

ARC RAyS can burn eyesand skin.• Wear eye, ear and body protec-

tion.

Observe all safety information throughoutthis manual.------------------------------------------------------------

WARNING

POWER MIG® 256

B-2 B-2OPERATIONPRODUCT DESCRIPTIONThe POWER MIG® 256 is a complete semiautomaticconstant voltage DC arc welding machine built to meetNEMA specifications. It combines a constant voltagepower source and a constant speed wire feeder with amicrocomputer-based controller to form a reliable high-performance welding system. A simple controlscheme, consisting of continuous full range voltageand wire feed speed controls, provides versatility withease of use and accuracy. The POWER MIG® 256 isSpool Gun ready and includes a second Gas Solenoidfor Spool Gun use. Refer to Accessories Section forApplicable Spool Guns.

Other features include a 2" (51 mm) O.D. wire reelspindle with adjustable brake, an integral gas cylindermounting undercarriage, an adjustable CO2 or Argonblend flow regulator with cylinder pressure gauge andinlet hose, a 15 ft. (4.6 m) Magnum® PRO 250L GMAWgun and cable, a 10 ft. (3.1 m) power cable with plug (208/230V models only) and a 10ft. (3.1 m) work cablewith clamp.

The POWER MIG® 256 features built in timer functionsthat provide variable burnback control, a spot function,a selectable 4-step trigger interlock and adjustable"Run In" for wire starting optimization. Optionalfeatures include a Dual Cylinder Mounting kit.

RECOMMENDED PROCESSES ANDEQUIPMENTThe POWER MIG® 256 is recommended for GMAwelding processes using 10 to 44 lb (4.5 to 20 kg)2"(51 mm) I.D. spools or Readi-Reel® coils (withoptional adapter) of .025" through .045" (0.6 – 1.1 mm)solid steel, .035" (0.9 mm) stainless, 3/64" (1.2 mm)aluminum and .045" (1.1 mm) Outershield® andUltracore® ; as well as .035" (0.9 mm) and .045" (1.1mm) Innershield® self-shielding electrodes.

The POWER MIG® 256 is factory equipped to feed .035"(0.9 mm) and .045(1.1mm) electrode. It also includes a200A, 60% duty cycle (or 250A, 40% duty cycle) rated,15 ft. (4.6 m) GMAW gun and cable assemblyequipped for these wire sizes. Use of GMAWprocesses requires a supply of shielding gas.

WELDING CAPABILITyThe POWER MIG® 256 is rated at 250 amps @ 26 volts,at a 40% duty cycle based on a ten minute cycle time.It is capable of higher duty cycles at lower outputcurrents and capable of up to 300 Amps at lower dutycycles.

LIMITATIONSPOWER MIG® 256 WILL NOT operate satisfactorily ifpowered with a portable or in-plant generating system.

DESCRIPTION OF CONTROLSSee Figure B.11. Power ON/OFF Switch — Place the lever in the"ON" position to energize the POWER MIG® 256.When the power is on, the red LED display lightsilluminate.

2. Voltage Control - This is a continuous control thatgives full range adjustment of power source outputvoltage. It can be adjusted while welding over its 10to 28 volt range.

3. Wire Speed Control - This controls the wire feedspeed from 50 – 700 inches per minute (1.2 – 17.8m/min). The control can be preset on the dial to thesetting specified on the Procedure Decal on theinside of the wire compartment door. Wire speed isnot affected when changes are made in the voltagecontrol.

4. Trigger Switch - Select the desired mode with thetoggle switch:

• Normal Welding mode (2 Step) provides weldpower only while the trigger switch is depressed.

• 4-Step Trigger interlock mode eliminates the needto hold the gun trigger while welding. It operates in4 steps:

1. Close trigger and establish welding arc.2. Release trigger and continue welding.3. Reclose trigger near end of weld.4. Release trigger again to stop welding.

If the arc is broken while using this feature, themachine will reset to the "trigger off" conditionautomatically.Note: 4 Step Trigger interlock mode does not functionwith a Spool Gun.

5. Spot Time - Spot Weld Mode is used for tackwelding parts into position or for spot plug welds tohold thin sheet metal together prior to manual stitchor continuous welding. To use this feature, adjustthe On-Time (0-25 seconds) as appropriate toobtain the desired results. Closing the triggerinitiates a single timed spot weld cycle. Plug welds are made by using a punch to make a3/16" (5 mm) diameter hole in the top sheet and arcwelding through the hole into the back sheet.

POWER MIG® 256

33

22

11

44

55

66

77

88

B-3 B-3OPERATION

To make spot plug welds, punch 3/16" (5 mm) holesin the top sheet. Set the Spot Time control toapproximately 1.2 seconds and set the procedure forthe metal thickness to be welded. Install spot weldnozzle (if available) on gun and press it against thetop sheet so the top and bottom sheets are tighttogether. Close trigger and hold it closed until the arcgoes out. If a spot weld nozzle is not used, smootherwelds will result by moving the welding wire in asmall circle during the weld.

6. Run-In Mode - is used to adjust the starting wirefeed speed. Starting conditions for certain weldingapplications can be improved with adjustment to theRun-In speed. The control allows for initial startingspeeds from 50 - 150 IPM. After the arc is started,the set point on the wire feed speed control willdominate. Note that the Run-in is not functional withthe spool gun. Also note that if Run-in is set fullycounter clockwise to "OFF", Run-in speed will equalthe preset WFS on the machine.

7. Burnback Time - Provides manual adjustment ofthe burnback time (0-250 milliseconds) for anyselected welding mode. this control should be set aslow as possible without the wire "sticking" in thepuddle after each weld. Too long of a burnback timemay form a "ball" on the end of the wire, or may"flash back" to the gun tip.

8. Spool Gun Gas Connection

FIGURE B.1The drive rolls installed with the POWER MIG® 256have two grooves one for .035(0.9mm) wire SolidSteel electrode and the other for .045(1.1mm) wire.Drive roll size is stenciled on each side of the driveroll. If feeding problems occur, check to make surethat the wire size and the drive roll size matches. See"Procedure for Changing Drive Roll" in this section.This information also appears on the Procedure Decalon the door inside the wire compartment. WIRE SIZE CONVERSION PARTSThe POWER MIG® 256 is rated to feed .025 through.045" (0.6-1.1 mm) solid or cored electrode sizes.

The drive roll kits and Magnum® PRO 250L gun andcable parts are available to feed different sizes andtypes of electrodes. See Accessories section.

PROCEDURE FOR CHANGINGDRIVE AND IDLE ROLL SETS1. Turn off the power source.2. Release the pressure on the idle roll by swingingthe adjustable pressure arm down toward the backof the machine. Lift the cast idle roll assembly andallow it to sit in an upright position.

3. Remove the outside wire guide retaining plate byloosening the two large knurled screws.

4. Twist the drive roll retaining mechanism to theunlocked position as shown below and remove thedrive roll. (See Figure B.2)

FIGURE B.25. Remove the inside wire guide plate.6. Replace the drive and idle rolls and inside wire

guide with a set marked for the new wire size.NOTE: Be sure that the gun liner and contact tipare also sized to match the selected wire size.

7. Manually feed the wire from the wire reel, over thedrive roll groove and through the wire guide andthen into the brass bushing of the gun and cableassembly.

8. Replace the outside wire guide retaining plate bytightening the two large knurled screws. Reposition

LOCKED POSITIONUNLOCKED POSITION

POWER MIG® 256

B-4 B-4 OPERATIONFIGURE B.3

POWER MIG® 256

WIRE REEL LOADING - READIREELS, SPOOLS OR COILS

To Mount a 30 Lb. (14 kg) Readi-Reel Package(Using the Molded Plastic K363-P Readi-ReelAdapter:)

(See Figure B.3)

1. Open the Wire Drive Compartment Door.

2. Depress the Release Bar on the Retaining Collarand remove it from the spindle.

3. Place the Optional Adapter on the spindle.

4. Re-install the Retaining Collar. Make sure that theRelease Bar "pops up" and that the collar retainersfully engage the retaining ring groove on the spindle.

5. Rotate the spindle and adapter so the retainingspring is at the 12 o'clock position.

6. Position the Readi-Reel so that it will rotate in adirection when feeding so as to be de- reeled fromtop of the coil.

7. Set one of the Readi-Reel inside cage wires on theslot in the retaining spring tab.

8. Lower the Readi-Reel to depress the retainingspring and align the other inside cage wires with thegrooves in the molded adapter.

9. Slide cage all the way onto the adapter until theretaining spring "pops up" fully.

CHECK TO BE SURE THE RETAINING SPRINGHAS FULLy RETURNED TO THE LOCKINGPOSITION AND HAS SECURELy LOCKED THEREADI-REEL CAGE IN PLACE. RETAININGSPRING MUST REST ON THE CAGE, NOT THEWELDING ELECTRODE.----------------------------------------------------------------------- 10. To remove Readi-Reel from Adapter, depress

retaining spring tab with thumb while pulling theReadi-Reel cage from the molded adapter withboth hands. Do not remove adapter from spindle.

CAUTION

2 IN. O.D.SPINDLE

ADAPTER

RETAININGSPRING

BRAKEHOLDING

PINGROOVES

READI-REEL

INSIDECAGEWIRES

RELEASE BAR

RETAININGCOLLAR

To Mount 10 to 44 Lb. (4.5-20 kg) Spools (12"/300mm Diameter) or 14Lb.(6 Kg) Innershield Coils:

(For 13-14 lb. (6 Kg) Innershield coils, a K435 CoilAdapter must be used).

(For 10 lb.(4.5 Kg) 8 inch(203mm) diameter spools, aK468 spindle adapter must be used).

1. Open the Wire Drive Compartment Door.

2. Depress the Release Bar on the Retaining Collarand remove it from the spindle.

3. Place the spool on the spindle making certain thespindle brake pin enters one of the holes in theback side of the spool (Note: an arrow mark on thespindle lines up with the brake holding pin to assistin lining up a hole). Be certain the wire comes offthe reel in a direction so as to de-reel from the topof the coil.

4. Re-install the Retaining Collar. Make sure that theRelease Bar "pops up" and that the collar retainersfully engage the retaining ring groove on the spin-dle.

TO START THE WELDERTurn the "Power Switch" switch to "ON". This lightsthe red LED display lights. With the desired voltageand wire speed selected, operate the gun trigger forwelder output and to energize the wire feed motor.

The pressure arm controls the amount of force thedrive rolls exert on the wire. Proper adjustment of bothpressure arm gives the best welding performance. Forbest results, set both pressure arms to the samevalue.

Set the pressure arm as follows (See Figure B.4):Aluminum wires between 1 and 3Cored wires between 3 and 4Steel, Stainless wires between 4 and 6

B-5 B-5 OPERATION

ALUMINUMOUTERSHIELDMETALSHIELDINNERSHIELD STEEL

STAINLESS

COREDWIRES SOLID WIRES

6

13 25 4

FIGURE B.4

POWER MIG® 256

FEEDING WIRE ELECTRODE

When triggering, the electrode and drive mecha-nism are electrically "hot" relative to work andground and remain "hot" several seconds afterthe gun trigger is released.-----------------------------------------------------------------------

NOTE: Check that drive rolls, guide plates and gunparts are proper for the wire size and type being used.Refer to Table C.1 in Accessories section.

1. Turn the Readi-Reel or spool until the free end ofthe electrode is accessible.

2. While securely holding the electrode, cut off thebent end and straighten the first six inches. (If theelectrode is not properly straightened, it may notfeed properly through the wire drive system).

3. Release the pressure on the idle roll by swinging theadjustable pressure arm down toward the back ofthe machine. Lift the cast idle roll assembly andallow it to sit in an upright position. Leave the outerwire guide plate installed. Manually feed the wirethrough the incoming guide bushing and through theguide plates (over the drive roll groove). Push asufficient wire length to assure that the wire has fedinto the gun and cable assembly without restriction.Reposition the adjustable pressure arm to its origi-nal position to apply pressure to the wire.

4. Press gun trigger to feed the electrode wire throughthe gun.

IDLE ROLL PRESSURE SETTING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the weld-ing power source before installation orchanging 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 andground and could remain energized several sec-onds after the gun trigger is released.

• Only qualified personnel should perform mainte-nance work.

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

WARNING

WARNING

B-6 B-6 OPERATION

GUN RECEIVER BUSHING

LOOSEN TIGHTEN

THUMB SCREW

OUTER WIRE GUIDE

SOCKET HEADCAP SCREW

CONNECTOR BLOCK

WIRE DRIVE CONFIGURATION(See Figure B.5)Changing the Gun Receiver Bushing

ELECTRIC SHOCK can kill.• Turn the input power OFF at the weld-

ing power source before installationor 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 groundand could remain energized several secondsafter the gun trigger is released.

• Only qualified personnel should perform mainte-nance work.

------------------------------------------------------------------------Tools required: • 1/4" hex key wrench.

Note: Some gun bushings do not require the use ofthe thumb screw.

1. Turn power off at the welding power source.

2. Remove the welding wire from the wire drive.

3. Remove the thumb screw from the wire drive.

4. Remove the welding gun from the wire drive.

Figure B.5

POWER MIG® 256

5. Loosen the socket head cap screw that holds theconnector bar against the gun bushing.Important: Do not attempt to completelyremove the socket head cap screw.

6. Remove the outer wire guide, and push the gunbushing out of the wire drive. Because of the pre-cision fit, light tapping may be required to removethe gun bushing.

7. Disconnect the shielding gas hose from the gunbushing, if required.

8. Connect the shielding gas hose to the new gunbushing, if required.

9. Rotate the gun bushing until the thumb screw holealigns with the thumb screw hole in the feed plate.Slide the gun receiver bushing into the wire driveand verify the thumb screw holes are aligned.

10. Tighten the socket head cap screw.

11. Insert the welding gun into the gun bushing andtighten the thumb screw.

WARNING

B-7B-7 OPERATIONthe adjustable pressure arm to its original positionto apply pressure. Adjust pressure as necessary.

MAKING A WELD1. Check that the electrode polarity is correct for the process

being used, then turn the power switch ON.

2. Set desired arc voltage and wire speed for the particularelectrode wire, material type and thickness, and gas (forGMAW) being used. Use the Application Chart on the doorinside the wire compartment as a quick reference for somecommon welding procedures.

3. Select the desired mode as described in "Description ofControls” Section.

4. Press the trigger to feed the wire electrode through thegun and cable and then cut the electrode withinapproximately 3/8" (10 mm) of the end of the contact tip[3/4" (20 mm) Outershield®].

NOTE: If set for slow run-in when the trigger is pulled, thewire feeder feeds wire at low speed regardless of the set wirefeed speed until the welding arc starts or 1 second haselapsed. This feature enhances starting and makes it easierto set the stickout. The 1 second limit permits high speedloading of the gun and cable. To change run-in mode, see"Run-In Mode" in Description of Controls Section.

5. If welding gas is to be used, turn on the gas supply and setthe required flow rate (typically 25-35 CFH; 12-16liters/min).

6. When using Innershield electrode, the gas nozzle may beremoved from the insulation on the end of the gun andreplaced with the gasless nozzle. This will give improvedvisibility and eliminate the possibility of the gas nozzleoverheating.

7. Connect work cable to metal to be welded. Work clampmust make good electrical contact to the work. The workmust also be grounded as stated in "Arc Welding Safety

Precautions".

When using an open arc process, it is necessaryto use correct eye, head, and body protection.------------------------------------------------------------------------

8. Position electrode over joint. End of electrode maybe lightly touching the work.

9. Lower welding helmet, close gun trigger, and beginwelding. Hold the gun so the contact tip to workdistance is about 3/8" (10 mm) [3/4" (20 mm) forOutershield].

10. To stop welding, release the gun trigger and thenpull the gun away from the work after the arc goes

out.

11. When no more welding is to be done, close valve ongas cylinder (if used), momentarily operate gun trig-ger to release gas pressure, and turn off POWERMIG® 256.

AVOIDING WIRE FEEDINGPROBLEMSWire feeding problems can be avoided by observing thefollowing gun handling procedures:

• Do not kink or pull cable around sharp corners.• Keep the gun cable as straight as possible when weld-ing or loading electrode through cable.

• Do not allow dolly wheels or trucks to run over cables.• Keep cable clean by following maintenance instruc-tions.

• Use only clean, rust-free electrode. The Lincoln elec-trodes have proper surface lubrication.

• Replace contact tip when the arc starts to becomeunstable or the contact tip end is fused or deformed.

• Keep wire reel spindle brake tension to minimumrequired to prevent excess reel over-travel which maycause wire "loop-offs" from coil.

• Use proper drive rolls and wire drive idle roll pressurefor wire size and type being used.

FAN CONTROLThe fan is designed to come on automatically when aweld arc is established. The fan will stay on for a minimumof 6 minutes after the weld arc is terminated. The fan willalso stay on when the machine’s welding and feeding aredisabled during thermostatic over temperature protection.(See Welding Thermal Overload Protection)

INPUT LINE VOLTAGE PROTECTIONHigh Line Voltage — If the line voltage exceeds 125% ofrated input voltage, the output will be reduced to the lowerlevel to protect voltage rating of the capacitor bank.

Low Line Voltage — You may not be able to getmaximum output from the machine if the line voltage isless than rated input. The unit will continue to weld, butthe output may be less than what is set.

WIRE FEED OVERLOAD PROTECTIONThe POWER MIG® 256 has solid state overloadprotection of the wire drive motor. If the motor becomesoverloaded, the protection circuitry turns off the wire feedspeed weld outputi and gas solenoid. Check for propersize tip, liner, and drive rolls, for any obstructions orbends in the gun cable, and any other factors that wouldimpede the wire feeding.

POWER MIG® 256

WARNING

B-8B-8 OPERATIONWELDING THERMAL OVERLOADPROTECTIONThe POWER MIG® 256 has built-in protectivethermostats that respond to excessive temperature.They open the wire feed and welder output circuits ifthe machine exceeds the maximum safe operatingtemperature because of a frequent overload, or highambient temperature plus overload. The thermostatsautomatically reset when the temperature reaches asafe operating level and welding and feeding areallowed again, when gun is retriggered.

OVERCURRENT PROTECTIONThe machine will automatically reduce the output if theload on the machine exceeds 300 to 320 amperes.This protects the welding power SCR’s from excessiveshort circuit currents and from exceeding theirtemperature rating before the thermostats can react.

WELDING PROCEDUREINFORMATIONNOTE: See inside cover of machine for additional,commonly used welding procedure.

POWER MIG® 256

C-1 C-1ACCESSORIESDRIVE ROLL KITSRefer to Table C.1 for various drive roll kits that areavailable for the POWER MIG® 256.The item in Boldis supplied standard with the POWER MIG® 256.

TABLE C.1

K2378-1 Canvas Cover

K1738-1 Spool Gun Holder for Power MIG - provideneat storage of spool gun cable, and gas hose forPower MIG. Also provide hardware for routing gasinside Power MIG when using a Prince XL gun.(Note: included in K1809-1 and K2310-1)

K468 Spindle Adapter - for 8” (203.2mm) O.D. spool.

K363P READI-REEL™ ADAPTERThe K363P Readi-Reel Adapter mounts to the 2"spindle. It is needed to mount the 22-30 lb. Readi-Reels.

K435 Spindle Adapter for 14 lbs. coils - the K435spindle adapter allows 14lbs. (6gg.) Innershield coilsto be mounted on 2” (51mm) O.D. spindle.

DUAL CyLINDER MOUNTING KIT(K1702-1)Permits stable side-by-side mounting of two full size228.6mm dia x 1.524m high(9" dia. x 5' high) gascylinders with “no lift” loading. Simple installation andeasy instructions provided. Includes upper and lowercylinder supports, wheel axles and mounting hard-ware.

Wire Wire Size Drive Roll Kit

.023”-.030” (0.6-0.8 mm) KP1696-030S .035” (0.9 mm) KP1696-035S Solid .045” (1.1 mm) KP1696-045S Steel .035”-.045” (0.9-1.1mm) KP1696-1 .040” (1.0mm) KP1696-2 Cored .035” (0.9 mm) KP1697-035C .045” (1.1 mm) KP1697-045C

Aluminum 3/64” (1.2 mm) KP1695-3/64A .035” (0.9 mm) KP1695-035A

POWER MIG® 256

ALTERNATIVE MAGNUM GMAWGUN AND CABLE ASSEMBLIESThe following Magnum® PRO 250L gun and cableassembly is separately available for use with thePOWER MIG® 256. Each is rated 200 amps 60% dutycycle (or 250 amps 40% duty) and is equipped with theintegrated connector, twist-lock trigger connector, fixednozzle and insulator, and includes a liner, diffuser, andcontact tips for the wire sizes specified:

1 Optional liners for different wire diameters are soldseparately, see table D.1 Maintenance Section.

20’ and 25’ Magnum PRO Curve 300 Guns -K2951-3 Magnum PRO Curve 300, 20’*K2951-4 Magnum PRO Curve 300, 25’** Requires K466-6 adapter and KP44-3545-25 liner

MAGNUM GUN CONNECTION KIT(Optional K466-6)Using the optional K466-6 Magnum Connection kit forthe POWER MIG permits use of standard Magnum200, 300 or 400 gun and cable assemblies.

SPOOL GUN Remove all input power to the POWER MIG® 256before proceeding.--------------------------------------------------------------------------------The POWER MIG® 256 provides direct connection anduse of the Spool Gun (with remote speed control).It also provides gun trigger switch transfer between themachine’s use with its feeder gun or the spool gun forsame polarity welding with different wire and gasprocesses.K2490-1 Magnum® 250LX K487-25 Magnum® SG Spool Gun (requires

K2445-1 Cable Adapter)

K2445-1 Magnum SG Spool gun Control CableAdapter. Allows the K487-25 Magnum SG spool gun’s6-pin control cable plug to connect to the POWERMIG® 256’s 7-pin spool gun control cable receptacle.

English Wire Metric Wire Length Part No. Size1 Size 15' (4.6 m) K3081-2 .035 – .045" 0.9 – 1.2 mm

C-2 C-2

in and will be ready to use.

Closing either gun trigger will cause the electrodeof both guns to be electrically "HOT". Be sureunused gun is positioned so electrode or tip willnot contact metal case or other metal common towork.------------------------------------------------------------------------1. Pulling the trigger for the built-in feeder gun: • Disables spool gun operation. • Closing feeder gun trigger starts feeder gun

welding and makes both electrodes electrically"HOT".

2. Pulling SPOOL GUN Trigger: • Disables built-in feeder gun operation. • Closing spool gun trigger starts spool gun weld-

ing and makes both electrodes electrically"HOT".

3. Operation with POWER MIG® 256: • Turn the POWER MIG® 256 input power ON. • Adjusting the voltage control will increase or

decrease your welding voltage. • Adjusting the wire speed control on the spool

gun will increase or decrease the spool gun wirefeed speed.

• To aid in set-up, the POWER MIG® 256 wire feedspeed(WFS) meter will display the approximateWFS of the gun. Actual WFS at the gun may vary

CONNECTING THE SPOOL GUN TOTHE POWER MIG® 256(See Figure C.1)

1. Connect the Spool Gun control cable to the mating7-pin receptacle in the Power MIG wire drivecompartment. K487-25 Magnum SG Spool Gunrequires K2445-1 cable 7-pin to 6-pin adapter.

2. Connect the Spool Gun electrode lead to the(+)positive stud with the Spool Gun electrode leadsandwiched between the (+)positive power sourceelectrode lead and the (+)positive stud. Tighten andbe careful not to strip the threads.

3. Attach the Spool Gun gas line to the 5/8 Gas fittingon the front of the machine.

4. Attach a Gas hose from the Gas supply to the rearinlet gas fitting marked “Spool” on the POWER MIG®

256.

MAKING A WELD WITH THE SPOOLGUNThe POWER MIG® 256 control circuitry is designed tosense either the spool gun or (built in) wire feedertrigger circuitry. The spool gun can easily be plugged

POWER MIG® 256

ACCESSORIES

K2445-1 CABLE ADAPTER(7-pin to 6-pin)Note: This adapter is only for The Magnum SG Spool Gun.

+ POSITIVE CABLE AND STUD

GAS LINE AND 5/8 FITTING

7-PIN SPOOL GUNRECEPTACLE

FIGURE C.1

CAUTION

C-3 C-3 See the following procedure for setting the WireSpeed Feed using the Magnum SG Spool Gun:

To determine spool gun wire feed speed use a handtachometer, or calculate the speed using the followingequation: IPM= Length of wire fed (inches) x 60 Time fed (seconds)4. To return to normal POWER MIG® 256 welding,release the spool gun trigger and reset feeder gunwelding procedures.

4. The following procedure settings for Aluminum4043 can be used as initial settings for making testwelds to determine final settings:

5. To return to normal POWER MIG® 256 welding,release the spool gun trigger and reset feeder gunvoltage procedure setting if necessary.

MAKING A WELD WITH THEMAGNUM SG SPOOL GUNThe POWER MIG® 256 control circuitry is designed tosense either the spool gun or (built in) wire feedertrigger circuitry. The spool gun can easily be pluggedin and will be ready to use.

Closing either gun trigger will cause the electrodeof both guns to be electrically "HOT". Be sureunused gun is positioned so electrode or tip willnot contact metal case or other metal common towork.

1. Pulling the trigger for the built-in feeder gun: • Disables spool gun operation. • Closing feeder gun trigger starts feeder gun

welding and makes both electrodes electrically"HOT".

2. Pulling SPOOL GUN Trigger: • Disables built-in feeder gun operation. • Closing spool gun trigger starts spool gun weld-

ing and makes both electrodes electrically"HOT".

3. Operation with POWER MIG® 256: • Turn the POWER MIG® 256 input power ON. • Adjusting the voltage control will increase or

decrease your welding voltage. • Adjusting the wire speed control on the spool gun

will increase or decrease the spool gun wire feedspeed.

• For the Magnum SG Spool Gun, the wire feedspeed is controlled by combination of the wirefeed speed displayed on the POWER MIG® 256and the wire speed control on the spool gun.

POWER MIG® 256

ACCESSORIES

Wire Diameter In. (mm)

.030” (.8mm)

.035” (.9mm)3/64” (1.2mm)

Wire Feed Speed Display270250240

Arc voltageSetting15V16V20V

CAUTION

Wire Feed Speed Display50300700

SG Spool Gun Wire Feed SpeedApproximate Range

50-200200-400300-600

D-1 D-1 MAINTENANCE3. If using optional adjustable slip-on nozzles. (Refer

to www.lincolnelectric.com)

• Be sure the nozzle insulator is fully screwedonto the gun tube and does not block the gasholes in the diffuser.

• Slip the appropriate gas nozzle onto the nozzleinsulator. Either a standard .50" (12.7 mm) oroptional .62" (15.9 mm) I.D. slip-on gas nozzlemay be used and should be selected based onthe welding application.

• Adjust the gas nozzle as appropriate for theGMAW process to be used. Typically, the con-tact tip end should be flush to .12" (3.2 mm)extended for the short-circuit ing transferprocess and .12" (3.2 mm) recessed for spraytransfer.

GUN TUBES AND NOZZLES1. Replace worn contact tips as required.

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

GUN CABLE CLEANINGTo help prevent feeding problems, clean cable linerafter using approximately 300 pounds (136 kg) ofelectrode. Remove the cable from the wire feeder andlay it out straight on the floor. Remove the contact tipfrom the gun. Using an air hose and only partial pres-sure, gently blow out the cable liner from the gas dif-fuser end.

Excessive pressure at the beginning of the clean-ing procedure may cause the dirt to form a plug.-----------------------------------------------------------------------Flex the cable over its entire length and again blowout the cable. Repeat this procedure until no furtherdirt comes out. If this has been done and feed prob-lems are experienced, try liner replacement, and referto trouble shooting section on rough wire feeding.

SAFETy PRECAUTIONS

ELECTRIC SHOCK can kill.• Have an electrician install and

service this equipment.• Turn the input power OFF at the

fuse box before working onequipment

• Do not touch electrically hotparts.

GENERAL MAINTENANCEIn extremely dusty locations, dirt may clog the air pas-sages causing the welder to run hot. Blow dirt out ofthe welder with low-pressure air at regular intervals toeliminate excessive dirt and dust build-up on internalparts.

The fan motors have sealed ball bearings whichrequire no service.

DRIVE ROLLS AND GUIDE PLATESAfter every coil of wire, inspect the wire drive mecha-nism. Clean it as necessary by blowing with low pres-sure compressed air. Do not use solvents for cleaningthe idle roll because it may wash the lubricant out ofthe bearing.

All drive rolls are stamped with the wire sizes they willfeed. If a wire size other than that stamped on the rollis used, the drive roll must be changed.

For instructions on replacing or changing drive roll,see “Wire Drive Rolls” in Operation section.

CONTACT TIP AND GAS NOZZLEINSTALLATION1. Choose the correct size contact tip for the elec-

trode being used (wire size is stenciled on the sideof the contact tip) and screw it snugly into the gasdiffuser.

2. Screw the appropriate fixed gas nozzle fully ontothe diffuser. Either the standard .50" (12.7 mm)flush nozzle or other optional flush or recessed(spray arc) nozzle sizes may be used. (Refer towww.lincolnelectric.com)

WARNING

POWER MIG® 256

CAUTION

D-2 D-2 MAINTENANCEtighten the set screw on the brass cable connector.The gas diffuser, at this time, should not beinstalled onto the end of the gun tube.

6. With the gas diffuser still removed from the guntube, be sure the cable is straight, and then trimthe l iner to the length shown in Figure D.1.Remove any burrs from the end of the liner.

7. Screw the gas diffuser onto the end of the gun tubeand securely tighten.

8. Tighten the set screw in the side of the gas diffuseragainst the cable liner using a 5/64" (2.0 mm) Allenwrench.

FIGURE D.1This screw should only be gently tightened.

Overtightening will split or collapse the liner andcause poor wire feeding.------------------------------------------------------------------------

GUN HANDLE DISASSEMBLy

LINER REMOVAL AND REPLACE-MENTNOTE: Changing the liner for a different wire sizerequires replacement of the gas diffuser per Table D.1to properly secure the different liner.

LINER REMOVAL, INSTALLATIONAND TRIMMING INSTRUCTIONSFOR MAGNUM® PRO 250LNOTE: The variation in cable lengths prevents theinterchangeability of liners between guns. Once a linerhas been cut for a particular gun, it should not beinstalled in another gun unless it can meet the linercutoff length requirement. Liners are shipped with thejacket of the liner extended the proper amount.

1. Remove the gas nozzle and nozzle insulator, ifused, to locate the set screw in the gas diffuserwhich is used to hold the old liner in place. Loosenthe set screw with a 5/64" (2.0 mm) Allen wrench.

2. Remove the gas diffuser from the gun tube.

3. Lay the gun and cable out straight on a flat surface.Loosen the set screw located in the brass connec-tor at the feeder end of the cable and pull the linerout of the cable.

4. Insert a new untrimmed liner into the connectorend of the cable. Be sure the liner bushing is sten-cilled appropriately for the wire size being used.

Note: For liners KP45-3545-15 and KP45-3545-25Before fully seating the liner bushing, it will be neces-sary to trim the liner’s inner tube flush with the linerbushing using a sharp blade. After trimming, removeany burrs from inner tube and insure that the openingis fully open.

5. Fully seat the liner bushing into the connector.

Replacement Size StencilledDiameter of Liner Part on End of Electrodes Used Number Liner Bushing .025”-.030" Steel KP42-25-15 .030” (0.8 mm) (0.6-0.8 mm).035”-.045" Steel KP42-4045-15 .045” (1.1 mm) (0.9-1.1 mm)3/64" Aluminum KP42N-3545-15 3/64" (1.2 mm) (1.2 mm)

TABLE D.1

SET SCREW

SET SCREW

BRASS CABLE CONNECTOR

GAS DIFFUSER

NOZZLE INSULATOR (IF USED)

GAS NOZZLE

.56"(14.2mm)

LINERTRIM

LENGTH

POWER MIG® 256

CAUTION

D-3 D-3 MAINTENANCEThe internal parts of the gun handle may beinspected or serviced if necessary.

The gun handle consists of two halves that areheld together with a collar on each end. Toopen up the handle, turn the collars approxi-mately 60 degrees counterclockwise (the samedirection as removing a right hand thread) untilthe collar reaches a stop. Then pull the collaroff the gun handle. If the collars are difficult toturn, position the gun handle against a corner,place a screwdriver against the tab on the col-lar and give the screwdriver a sharp blow toturn the collar past an internal locking rib.

Counterclockwise

POWER MIG® 256

E-1 E-1 TROUBLESHOOTING

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING

POWER MIG® 256


PROBLEMS(SyMPTOMS)

Major Physical or ElectricalDamage is Evident

There is no wire feed or open cir-cuit voltage when the gun trigger ispulled. Input power is applied toPOWER MIG® 256.

Output voltage and wire feed is pre-sent when gun trigger is not pulled(not activated).

Machine output is low. Welds are“cold”, weld bead is rounded orbumped up demonstrating poorwetting into plate.

POSSIBLE CAUSE

1. Contact your Local LincolnAuthorized Field Service Facility.

1 The gun trigger or cable may befaulty. Check or replace gunassembly.

2. The thermal protection circuitmay be activated. If this is thecase, allowing the machine tocool will clear the error condition.

3. Make sure input voltage is cor-rect and matches nameplate rat-ing and reconnect panel configu-ration.

4. If spool gun option kit is in-stalled, check to see that it is setto “Push Gun” if pulling the guntrigger associated with built infeeder, and “Spool Gun” if pullingspool gun trigger.

1. Remove gun assembly frommachine. If problem is solved,gun assembly is faulty. Repair orreplace.

2. If problem persists when gunassembly is removed frommachine, then the problem iswithin the POWER MIG® 256.

1. Check input voltage. Make sureinput voltage matches name-plate rating and reconnect panelconfiguration.

2. Make sure settings for wire feedspeed and voltage are correctfor process being used.

3. Make sure output polarity is cor-rect for process being used.

4. Check welding cables and gunassembly for loose or faulty con-nections.

RECOMMENDEDCOURSE OF ACTION

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.

OUTPUT PROBLEMS

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITy for assistance before you proceed.

CAUTION

Observe all Safety Guidelines detailed throughout this manual

POWER MIG® 256


PROBLEMS(SyMPTOMS)

Poor arc striking with electrodesticking or blasting off.

Rough wire feeding or wire will notfeed but drive rolls are turning.

POSSIBLE CAUSE

1. Make sure settings for wire feedspeed and voltage are correctfor process being used.

2. The gas shielding may beimproper for process being used.

3. Check input line voltage to bewithin machine’s recommendedrating range.

4. Check that the machine recon-nect panel is configured properlyfor the applied voltage.

1. The gun cable may be kinked or twisted.2. The wire may be jammed in the gun

cable, or gun cable may be dirty.3. Check drive roll tension andposition of grooves.

4. Check for worn or loose drive rolls.5. The electrode may be rusty or dirty.6. Check for damaged or incorrectcontact tip.

7. Check wire spindle for ease ofrotation and adjust break ten-sion knob if necessary.

8. Check that the gun is pushed allthe way into gun mount andproperly seated.



OUTPUT PROBLEMS


CAUTION

FEEDING PROBLEMS


POWER MIG® 256

E-4 E-4TROUBLESHOOTING

PROBLEMS(SyMPTOMS)

The wire feed stops while welding.When trigger is released andpulled again the wire feed starts.

No control of wire feed speed.Other machine functions are nor-mal.

Gas does not flow when gun triggeris pulled.

POSSIBLE CAUSE

1. Check the wire feed drive rollsand motor for smooth operation.

2. Check for restrictions in the wirefeed path. Check the gun andcable for restrictions.

3. Make sure gun liner and tip arecorrect for wire size being used.

4. Make sure drive rolls and guide platesare clean and are the correct size.

5. Check spindle for ease of rotation.

1. The wire feed speed control maybe dirty. Rotate several timesand check if problem is resolved.

1. Make sure gas supply is con-nected properly and turned“ON”.

2. If the gas solenoid does actuate(click) when the gun trigger ispulled, there may be a restrictionin the gas supply line.

3. The gun cable assembly may befaulty. Check or replace.

4. If gas solenoid does not operatewhen gun trigger is pulled, theproblem is within the POWERMIG® 256.

5. Make sure the gun is pushed allthe way into gun mount and isproperly seated.



GAS FLOW PROBLEMS


CAUTION

FEEDING PROBLEMS


POWER MIG® 256

F-1 F-1 WIRING DIAGRAMS

POWER MIG® 256

NOTE

: This dia

gram

is for reference only

. It may not be accurate for all m

achin

es co

vered by this manual. The specific

diag

ram for a particula

r code is paste

d ins

ide the machin

e on

one of the enclo

sure panels

. If the dia

gram

is illegible, write to the Se

rvice

Department for a repla

cement. Give

the equip

ment code number.

Wiri

ng D

iagr

am fo

r (20

8/23

0V)

Code

s: 11

780

F-2 F-2 WIRING DIAGRAMS

NOTE

: This dia

gram

is for reference only

. It may not be accurate for all m

achin

es co

vered by this manual. The specific

diag

ram for a particula

r code is paste

d ins

ide the machin

e on

one of the enclo

sure panels

. If the dia

gram

is illegible, write to the Se

rvice

Department for a repla

cement. Give

the equip

ment code number.

POWER MIG® 256

Wiri

ng D

iagr

am fo

r (23

0/46

0/57

5V) C

odes

: 117

81

F-3F-3 DIMENSION PRINT

POWER MIG® 256

WARNING

AVISO DEPRECAuCION

ATTENTION

WARNuNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

l Do not touch electrically live parts orelectrode with skin or wet clothing.

l Insulate yourself from work andground.

l No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

l Aislese del trabajo y de la tierra.

l Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

l Isolez-vous du travail et de la terre.

l Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

l Isolieren Sie sich von denElektroden und dem Erdboden!

l Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

l Isole-se da peça e terra.

l Keep flammable materials away.

l Mantenga el material combustiblefuera del área de trabajo.

l Gardez à l’écart de tout matérielinflammable.

l Entfernen Sie brennbarres Material!

l Mantenha inflamáveis bem guarda-dos.

l Wear eye, ear and body protection.

l Protéjase los ojos, los oídos y elcuerpo.

l Protégez vos yeux, vos oreilles etvotre corps.

l Tragen Sie Augen-, Ohren- und Kör-perschutz!

l Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAuCION

ATTENTION

WARNuNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

l Keep your head out of fumes.l Use ventilation or exhaust to

remove fumes from breathing zone.

l Los humos fuera de la zona de res-piración.

l Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

l Gardez la tête à l’écart des fumées.l Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

l Vermeiden Sie das Einatmen vonSchweibrauch!

l Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

l Mantenha seu rosto da fumaça.l Use ventilação e exhaustão para

remover fumo da zona respiratória.

l Turn power off before servicing.

l Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

l Débranchez le courant avant l’entre-tien.

l Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

l Não opere com as tampas removidas.l Desligue a corrente antes de fazer

serviço.l Não toque as partes elétricas nuas.

l Do not operate with panel open orguards off.

l No operar con panel abierto oguardas quitadas.

l N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

l Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

l Mantenha-se afastado das partesmoventes.

l Não opere com os paineis abertosou guardas removidas.

CUSTOMER ASSISTANCE POLICY

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

Lincoln Electric is a responsive manufacturer, but the selection anduse of specific products sold by Lincoln Electric is solely within thecontrol of, and remains the sole responsibility of the customer. Manyvariables beyond the control of Lincoln Electric affect the resultsobtained in applying these types of fabrication methods and servicerequirements.

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

TABLE OF CONTENTS GENERAL DESCRIPTIONINSTALLATIONOPERATIONACCESSORIESMAINTENANCETROUBLESHOOTINGDIAGRAMS

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