Lincoln-electric IM10096 POWER MIG 256 User Manual

POWER MIG®256OPERATORʼS MANUALIM10096July, 2011Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind.

FIGURE A.1 — Dual Voltage Machine InputConnectionsA-2 A-2INSTALLATIONRead entire installation section before startinginstallation.SAFETY PRECAUTIONSIN

Hand Screw Male End Gun and Cable Gun Adapter ReceptacleGun Trigger Connector3. The 208/230 volt 60 Hz model POWER MIG isshipped with a 10 ft

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

B-1 B-1 OPERATIONRead entire Operation section beforeoperating the POWER MIG®256.ELECTRIC SHOCK can kill.• Do not touch electrically liveparts or elec

B-2 B-2OPERATIONPRODUCT DESCRIPTIONThe POWER MIG®256 is a complete semiautomaticconstant voltage DC arc welding machine built to meetNEMA specificatio

32145678B-3B-3OPERATIONTo make spot plug welds, punch 3/16" (5 mm) holesin the top sheet. Set the Spot Time control toapproximately 1.2 seconds a

B-4 B-4 OPERATIONFIGURE B.3POWER MIG®256WIRE REEL LOADING - READIREELS, SPOOLS OR COILSTo Mount a 30 Lb. (14 kg) Readi-Reel Package(Using the Molded P

The pressure arm controls the amount of force thedrive rolls exert on the wire. Proper adjustment of bothpressure arm gives the best welding performan

B-6 B-6 OPERATION GUN RECEIVER BUSHINGLOOSEN TIGHTENTHUMB SCREWOUTER WIRE GUIDESOCKET HEADCAP SCREWCONNECTOR BLOCKWIRE DRIVE CONFIGURATION(See Figur

B-7B-7 OPERATIONMAKING A WELD1. Check that the electrode polarity is correct for the processbeing used, then turn the power switch ON.2. Set desired

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

B-8B-8 OPERATIONWELDING THERMAL OVERLOADPROTECTIONThe POWER MIG® 256has built-in protectivethermostats that respond to excessive temperature.They open

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 s

C-2 C-2 Closing either gun trigger will cause the electrodeof both guns to be electrically "HOT". Be sureunused gun is positioned so electro

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 handtach

D-1 D-1 MAINTENANCE3. If using optional adjustable slip-on nozzles. (Referto www.lincolnelectric.com)• Be sure the nozzle insulator is fully screwedon

D-2 D-2MAINTENANCE5. Fully seat the liner bushing into the connector.tighten the set screw on the brass cable connector.The gas diffuser, at this time

D-3 D-3 MAINTENANCEGUN HANDLE DISASSEMBLYThe internal parts of the gun handle may beinspected or serviced if necessary.The gun handle consists of two

E-1 E-1 TROUBLESHOOTINGIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLoca

E-2 E-2TROUBLESHOOTINGPROBLEMS(SYMPTOMS)Major Physical or ElectricalDamage is EvidentThere is no wire feed or open cir-cuit voltage when the gun trigg

E-3 E-3 TROUBLESHOOTINGPROBLEMS(SYMPTOMS)Poor arc striking with electrodesticking or blasting off.Rough wire feeding or wire will notfeed but drive ro

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

E-4 E-4TROUBLESHOOTINGPROBLEMS(SYMPTOMS)The wire feed stops while welding.When trigger is released andpulled again the wire feed starts.No control of

F-1 F-1 WIRING DIAGRAMSL12464-2A.01COLOR CODE:ELECTRICAL SYMBOLS PER E1537GENERAL INFORMATION265263260261U - BLUER - REDW - WHITEB - BLACKINDICATES C

F-2 F-2 WIRING DIAGRAMSNOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag

F-3F-3 DIMENSION PRINTM19231-1A.0219.1539.9212.0038.5832.5629.7330.4320.12POWER MIG®256

NOTES

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB 

iiiSAFETYiiiFOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b.

ivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parra

vvThank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much

vi vi TABLE OF CONTENTSPage________________________________________________________________________Installation ...

vii viiTABLE OF CONTENTS Page________________________________________________________________________Maintenance ...

A-1 A-1 INSTALLATIONInput Ampere Input Voltage Fuse or Breaker Rating On Frequency (Hz) Size (Super Lag)