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IM756-A
HANDY MIG August, 2005
For use with machine Code Number:10919, 11205
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S MANUAL
ISO 9001
ANSI RAB
QMS
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
Copyright © 2005 Lincoln Global Inc.
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, coversand devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
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
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “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
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Pour votre propre protection lire et observer toutes les instruc-
tions et les précautions de sûreté specifiques qui parraissent
6. Eloigner les matériaux inflammables ou les recouvrir afin de
dans ce manuel aussi bien que les précautions de sûreté
prévenir tout risque d’incendie dû aux étincelles.
générales suivantes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
Sûreté Pour Soudage A L’Arc
la masse. Un court-circuit accidental peut provoquer un
1. Protegez-vous contre la secousse électrique:
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
8. S’assurer que la masse est connectée le plus prés possible
quand la machine à souder est en marche. Eviter toujours
de la zone de travail qu’il est pratique de le faire. Si on place
tout contact entre les parties sous tension et la peau nue
la masse sur la charpente de la construction ou d’autres
ou les vétements mouillés. Porter des gants secs et sans
endroits éloignés de la zone de travail, on augmente le risque
trous pour isoler les mains.
de voir passer le courant de soudage par les chaines de lev-
b. Faire trés attention de bien s’isoler de la masse quand on
age, câbles de grue, ou autres circuits. Cela peut provoquer
soude dans des endroits humides, ou sur un plancher
des risques d’incendie ou d’echauffement des chaines et des
metallique ou des grilles metalliques, principalement dans
câbles jusqu’� ce qu’ils se rompent.
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
9. Assurer une ventilation suffisante dans la zone de soudage.
masse.
Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble
galvanisées plombées, ou cadmiées ou tout autre métal qui
de soudage et la machine à souder en bon et sûr état
produit des fumeés toxiques.
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir.
d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension
chaleur ou les rayons de l’arc peuvent réagir avec les
des porte-électrodes connectés à deux machines à soud-
vapeurs du solvant pour produire du phosgéne (gas forte-
er parce que la tension entre les deux pinces peut être le
ment toxique) ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
11. Pour obtenir de plus amples renseignements sur la sûreté,
courant pour soudage semi-automatique, ces precautions
voir le code “Code for safety in welding and cutting� CSA
pour le porte-électrode s’applicuent aussi au pistolet de
Standard W 117.2-1974.
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se pro-
téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
PRÉCAUTIONS DE SÛRETÉ POUR
partie du corps.
LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
TRANSFORMATEUR ET À
donc:
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude 1. Relier à la terre le chassis du poste conformement au code
ou quand on regarde l’arc. de l’électricité et aux recommendations du fabricant. Le dis-
b. Porter des vêtements convenables afin de protéger la positif de montage ou la piece à souder doit être branché Ã
peau de soudeur et des aides contre le rayonnement de une bonne mise à la terre.
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au 2. Autant que possible, I’installation et l’entretien du poste
soudage à l’aide d’écrans appropriés et non-inflamma- seront effectués par un électricien qualifié.
bles.
3. Avant de faires des travaux à l’interieur de poste, la
4. Des gouttes de laitier en fusion sont émises de l’arc de debrancher à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leur
pantalons sans revers, et chaussures montantes. place.
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
� For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
� For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links� and then
“Product Registration�. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi vi
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Identify and Locate Components ...........................................................................A-2
Select Suitable Location ........................................................................................A-3
Stacking .................................................................................................................A-3
Changing Polarity ..................................................................................................A-3
Gun Installation......................................................................................................A-3
Input Connections..................................................................................................A-3
Gas Connections ...................................................................................................A-3
Shielding Gas Connections ...................................................................................A-4
Code Requirements ..............................................................................................A-4
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description ...............................................................................................B-1
Recommended Processes.....................................................................................B-1
Operation Features and Controls .........................................................................B-1
Design Features ....................................................................................................B-1
Welding Capability .................................................................................................B-2
Limitations..............................................................................................................B-2
Controls and Settings ............................................................................................B-2
Welding Operations ...............................................................................................B-2
Shielding Gas ........................................................................................................B-3
Making a Weld and Process Table ........................................................................B-4
Cleaning Tip and Gas Nozzle ................................................................................B-5
Changing Machine over to Feed Other Wire Sizes,Overload Protection...............B-5
________________________________________________________________________
Accessories .....................................................................................................Section C
Accessories ...........................................................................................................C-1
Replacement Parts ................................................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Items Requiring No Maintenance ..........................................................................D-1
Routine Maintenance.............................................................................................D-1
Cleaning the Gun Liner..........................................................................................D-2
Cleaning Components as Required.......................................................................D-2
Component Replacement Procedures ..................................................................D-2
Changing Contact Tip............................................................................................D-2
Changing the Drive Roll.........................................................................................D-2
Gun Assembly Removal ........................................................................................D-3
Work Cable Installation..........................................................................................D-3
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.........................................................................E-2 THRU E-4
________________________________________________________________________
Wiring Diagrams ..............................................................................................Section F
Wiring Diagram .....................................................................................................F-1
________________________________________________________________________
Parts Lists ....................................................................................................P437 Series
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS � HANDY MIG
INPUT � SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current
120V/60Hz 20 Amps - Rated Output
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
20% Duty Cycle 70 17
OUTPUT RANGE
Welding Current Range Maximum-Open Circuit Voltage No Load 0 - 450 in/min
DC OUTPUT: 35-88 Amps 29V (0 - 17.7m/min)
While welding 0-300 in/min.
(0-11.8 m/min.)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse or
Output Mode Input Voltage Breaker Size1 Input Amps Power Cord Extension Cord
AT
RATED 120V/60Hz 20 Amp 20 15 Amp, 125V, Three Conductor
OUTPUT Three Prong Plug #12 AWG
(3.3 mm2) or Larger
(NEMA Type 5-15P)
Up to 50 Ft. (15.2 mm)
PHYSICAL DIMENSIONS
Height Width Depth Weight
12.8 in 8.8 in 18 in 46 Ibs
325 mm 224 mm 457 mm 20.9 kg
1If connected to a circuit protected by fuses use Time Delay Fuse marked “D�.
HANDY MIG
A-2 A-2
INSTALLATION
Read entire installation section before starting
installation.
FIGURE A.1
SAFETY PRECAUTIONS 1
WARNING
ELECTRIC SHOCK can kill.
� Only qualified personnel should perform
this installation.
� Only personnel that have read and under-
stood the Machine Operating Manual
should install and operate this equipment.
� Machine must be plugged into a receptacle
0
.04
which is grounded per any national, local 0
.04
IM000
AL
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1.0
2 AL
October 1998
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Handy Mig 101
1.0
00000
For use with machines having Code Numbers:
or other applicable electrical codes. Safety Depends on You
3
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation...and thoughtful
operation on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND THE
� The Machine power switch is to be in the
SAFETT PRECAUTIONS
CONTAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
OFF (“O�) position when installing work
cable and gun and when connecting power
cord to input power. World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, ohio 44117-1199 U.S.A. Tel. (216) 481-8100
0
.04
0
0 .04
.04 AL
-
1.0
AL
-
AL
1.0
-
1.0
4
IDENTIFY AND LOCATE
COMPONENTS 5
If you have not already done so, unpack the machine
from its carton and remove all packing material
6
around the machine. The following items are shipped
loose. (see Figure A.1):
1. HANDY MIG with work clamp, Gun and cable 8
assembly attached. 7
2. This operating manual
10
3. Two contact tips for .035(0.9mm) diameter wire.
9
4. Three contact tips for .025(0.6mm) diameter wire.
5. Gas Nozzle.
6. Chipping hammer and brush.
7. Starter spool of .035� (0.9mm) NR211-MP flux
cored wire.
8. Starter spool of .025� (0.6mm) solid mig wire.
9. Gas regulator and hose with hose clamps.
10. Handshield with filter plate and lens.
For available options and accessories refer to the
Accessories Section of this manual.
HANDY MIG
A-3 A-3
INSTALLATION
SELECT SUITABLE LOCATION INPUT CONNECTIONS
(FIGURE A.4)
Place the machine on a secure, level surface or rec- GAS INLET FITTING
ommended undercarriage. The machine may topple
over if this procedure is not followed. To minimize over
heating, locate the welder in a dry location where there POWER INPUT CABLE
is free circulation of clean air. Do not place on com-
bustible surfaces.
STACKING
Machines cannot be stacked.
CHANGING POLARITY
Refer to Figure A.4.
1. For NegativeWORK CABLE
Polarity Welding (DC-): Refer to
The machine has two input connections, the power
Figure GUN CABLE As delivered, the machine is wired for
A.2.
input cable and the gas inlet fitting. The power input
Negative polarity with the gun cable connected to
cable and gas inlet fitting are located on the rear.
the Negative (-) output terminal and the work cable
to the Positive (+) output terminal. Make sure that
GUN CABLE
GAS CONNECTION
both thumbscrews are tight. This is the typical con-
WORK CABLE
figuration for Flux Cored Welding (FCAW).
When using the MIG process, a cylinder of shielding
FIGURE A.2 gas (appropriate for the metal being welded) must be
WORK CABLE
GUN CABLE
obtained.
GUN CABLE
WARNING
WORK CABLE
CYLINDER may explode if damaged.
GUN CABLE Keep cylinder upright and chained to
WORK CABLE
support.
� Keep cylinder away from areas where it
2.For Positive Polarity Welding (DC+): Refer to
may be damaged.
Figure A.3. To wire for Positive polarity, connect
� Never lift welder with cylinder attached.
the gun cable to the Positive (+) output terminal and
GUN CABLE
� Never allow welding electrode to touch cylinder.
the work cable to the Negative (-) terminal. This is
� Keep cylinder away from welding or other live
the typical configuration for the Metal Inert Gas
WORK CABLE
electrical circuits.
(MIG) process. Make sure that both thumbscrews
are tight.
BUILDUP OF SHIELDING GAS may harm
GUN CABLE
(FIGURE A.3) WORK CABLE
health or kill.
� Shut off shielding gas supply when not
in use.
GUN CABLE
� SEE AMERICAN NATIONAL STANDARD Z-49.1,
“SAFETY IN WELDING AND CUTTING� PUB-
WORK CABLE
LISHED BY THE AMERICAN WELDING SOCIETY.
------------------------------------------------------------------------
HANDY MIG
A-4 A-4
INSTALLATION
SHIELDING GAS CONNECTION CODE REQUIREMENTS FOR ELECTRI-
(FIGURE A.5) CAL INPUT CONNECTIONS
REGULATOR CYLINDER VALVE
WARNING
This welding machine must be connected to a
power source in accordance with applicable elec-
trical codes.
HOSE GAS CYLINDER
------------------------------------------------------------------------
The United States National Electrical Code (Article
630-B, 1990 Edition) provides standards for amperage
handling capability of supply conductors based on
duty cycle of the welding source.
If there is any question about the installation meeting
applicable electrical code requirements, consult a
Refer to Figure A.5. qualified electrician.
1. Chain the cylinder to a wall or other stationary sup-
CAUTION
port to prevent the cylinder from falling over.
Insulate the cylinder from the work circuit work Do not connect the machine to an input power
ground. supply with a rated voltage that is greater than 125
2. With the cylinder securely installed, remove the volts.
cylinder cap. Stand to one side away from the out-
let and open the cylinder valve very slightly for an Do not remove the power cord ground prong.
instant. This blows away any dust or dirt which may
have accumulated in the valve outlet. REQUIREMENTS FOR MAXIMUM OUTPUT
A line cord with a 15 amp, 125 volt, three-prong plug
WARNING (NEMA Type 5-15P) is factory installed on the
machine Connect this plug to a mating grounded
receptacle which is connected to a 20 amp branch cir-
BE SURE TO KEEP YOUR FACE AWAY FROM cuit with a nominal voltage rating of 115 volts to 125
THE VALVE OUTLET WHEN “CRACKING� THE volts, 60 hertz, AC only. If connected to a circuit pro-
VALVE. Never stand directly in front of or behind tected by fuses, use a time delay fuse marked “D�.
the flow regulator when opening the cylinder With this installation, the machine can be used at an
valve. Always stand to one side. output of 70 amps, 17 volts, 20% duty cycle (2 min-
------------------------------------------------------------------------ utes of every 10 minutes used for welding).
3. Attach one end of the inlet gas hose to the outlet fit-
ting of the gas cylinder secure with hose clamp.
EXTENSION CORD USAGE
Connect the other end to the Gas Inlet Fitting on
the machine and secure with hose clamp. Make
If an extension cord is required, use one that is rated
certain the gas inlet hose is not kinked or twisted.
for the application and is 3 conductor #14 AWG (2.1
mm2) or larger. The recommended maximum lengths
4. The machine is supplied with a regulator suitable
are 25 ft (7.5 m) if #14 AWG (2.1 mm2) is used and 50
for a mixed shielding gas CO2 Argon. For welding
ft (15 m) if #12 AWG (3.3 mm2) is used.
with 100% CO2 a suitable regulator or adapter must
be purchased separately from a welding gas suppli-
er. To prevent leakage, if welding with 100% CO2
shielding gas the regulator for carbon dioxide must
have a plastic adapter washer seated in the fitting
that attaches to the cylinder. This adapter is avail-
able from your local gas supplier.
HANDY MIG
B-1 B-1
OPERATION
Read entire operation section before GENERAL DESCRIPTION
operating the machine.
The machine is a semiautomatic constant voltage DC
arc welder. The machine uses a single phase con-
stant voltage transformer, solid state rectifier and a
WARNING
DC permanent magnet motor for feeding and welding
solid steel electrode and flux-cored electrode.
ELECTRIC SHOCK can kill.
The machine is ideally suited for individuals having
� Do not touch electrically live access to 115 volt AC input power and wanting the
parts or electrode with skin or ease of use, quality and dependability of both metal
wet clothing. Insulate yourself inert gas (MIG) welding and the Innershield electrode
from work and ground. process (self-shielded flux-cored welding). The
machine will handle reels of wire up to 2 lbs(1 kg).
� Always wear dry insulating
gloves.
RECOMMENDED PROCESSES
The machine can be used for welding carbon and low-
FUMES AND GASES can be
alloy steel with CO2 or argon/CO2 mixture shielding
dangerous.
gas. The welder can also be used without gas for the
� Keep your head out of fumes.
self-shielded, Innershield electrode process. The
� Use ventilation or exhaust to machine is configured for the Flux Cored Arc Welding
remove fumes from breathing process as delivered from the factory.
zone.
OPERATIONAL FEATURES AND CONTROLS
WELDING SPARKS can The machine has the following controls as standard:
cause fire or explosion. � Power ON/OFF Switch
� Heat Range Switch
� Keep flammable material away.
� 1 � 2 Fine Heat Adjustment Switch
� Do not weld on closed contain-
� Wire Speed Control
ers.
DESIGN FEATURES AND ADVANTAGES
� Operates on 115 volt input - no special wiring
required.
ARC RAYS can burn eyes � Solid state output control.
and skin. � Overload protection - incorporates a thermostat to
protect the welder from overheating caused by mal-
� Wear eye, ear and body protec-
functions or overly heavy use.
tion.
� Permanent magnet wire drive motor.
� Easy-to-set controls for arc voltage and wire speed.
� Thumbscrew release idle roll pressure arm is easily
adjusted.
� Reversible, dual groove drive roll will feed .023-
.035� (0.6- 0.9 mm) diameter wire.
Observe all safety information throughout � Accommodates spools of wire up to 2 lbs(1 kg) in
this manual. weight.
� No external shielding gas is required when used
with Lincoln Innershield .035� (0.9 mm) NR®-211-
MP electrode.
� Easy to change polarity.
HANDY MIG
B-2 B-2
OPERATION
WELDING CAPABILITY TABLE B.1 � MIG WELDING MATERIAL/GAS COMBINATIONS
The machine is rated at 70 amps, 17 volts, at 20% Material Gas
duty cycle on a ten minute basis. It is capable of high- Carbon Steel CO2 or Argon/CO2
er output currents at lower duty cycles. Low Alloy Steel CO2 or Argon/CO2
LIMITATIONS FLUX-CORED (INNERSHIELD) WELDING
The recommended electrode for the flux-cored, self-
The machine is recommended for welding on mild
shielded process is 0.035� (0.9 mm) diameter Lincoln
steel up to 1/8� thick.
Innershield NR-211-MP on 2 lbs. (.9 kg) spools.
SEQUENCE OF OPERATIONS
CONTROLS AND SETTINGS WIRE LOADING AND THREADING
FIGURE B.1
Refer to Figure B.2.
4 Turn machine power switch to the OFF (�0�) position
before working inside the wire feed enclosure.
Make sure that the wire feed drive roll and the contact
tip of the gun match the diameter and type of wire
3 used.
1. Push the spool onto the spindle so that the wire
feeds off the bottom of the spool, toward the drive
roll.
1 2. Push the spool spacer onto the spindle, against the
spool.
3. Slide the spring onto the spool, then press on the
2 spool lock, turning it clockwise to lock the spool
assembly onto the spindle.
Refer to Figure B.1.
1. Power ON/OFF Switch -When the power is ON FIGURE B.2
the welding output and wire feeder are ON (“hot�)
when the gun trigger is pressed.
2. Low / High Heat Range Switch. -A rocker switch
control that gives low or high coarse range adjust- SPOOL
ment of the power source output voltage. SPACER
3. 1 � 2 Fine Heat Adjustment Switch. -Allows fine SPINDLE
adjustment of the voltage within the selected Low
SPOOL
or High output range.
LOCK
SPOOL
4. Wire Speed Control. -Controls the wire feed
SPRING
speed. Wire speed is not affected when changes
are made in the voltage control.
WELDING OPERATIONS
PROCESS GUIDELINES
MIG WELDING
Table B.1 shows the recommended material/gas
combinations for MIG welding with solid electrodes.
HANDY MIG
B-3 B-3
OPERATION
FIGURE B.4 � WIRE STICKOUT
FIGURE B.3 � WIRE THREADING DETAILS
Spring Loaded Thumb Screw
Ingoing Guide Tube
Upper
Idler Roll Arm
Wire
CONTACT
TIP
Wire Feed
3/8"
Lower Drive Roll WIRE Contact Tip To Work
ELECTRODE Distance (CTWD)
Refer to Figure B.3.
10. Remove the gas nozzle and contact tip from the
4. Release the spring loaded thumbscrew and lift up
gun.
the idle roll arm away from the wire feed drive roll.
11. Turn the machine ON (“I�).
Ensure that the visible, stenciled size on the drive
12. Straighten the gun cable assembly.
roll side facing you matches the wire size being
13. Depress the gun trigger switch and feed welding
used.
wire through the gun and cable. (Point the gun
5. Carefully detach the end of the wire from the spool
away from yourself and others while feeding wire.)
maintain tension on the wire. To prevent the spool
Release the gun trigger after wire appears at the
from unwinding and do not release the wire until
end of the gun.
after step 8.
14. Turn off the machine.
6. Cut the bent portion of wire off and straighten the
15. Replace the contact tip. Refer to Figure B-4. Cut
first 4� (100 mm).
the wire off so that 3/8� to 5/8� (10 - 15 mm) pro-
7. Thread the wire through the ingoing guide tube,
trudes from the end of the tip.
over the drive roll, and into the gun liner.
16. Turn on the machine. The machine is now ready
8. Close the idle roll arm and turn down the thumb-
to weld.
screw until the idle roller presses down firmly on the
wire. (Now you may release the welding wire).
SHIELDING GAS
Make sure the wire is positioned in the groove of
When using the MIG process, you will need a cylinder
the lower drive roll.
of carbon dioxide (CO 2 ) or argon-carbon dioxide
9. The spring loaded thumbscrew on the idle roll arm
mixed shielding gas.
adjusts the pressure on the wire. Adjust pressure
by turning the thumbscrew to prevent spool over-
The preset regulator supplied with the machine is
run, but still allow smooth and easy wire feeding.
designed for use with argon blend gas. An adapter
Start with the pressure set to an intermediate value.
and plastic washer are needed for using 100% CO2
Readjust, if necessary. Slightly less pressure may
be required when using 0.023 - 0.025� (0.6 mm) gas. This adapter is available from your local gas sup-
wire. If the drive roll slips while feeding wire, the plier.
pressure should be increased until the wire feeds
properly. 1. Open the cylinder valve slowly a fraction of a turn.
When the cylinder pressure gauge pointer stops
moving, open the valve fully.
WARNING
2. Keep the cylinder valve closed, except when weld-
� When feeding the welding wire ing. When finished welding:
through the gun, the drive roll, the � Close the cylinder valve to stop gas flow.
gun connector block and the gun � Depress the gun trigger briefly to release the
contact tip are always energized rela- pressure in the gas hose.
tive to work and ground. � Turn off the machine.
HANDY MIG
B-4 B-4
OPERATION
MAKING A WELD 4. Check that the polarity is correct for the welding wire
being used and that the gas supply, if required, is
FIGURE B.5 � WELDING SETUP
turned on.
5. Refer to Figure B.5. Connect the work clamp to the
metal to be welded. The work clamp must make
good electrical contact to the work piece. The work
piece must also be grounded as stated in Arc
Welding Safety Precautions in the beginning of this
GUN CABLE
manual.
6. Based on the welding process type and material
thickness of the work piece, use the chart below (or
on the procedure decal located on the wire drive
WORKPIECE ARC
door) to set the correct wire feed speed and heat
range setting.
WORK CLAMP
7. Based on the weld joint type and orientation of the
READ the LEARNING TO WELD (LTW1) manual
weld joint, position the gun into the joint at the cor-
prior to making your first weld. Also, refer to Table
rect angle. Refer to the LEARNING TO
B.1 and the Procedure Decal located on the inside of
WELD(LTW1) manual.
the wire drive compartment door of your machine for
8. To begin welding, raise your hand shield to protect
process selection, consumables, and quick tips for
your eyes and pull the trigger.
welding.
9. While welding, travel at a constant speed and main-
tain an electrode stickout of 3/8". Follow the correct
1. Select the right welding process based on the type
direction of travel for the process and joint type and
and condition of the pieces to be welded; the envi-
orientation as detailed in the LEARNING TO WELD
ronment in which welding is to be done; and the
(LTW1) manual.
desired finished appearance of the weld.
10. To stop welding, release the gun trigger.
2. Select and install the welding wire to match the
11. When no more welding is to be done, close the
process. Use Genuine Lincoln Electric Brand wire.
valve on the gas cylinder (if used), momentarily
Wire quality is essential for successful welding.
operate the gun trigger to release gas pressure,
3. Install the drive roll, contact tip, and nozzle appro-
and turn off the machine.
priate for the weld process.
TABLE B.1
1
2
3
4
1
5
6
7 8 8 8
7
7
HANDY MIG
B-5 B-5
OPERATION
CLEANING TIP AND GAS NOZZLE
Clean the contact tip and gas nozzle to avoid arc
bridging between them. Bridging can result in a short-
ed nozzle, poor welds and an overheated gun. Hint:
Anti-stick spray or gel, available from a welding supply
distributor, may reduce buildup and aid in spatter
removal.
CHANGING MACHINE OVER TO FEED
OTHER WIRE SIZES
The machine is shipped from the factory ready to feed
0.035� (0.9 mm) diameter wire. To operate the
machine with other sizes of wire, it is necessary to
change the contact tip and change the drive roll to
other sizes. Refer to Changing the Contact Tip and
Changing the Drive Roll in the MAINTENANCE sec-
tion for specific information on these procedures.
OVERLOAD PROTECTION
THERMAL PROTECTION
The machine has a maximum output duty cycle of
20%. If the duty cycle is exceeded, a thermal protector
will shut off the output until the machine cools to a
normal operating temperature. This is an automatic
function of the machine and does not require user
intervention.
HANDY MIG
C-1 C-1
ACCESSORIES
ACCESSORIES
INNERSHIELD WELDING WIRE
NR-211-MP Innershield welding wire - .035� (0.9 mm)
diameter flux-cored electrode.
MIG WELDING WIRE
Lincoln L56- .025� (0.6mm) diameter solid steel elec-
trode)
CONSUMABLE PARTS
The following items are commonly consumed over the
life of the welder and may need to be ordered. See
the complete parts list at the end of this manual for
machine replacement parts.
ITEM DESCRIPTION PART NO.
1 Chipping Hammer/Brush S24355-12
2 Face Shield G3364
3 Filter Lens/Clear Cover Lens G3364-C & -D
4 Drive Roll - �.023-.035�
(0.6-0.9 mm) KP2315-1
5 Contact Tip �.023-.025�
(0.6 mm) KH710
6 Contact Tip �.035�(0.9 mm) KH712
7 Flux Nozzle (Gasless) KH726
8 Gas Nozzle KH725
9 Gas Hose T10642-120
10 Gas Diffuser S25351-1
11 Liner S25351-50
HANDY MIG
D-1 D-1
MAINTENANCE
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
� Disconnect input power by removing
plug from receptacle before working
inside machine. Use only grounded
receptacle. Do not touch electrically
“hot� parts inside machine
� Have qualified personnel do the mainte-
nance and trouble shooting work.
ITEMS REQUIRING
NO MAINTENANCE
� Drive Motor and Gearbox � Lifetime lubrication
� Wire Reel Spindle � Do NOT lubricate shaft
ROUTINE AND PERIODIC
MAINTENANCE
BEFORE EACH USE
� Check over machine and accessories for any obvious condi-
tion that may prevent safe performance or operation. Repair
or replace items as necessary to correct any abnormal con-
dition.
AFTER 5 MINUTES OF WELDING
or when spatter accumulates in the gas nozzle:
� Clean the contact tip and gas nozzle to avoid bridging
between the nozzle and contact tip. Bridging results in a
shorted nozzle, poor welds and overheated gun. Hint: Anti-
stick spray or gel available from a welding supply distributor
may reduce buildup and aid in spatter removal.
HANDY MIG
D-2 D-2
MAINTENANCE
COMPONENT REPLACEMENT
CLEANING THE GUN LINER
PROCEDURES
� Unplug the machine or turn the power switch to the
OFF - �0� position. FIGURE D.1 � CONTACT TIP REPLACEMENT
� Remove the gas nozzle and contact tip from the CONTACT
gun. TIP
� Clean the inside diameter with a short piece of wire. EN
50
07
0-.040
AL
8 1.
� Clean the cable liner when rough and erratic wire
feeding occur:
NOZZLE
Lay the cable out straight. Blow out gently with dry
compressed air (max 145 psi) through the wire guide
tube and check the condition of the tube. Bend the
cable back and forth, then blow the tube out again.
Repeat until clean. CHANGING THE CONTACT TIP
CAUTION 1. Refer to Figure D.1. Remove the gas nozzle from
the gun by unscrewing it counter-clockwise.
Excessive pressure at start may cause the dirt to
form a plug. 2. Remove the existing contact tip from the gun by
------------------------------------------------------------------------ unscrewing it counter-clockwise.
CLEANING COMPONENTS AS REQUIRED
3. Insert and tighten the desired contact tip. Do not
� Unplug the machine or turn the power switch to the overtighten.
OFF - �0� position.
4. Replace the gas nozzle.
� Blow dirt out of the welder with low pressure air to
eliminate excessive dirt and dust buildup that could CHANGING THE DRIVE ROLL
cause the welder to run hot.
FIGURE D.2 � DRIVE ROLL REPLACEMENT
� Vacuum accumulated dirt from the gear-box and
wire feed section. SPRING LOADED
HANDLE SCREW
� Inspect the incoming guide tube and clean the
inside diameter if necessary. Replace when exces-
WIRE
sively worn. UPPER
IDLER ROLL ARM
INCOMING GUIDE TUBE
WIRE FEED
� Replace Contact Tip - when the hole is enlarged or LOWER DRIVE ROLL
AND THUMB SCREW
elongated. (Refer to Changing The Contact Tip, in
this section.)
� Check the condition of the wire feed rollers.
Remove any metallic dust deposited in the feed The machine Wire Feed Drive Roll has two grooves;
area (rollers and entrance and outlet wire guide). one for 0.023� - 0.025� (0.6 mm) solid steel electrode
and the other for 0.030� (0.8 mm) solid and 0.035�
� Check the gas hose and fittings for tightness. (0.9 mm) flux-cored steel electrode. See Figure D.2.
Use the appropriate sized groove for the wire used (as
indicated by the stenciling on the side of the drive roll).
Reverse the drive roll as follows.
Refer to Figure D.2.
1. Make certain the machine power switch is OFF -
�0�.
2. Open the spring loaded pressure arm. Lift up the
idle roll arm.
HANDY MIG
D-3 D-3
MAINTENANCE
3. Remove the Thumbscrew holding the drive roll.
4. Replace the drive roll so that the desired size, sten-
ciled on the side of the drive roll, is toward the
inside and visible.
5. Replace the Thumbscrew and tighten.
GUN ASSEMBLY REMOVAL
1. Unplug machine and disconnect gas supply.
2. Remove wire drive door and left case side.
3. Remove trigger leads. the trigger leads are routed
through the center panel and connected to the P.C.
board (3/1,3/2). Use care in removal as not to dam-
age the P.C. board or adjoining leads.
4. Remove gas line connections.
5. Remove gun connections from output studs.
6. Disconnect the gun liner from the wire drive.
Remove nut and spacer and slide liner back and
out.
7. Installation is the reverse of removal. (7 thru 1)
WORK CABLE INSTALLATION
The work cable and clamp comes already installed. If
you should ever need to replace or reinstall the cable,
do the following. Refer to Figure D.3.
FIGURE D.3
WORK CABLE AND GROMMET
1. Remove the case sides.
2. Pass the end of the work cable with the terminal lug
through the Work Cable Access Hole in the case
front.
3. Route the cable as detailed in the picture. The work
cable should be routed between the metal divider
panel and the wire feed gear box and gun assem-
bly.
HANDY MIG
E-1 E-1
TROUBLESHOOTING
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.
HANDY MIG
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage None
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. applied to the machine (115vac).
2. Make certain that power switch
is in the ON position.
3. The thermostat may be tripped
If all recommended possible areas
due to overheating. Let machine
of misadjustment have been
cool. Weld within the duty cycle
checked and the problem persists,
or remove any air obstruction to
Contact your local Lincoln
the machine.
Authorized Field Service
No weld output when gun trigger is Facility.
1. Gun tip may be worn. Replace.
pulled.
2. Gun trigger may be faulty.
3. The gun or work cable may be
faulty.
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.
HANDY MIG
E-3 E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
FEEDING PROBLEMS
No wire feed when gun trigger is 1. The thermostat may be tripped
pulled. due to overheating. Let machine
cool. Weld within the duty cycle
or remove any air obstruction to If all recommended possible areas
the machine. of misadjustment have been
checked and the problem persists,
2. Gun trigger may be faulty. Contact your local Lincoln
Authorized Field Service
3. Drive Roll tension is set too high. Facility.
4. Wire may be kinked or jammed.
Inspect Drive Roll and Guide
Tubes.
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.
HANDY MIG
E-4 E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
WELDING PROBLEMS
Bead is too thin (intermittently). 1. Travel speed is inconsistent.
Decrease and maintain a con-
stant travel speed.
2. Output heat range is too low.
Set the Low � High Heat Range
switch to High or the Fine Heat
Adjustment to MAX.
If all recommended possible areas
of misadjustment have been
Bead is too thick (intermittently). 1. Travel speed is slow and/or
checked and the problem persists,
inconsistent. Increase and main-
Contact your local Lincoln
tain a constant travel speed.
Authorized Field Service
Facility.
2. Output heat range is too high.
Set the Low � High Heat Range
switch to Low or the Fine Heat
Adjustment to MIN.
Bead does not penetrate base 1. Travel speed is inconsistent.
metal. Decrease and maintain a con-
stant travel speed.
2. Output heat range is too low.
Set the Low � High Heat Range
switch to High or the Fine Heat
Adjustment to MAX.
Wire sputters and sticks to work- 1. The wire is damp. Change to dry
piece. wire. Be sure wire is stored in a
dry location.
2. Wire feed speed (WFS) is too
fast. Reduce WFS.
Edge of weld has ragged depres- 1. Travel speed is too fast. Reduce
sions. travel speed.
2. WFS is too fast. Reduce WFS.
3. Output heat range is too high.
Set the Low � High Heat Range
switch to Low or the Fine Heat
Adjustment to MIN
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.
HANDY MIG
ENHANCED DIAGRAM
F-1 F-1
DIAGRAMS
M19903
GAS
A
HANDY MIG WIRING DIAGRAM FOR CODE 10919
R1
X1
X2
NO GAS
M2
X2
X1
black
red
3
2
1
X1/1
X1
X2
X8
X1/2
X1/3
L
X3/1
X3/2
1
X2
2
X4/1 g
V
X4/2
H2
X7
X6
X5
g
2
1
1
2
T
4
1
2
3
A2
A1
22
21
1
6
3
4
5
6
2
5
3
4
S2
1
2
K
M1
5
2
S1
0I
4
1
W
G
B
PLUG 115V
WELDER
CABLE
INPUT
GREEN LEAD
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.
HANDY MIG
F-2 F-2
DIAGRAMS
M20242
A
GAS
X1
X2
GAS
NO G
X2
X1
M2
black
X2
X1
red
X11
X10
L
X9
X8
X7
X6
WIRING DIAGRAM FOR CODE 11205
X5
V
g
X4
g
X2
X3
X1
T 1
2
3
4
6
4
1
3
2
5
S2
M1
5
2
S1
0I
4
1
W
G
B
WELDER
LDER
CABLE
PUT
INPUT
CABL
PLUG
LEAD
GREEN LEAD
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.
HANDY MIG
HINGE DOOR ASSEMBLY FOR CODE 10919 ONLY
HANDY MIG
NOTES
HANDY MIG
NOTES
HANDY MIG
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES 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 A
ETRE 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 UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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