IM10464 Power MIG 260 - Lincoln Electric · 5/16/2018 · Power MIG ®260 Need Help? Call 1.888.935.3877 to talk to a Service Representative Hours of Operation: 8:00 AM to 6:00 PM

Operator’s Manual

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IM10464-A | Issue D ate May-19

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

12728, 12931

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

Power MIG ®260

Need Help? Call 1.888.935.3877 to talk to a Service Representative

Hours of Operation: 8:00 AM to 6:00 PM (ET) Mon. thru Fri.

After hours? Use “Ask the Experts” at lincolnelectric.comA Lincoln Service Representative will contact you no later than the following business day.

For Service outside the USA: Email: [email protected]

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 SITUATIONS

DO 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 measures

PROTECT compressed gas cylinders from excessive heat,mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FORIMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 5/16/2018

SECTION A:WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaustexposes you to chemicals known to the Stateof California to cause cancer and birth defects,

or other reproductive harm.• Always start and operate the engine in a

well-ventilated area.• If in an exposed area, vent the exhaust to the outside.• Do not modify or tamper with the exhaust system. • Do not idle the engine except as necessary.For more information go to www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or

cutting, produces fumes or gases which contain

chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California

Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm

www.P65warnings.ca.gov

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-ventilated areas or vent the engineexhaust fumes outdoors.

1.c. Do not add the fuel near an open flame weldingarc or when the engine is running. Stop theengine and allow it to cool before refueling toprevent spilled fuel from vaporizing on contact

with hot engine parts and 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

Safety 02 of 04 - 5/16/2018

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, if

welding must be performed under electrically

hazardous conditions (in damp locations or while

wearing wet clothing; on metal structures such as

floors, gratings or scaffolds; when in cramped

positions such as sitting, kneeling or lying, if there

is a high risk of unavoidable or accidental contact

with the workpiece or ground) use the following

equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic 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 thesefumes and gases. When welding, keep your head out of the fume.Use enough ventilation and/or exhaust at the arc to keep fumesand gases away from the breathing zone. When welding

hardfacing (see instructions on container or SDS)

or on lead or cadmium plated steel and other

metals or coatings which produce highly toxic

fumes, keep exposure as low as possible and

within applicable OSHA PEL and ACGIH TLV limits

using local exhaust or mechanical ventilation

unless exposure assessments indicate otherwise.

In confined spaces or in some circumstances,

outdoors, a respirator may also be required.

Additional precautions 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 - 5/16/2018

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 to

http://www.lincolnelectric.com/safety

for additional safety information.

SAFETY

Safety 04 of 04 - 5/16/2018

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes lesinstructions et les précautions de sûreté specifiques qui par-raissent dans ce manuel aussi bien que les précautions desûreté générales suivantes:

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

a. Les circuits à l’électrode et à la piéce sont sous ten-sion quand la machine à souder est en marche. Evitertoujours tout contact entre les parties sous tension etla peau nue ou les vétements mouillés. Porter desgants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quandon soude dans des endroits humides, ou sur unplancher metallique ou des grilles metalliques, princi-palement dans les positions assis ou couchépour lesquelles une grande partie du corps peut êtreen contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, lecâble de soudage et la machine à souder en bon et sûrétat defonctionnement.

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

e. Ne jamais toucher simultanément les parties sous ten-sion des porte-électrodes connectés à deux machinesà souder parce que la tension entre les deux pincespeut être le total de la tension à vide des deuxmachines.

f. Si on utilise la machine à souder comme une sourcede courant pour soudage semi-automatique, ces pre-cautions pour le porte-électrode s’applicuent aussi aupistolet de 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’importequelle partie du 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 appro-prié ainsi qu’un verre blanc afin de se protéger lesyeux du rayonnement de l’arc et des projectionsquand on soude ou quand on regarde l’arc.

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

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

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protectionlibres de l’huile, tels que les gants en cuir, chemiseépaisse, pantalons sans revers, et chaussures mon-tantes.

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

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

7. Quand on ne soude pas, poser la pince à une endroitisolé de la masse. Un court-circuit accidental peut provo-quer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possi-ble de la zone de travail qu’il est pratique de le faire. Si onplace la masse sur la charpente de la construction oud’autres endroits éloignés de la zone de travail, on aug-mente le risque de voir passer le courant de soudage parles chaines de levage, câbles de grue, ou autres circuits.Cela peut provoquer des risques d’incendie ou d’echauf-fement des chaines et des câbles jusqu’à ce qu’ils serompent.

9. Assurer une ventilation suffisante dans la zone desoudage. Ceci est particuliérement important pour lesoudage de tôles galvanisées plombées, ou cadmiées outout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chloreprovenant d’opérations de dégraissage, nettoyage ou pis-tolage. La chaleur ou les rayons de l’arc peuvent réagiravec les vapeurs du solvant pour produire du phosgéne(gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur lasûreté, voir le code “Code for safety in welding and cut-ting” CSA Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement aucode de l’électricité et aux recommendations du fabri-cant. Le dispositif de montage ou la piece à souder doitêtre branché à une bonne mise à la terre.

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

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

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

2

3

TABLE OF CONTENTS

INSTALLATION .............................................................................................................................................SECTION ATECHNICAL SPECIFICATIONS ....................................................................................................................................A-1UNCRATING ............................................................................................................................................................A-2PRODUCT DESCRIPTION ............................................................................................................................................A-2LOCATION ............................................................................................................................................................A-2TILTING ............................................................................................................................................................A-2OUTPUT POLARITY CONNECTIONS.............................................................................................................................A-2INPUT POWER, GROUNDING AND CONNECTION DIAGRAM..........................................................................................A-2GUN AND CABLE INSTALLATION ................................................................................................................................A-2SHIELDING GAS .........................................................................................................................................................A-2AUXILIARY POWER RECEPTACLES..............................................................................................................................A-2

OPERATION ................................................................................................................................................SECTION BRECOMMENDED PROCESSES AND EQUIPMENT .........................................................................................................B-1WELDING CAPABILITY................................................................................................................................................B-1LIMITATIONS ............................................................................................................................................................B-1GRAPHIC SYMBOLS USED IN THIS MANUAL...............................................................................................................B-1CASE FRONT CONTROLS ...........................................................................................................................................B-2CASE BACK CONTROLS .............................................................................................................................................B-2INTERNAL CONTROLS................................................................................................................................................B-3WIRE SIZE CONVERSION PARTS.................................................................................................................................B-4PROCEDURE FOR CHANGING DRIVE AND IDLE ROLL SETS .........................................................................................B-4WIRE REEL LOADING - READI REELS, SPOOLS OR COILS ...........................................................................................B-4TO START THE WELDER ............................................................................................................................................B-5FEEDING WIRE ELECTRODE .......................................................................................................................................B-5IDLE ROLL PRESSURE SETTING .................................................................................................................................B-5WIRE DRIVE CONFIGURATION.....................................................................................................................................B-6DISPLAY OPERATION: ................................................................................................................................................B-7MAKING A WELD........................................................................................................................................................B-9AVOIDING WIRE FEEDING PROBLEMS ........................................................................................................................B-9FAN CONTROL...........................................................................................................................................................B-9INPUT LINE VOLTAGE PROTECTION............................................................................................................................B-9WIRE FEED OVERLOAD PROTECTION .........................................................................................................................B-9WELDING THERMAL OVERLOAD PROTECTION............................................................................................................B-9OVERCURRENT PROTECTION .....................................................................................................................................B-9

OPTIONS / ACCESSORIES.............................................................................................................................SECTION CDRIVE ROLL KITS.......................................................................................................................................................C-1ALTERNATIVE MAGNUM GMAW GUN AND CABLE ASSEMBLIES..................................................................................C-1MAGNUM GUN CONNECTION KIT (OPTIONAL K466-6) ................................................................................................C-1SPOOL GUN ............................................................................................................................................................C-1CONNECTING THE SPOOL GUN TO THE POWER MIG® 260 ........................................................................................C-2MAKING A WELD WITH THE SPOOL GUN ....................................................................................................................C-2MAKING A WELD WITH THE MAGNUM SG SPOOL GUN ...............................................................................................C-3CONNECTING THE PUSH-PULL GUN ..........................................................................................................................C-3WELDING WITH THE PUSH-PULL GUN ........................................................................................................................C-3PUSH-PULL CALIBRATION..........................................................................................................................................C-3

MAINTENANCE .............................................................................................................................................SECTION DGENERAL MAINTENANCE...........................................................................................................................................D-1DRIVE ROLLS AND GUIDE PLATES..............................................................................................................................D-1CONTACT TIP AND GAS NOZZLE INSTALLATION.........................................................................................................D-1GUN TUBES AND NOZZLES ........................................................................................................................................D-1GUN CABLE CLEANING ..............................................................................................................................................D-1LINER REMOVAL AND REPLACEMENT........................................................................................................................D-1LINER REMOVAL, INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM® PRO 250L ....................................D-1GUN HANDLE DISASSEMBLY .....................................................................................................................................D-2

TROUBLESHOOTING......................................................................................................................................SECTION E

DIAGRAMS ................................................................................................................................SECTION G

PARTS LIST...............................................................................................PARTS.LINCOLNELECTRIC.COMCONTENT/DETAILS MAY BE CHANGED OR UPDATED WITHOUT NOTICE. FOR MOST CURRENT INSTRUCTIONMANUALS, GO TO PARTS.LINCOLNELECTRIC.COM

A-1

INSTALLATIONPOWER MIG® 260

TECHNICAL SPECIFICATIONS – POWER MIG® 260

Input Ampere

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

208/60 60 59A 8230/60 60 55A 10460/60 30 27A 14 575/60 25 21A 14

INPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT*

RECOMMENDED INPUT WIRE AND FUSE SIZES

Height Width Depth Weight

37.25 in. 19.15 in. 40.4 in. 247 Lbs 946.15 mm 486 mm 1026 mm 112 kgs

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 208/230/460/575/1/60 Hz 50/46/23/19 Amps 56/53/27/22 Amps

Duty Cycle Amps Volts at Rated Amperes 40% 250 Amps 26.5 Volts 60% 200 Amps 24 Volts 100% 145 Amps 21.5 Volts

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

TEMPERATURE RANGES

STORAGE 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

A-2


INSTALLATIONRead entire installation section before startinginstallation.

Safety Precautions

ELECTRIC SHOCK can kill.• Only qualified personnel should

perform this installation.

• Only personnel that have read andunderstood the POWER MIG® 260Operator’s Manual should install andoperate this equipment.

• Machine must be grounded per any national, local orother applicable electrical codes.

• The POWER MIG® 260 power switch is to be in the OFFposition when installing work cable and gun and whenconnecting other equipment.

UNCRATING THE POWER MIG® 260

Cut banding and lift off cardboard carton. Cut banding holding themachine to the skid. Remove foam and corrugated packingmaterial. Untape accessories from Gas Bottle Platform. Unscrewthe two wood screws (at the Gas Bottle Platform) holding themachine to the skid. Roll the machine off the skid assembly.

PROdUCT dESCRIPTION

The POWER MIG® 260 is a complete semiautomatic constantvoltage DC arc welding machine built to meet NEMA specifi-cations. It combines a constant voltage power source and aconstant speed wire feeder with a microcomputer-basedcontroller to form a reliable high performance welding system. Asimple control scheme, consisting of continuous full range voltageand wire feed speed controls, provides versatility with ease of useand accuracy. The POWER MIG® 260 is Spool and Push Pull Gunready and includes a second Gas Solenoid for spool gun use. Referto Accessories Section for applicable push pull and spool guns.

Other features include a 7” Digital User Interface with synergiccontrols and memory capability, a 2” (51 mm) O.D. wire reelspindle with adjustable brake, an integral gas cylinder mountingunder carriage, an adjustable CO2 or Argon blend flow regulatorwith cylinder pressure gauge and inlet hose, a 15 ft (4.6 m)Magnum® PRO 250L GMAW gun and cable, a 10ft. (3.1 m) powercable with NEMA R Type 6-50N three prong plug and a 10 ft (3.1 m) work cable with clamp.

The POWER MIG® 260 features built in timer functions thatprovide variable burnback control, a spot function, a selectable 4-step trigger interlock and adjustable “Run-In” for wire startingoptimization. ARCFX™ technology comes standard and provides away to graphically communicate instant feedback of how the enduser settings affect the weld outcome when adjusting wire feedspeed and voltage.

LOCATION

Locate the welder in a dry location where there is free circulationof clean air into the louvers in the back and the louvers out thefront. A location that minimizes the amount of smoke and dirtdrawn into the rear louvers reduces the chance of dirtaccumulation that can block air passages and cause overheating.

TILTING

Each machine must be placed on a secure, level surface, eitherdirectly or on a recommended cart. The machine may topple overif this precaution is not followed.

OUTPUT POLARITY CONNECTIONS

The welder, as shipped from the factory, is connected forelectrode positive (+) polarity. This is the normal polarity forGMAW.

If negative (–) polarity is required, interchange the connection ofthe two cables located in the wire drive compartment near thefront panel. The electrode cable, which is attached to the wiredrive, is to be connected to the negative (–) labeled terminal andthe work lead, which is attached to the work clamp, is to beconnected to the positive (+) labeled terminal.

INPUT POWER, GROUNdING ANd CONNECTION dIA-GRAM

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

as output terminals or internal wiring.

• All input power must be electricallydisconnected before proceeding.

The Power MIG 260 is not equipped with 460/575 volt 60 Hz plug,an input cable or a receptacle.

1. Before starting the installation, check with the local powercompany if there is any question about whether your powersupply is adequate for the voltage, amperes, phase, andfrequency specified on the welder rating plate. Also be surethe planned installation will meet the U.S. National ElectricalCode and local code requirements. This welder may beoperated from a single phase line or from one phase of a twoor three phase line.

2. Power MIG 260 has multiple input voltages specified on thenameplate. The unit is shipped connected for the 230 voltage.If the welder is to be operated on 208 voltage, it must bereconnected according to the instructions in Figure A.1. Forhigher voltage (460 & 575) reconnect per Figure A.1. Installappropriate input cable per local and national electrical code.

WARNING

WARNING

A-3


Make certain that the input power is electricallydisconnected before removing the screw on the reconnectpanel access cover.

FIGURE A.1

3.3. The POWER MIG 260 is shipped with a 10 ft. NEMA R Type 6-

50N three prong plug and cable connected to the welder.Obtain a receptacle and mount it in a suitable location. Besure it can be reached by the plug on the input cable attachedto the welder. Mount with the grounding terminal at the top toallow the power cable to hang down without bending.

GUN ANd CABLE INSTALLATION

The Magnum® PRO 250L gun and cable provided with thePOWER MIG® 260 is factory installed with a liner for .035-.045"(0.9-1.1 mm) electrode and an .035" (0.9 mm) contact tip. Installthe .045” tip (also provided) if this wire size is being used.

Turn the welder power switch off before installing gun andcable.

(See Figure A.4)

1. Lay the cable out straight.

2. Unscrew the Hand Screw on the drive unit front end (insidewire feed compartment - Item 3) until tip of screw no longerprotrudes into Gun Adapter opening as seen from front ofmachine. (See Figure A.4)

3. Insert the male end of gun cable into the Gun Adapter (Item 2)through the opening in front panel. Make sure connector isfully inserted and tighten Hand Screw.

4. Connect the Gun Trigger Connector from the gun and cable tothe mating Receptacle inside the compartment located left onthe Front Panel - Item 1. Make sure that the keyways arealigned, insert and tighten retaining ring.

FIGURE A.4

FIGURE A.5

A Coil Claw™ [Fig A.4 (Item 5)] and tool holder are included withPower MIG 260. To remove/reposition the tool holder, remove thescrew and insert. Reposition into desired slot on the gas bottleupper bracket (G9040).

3

WARNING

2

1

4

5

WARNING

A-4


SHIELdING GAS

[For Gas Metal Arc Welding(GMAW) Processes]

Customer must provide cylinder of appropriate type shielding gasfor the process being used.

A gas flow regulator, for Argon blend gas, an inlet gas hose, and aregulator adapter are factory provided with the POWER MIG® 260.When using 100% CO2, the regulator adapter will be required toconnect the regulator to the gas bottle.

CYLINDER may explode if damaged.• Gas under pressure is explosive. Always

keep gas cylinders in an upright positionand always keep chained to undercarriageor stationary support.

See American National Standard Z49.1, “Safety in Weldingand Cutting” published by the American Welding Society.

Install shielding gas supply as follows:

1. Set gas cylinder on rear platform of POWER MIG® 260. Hookchain in place to secure cylinder to rear of welder.

2. Remove the cylinder cap. Inspect the cylinder valves andregulator for damaged threads, dirt, dust, oil or grease.Remove dust and dirt with a clean cloth.

DO NOT ATTACH THE REGULATOR IF OIL, GREASE ORDAMAGE IS PRESENT! Inform your gas supplier of thiscondition. Oil or grease in the presence of high pressureoxygen is explosive.

3. Stand to one side away from the outlet and open the cylindervalve for an instant. This blows away any dust or dirt whichmay have accumulated in the valve outlet.

Be sure to keep your face away from the valve outlet when“cracking” the valve.

4. Attach the flow regulator to the cylinder valve and tighten theunion nut(s) securely with a wrench.

NOTE: If connecting to 100% CO2 cylinder, the regulatoradapter provided must be installed between the regulator andcylinder valve.

5. Attach one end of the inlet gas hose to the outlet fitting of theflow regulator, the other end to the POWER MIG® 260 rearfitting marked “Feeder” and tighten the union nuts securelywith a wrench.

6. Before opening the cylinder valve, turn the regulator adjustingknob counterclockwise until the adjusting spring pressure isreleased.

7. Standing to one side, open the cylinder valve slowly a fractionof a turn. When the cylinder pressure gauge pointer stopsmoving, open the valve fully.

Never stand directly in front of or behind the flow regulatorwhen opening the cylinder valve. Always stand to one side.

8. The flow regulator is adjustable. Adjust it to the flow raterecommended for the procedure and process being usedbefore making the weld.

AUXILIARY POWER RECEPTACLES

This machine is equipped with 15Amp 120V receptacle with15Amp Circuit Breaker. The receptacle is UL and CSA approved.The location can be seen in Fig A.4 (Item 4).

WARNING

WARNING

WARNING

B-1

OPERATIONPOWER MIG® 260

OPERATIONSAFETY PRECAUTIONSRead this entire section of operating instructions before operatingthe machine.

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

electrode with skin or wet clothing.Insulate yourself from work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be danger-ous.• Keep your head out of fumes.

• Use ventilation or exhaust to removefumes from breathing zone.

WELDING SPARKS can cause fire or explo-sion.• Keep flammable material away.

• Do not weld on containers that have heldcombustibles.

ARC RAYS can burn.• Wear eye, ear, and body protection.

RECOMMENdEd PROCESSES ANd EQUIPMENT

The POWER MIG® 260 is recommended for GMAW weldingprocesses using 10 to 44 lb (4.5 to 20 kg) 2"(51 mm) I.D. spoolsor Readi-Reel® coils (with optional 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" (1.1 mm)Innershield® self-shielding electrodes.

The POWER MIG® 260 is factory equipped to feed .035" (0.9 mm)and .045” (1.1mm) electrode. It also includes a 200A, 60% dutycycle (or 250A, 40% duty cycle) rated, 15 ft. (4.6 m) GMAW gunand cable assembly equipped for these wire sizes. Use of GMAWprocesses requires a supply of shielding gas.

WELdING CAPABILITY

The POWER MIG® 260 is rated at 250 amps @ 26 volts, at a 40%duty cycle based on a ten minute cycle time. It is capable ofhigher duty cycles at lower output currents and capable of up to300 Amps at lower duty cycles.

LIMITATIONS

POWER MIG® 260 WILL NOT operate satisfactorily if powered witha portable or in-plant generating system.

GRAPHIC SYMBOLS USEd IN THIS MANUAL

WARNING

B-2


CASE FRONT CONTROLS

1. Color LED Screen – Permits visualization of welding process andparameters. The screen features a replaceable screen shield forprotecting against dust & dirt.

2. Back Button/Knob --- rotate adjusts value, push to move backto previous selection

3. Home Button – Returns the user to the Home Screen. At the HomeScreen, the user can select a welding process or the displaysettings can be configured.

4. Select Button/Knob --- rotate adjusts value, push confirms theselected value or choice

5. Seven Pin Connector - For attaching optional remote controlequipment. Includes auto-sensing remote control circuit.

6. Four Pin Trigger Receptacle – Permits triggering the machine forMIG/FCAW or aluminum MIG. Connect the 4-pin connector presenton the welding gun to the receptacle.

7. Gun Connection – Permits attachment of a MIG welding gun.Ensure the gun is fully seated into the brass receptacle.

8. Power Switch – Permits turning the machine on or off.

9. 115V receptacle

CASE BACk CONTROLS

1. Decal – serial number.

2. Decal – Input supply connection diagram

3. Reconnect Panel Assembly

4. Input Cable Connecting Block

5. Grounding – Input cable ground cable connector

6. Input power cord

7. Spool Gun Bypass Gas Solenoid

8. MIG/Push-Pull Gas Solenoid Connector – connection to gas hose

6

5

7

8

9

1

3

4

2

1 3

4

5

6

8

2

7

B-3


INTERNAL CONTROLS

1. Wire Drive Tension Pressure Adjustment – Permits increasing ordecreasing the pressure applied to the top drive roll.

2. Wire Drive Spindle – Supports a 4-inch or 8-inch spool of wire.The center wing-nut can be adjusted to increase tension on thewire.

3. Positive Output Receptacle – Permits attaching a work lead,electrode stinger or the center wire drive polarity lead to DCpositive polarity. Rotate clockwise to lock into place.

4. Negative Output Receptacle – Permits attaching a work lead,electrode stinger, or the center wire drive polarity lead to DCnegative polarity. Rotate connector clockwise to lock into place.

5. Thermal Breaker – The Power MIG 260 features a resettable 15amp thermal breaker. If the current conducted through thebreaker exceeds 15 amps for an extended period of time, thebreaker will open and require manual reset.

1

34

2

5

B-4


The drive rolls installed with the POWER MIG® 260 have twogrooves one for .035” (0.9mm) wire Solid Steel electrode and theother for .045” (1.1mm) wire. Drive roll size is stenciled on eachside of the drive roll. If feeding problems occur, check to makesure that the wire size and the drive roll size matches. See"Procedure for Changing Drive Roll" in this section. Thisinformation also appears on the Procedure Decal on the doorinside the wire compartment.

WIRE SIZE CONVERSION PARTS

The drive roll kits and Magnum® PRO 250L gun and cable partsare available to feed different sizes and types of electrodes. SeeAccessories section.

PROCEdURE FOR CHANGING dRIVE ANd IdLE ROLLSETS

1. Turn off the power source.

2. Release the pressure on the idle roll by swinging theadjustable pressure arm down toward the back of themachine. Lift the cast idle roll assembly and allow it to sit inan upright position.

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

4. Twist the drive roll retaining mechanism to the unlockedposition as shown below and remove the drive roll. (SeeFigure B.2)

FIGURE B.2

5. Remove the inside wire guide plate.

6. Replace the drive and idle rolls and inside wire guide with a setmarked for the new wire size. NOTE: Be sure that the gunliner and contact tip are also sized to match the selected wiresize.

7. Manually feed the wire from the wire reel, over the drive rollgroove and through the wire guide and then into the brassbushing of the gun and cable assembly.

8. Replace the outside wire guide retaining plate by tightening thetwo large knurled screws. Reposition the adjustable pressurearm to its original position to apply pressure. Adjust pressureas necessary.

WIRE REEL LOAdING - REAdI REELS, SPOOLS ORCOILSTo Mount a 30 Lb. (14 kg) Readi-Reel Package (Using the MoldedPlastic K363-P Readi-Reel Adapter:)

(See Figure B.3)FIGURE B.3

1. Open the Wire Drive Compartment Door.

2. Depress the Release Bar on the Retaining Collar and remove itfrom the spindle.

3. Place the Optional Adapter on the spindle.

4. Re-install the Retaining Collar. Make sure that the Release Bar"pops up" and that the collar retainers fully engage theretaining ring groove on the spindle.

5. Rotate the spindle and adapter so the retaining spring is at the12 o'clock position.

6. Position the Readi-Reel so that it will rotate in a direction whenfeeding so as to be de- reeled from top of the coil.

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

8. Lower the Readi-Reel to depress the retaining spring and alignthe other inside cage wires with the grooves in the moldedadapter.

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

CHECK TO BE SURE THE RETAINING SPRING HAS FULLYRETURNED TO THE LOCKING POSITION AND HASSECURELY LOCKED THE READI-REEL CAGE IN PLACE.RETAINING SPRING MUST REST ON THE CAGE, NOT THEWELDING ELECTRODE.

10. To remove Readi-Reel from Adapter, depress retaining springtab with thumb while pulling the Readi-Reel cage from themolded adapter with both hands. Do not remove adapter fromspindle.

LOCKED POSITIONUNLOCKED POSITION

2 IN. O.D.�SPINDLE

ADAPTER

RETAINING�SPRING

BRAKE�HOLDING�

PINGROOVES

READI-REEL

INSIDE�CAGE�WIRES

RELEASE�BAR

RETAINING�COLLAR

CAUTION

B-5


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

(For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil Adapter mustbe used).

(For 10 lb.(4.5 Kg) 8 inch(203mm) diameter spools, a K468spindle adapter must be used).

1. Open the Wire Drive Compartment Door.

2. Depress the Release Bar on the Retaining Collar and remove itfrom the spindle.

3. Place the spool on the spindle making certain the spindle brakepin enters one of the holes in the back side of the spool (Note:an arrow mark on the spindle lines up with the brake holdingpin to assist in lining up a hole). Be certain the wire comes offthe reel in a direction so as to de-reel from the top of the coil.

4. Re-install the Retaining Collar. Make sure that the Release Bar"pops up" and that the collar retainers fully engage theretaining ring groove on the spindle.

TO START THE WELdER

Turn the "Power Switch" switch to "ON". This lights the red LEDdisplay lights. With the desired voltage and wire speed selected,operate the gun trigger for welder output and to energize the wirefeed motor.

FEEdING WIRE ELECTROdE

When triggering, the electrode and drive mechanism areelectrically "hot" relative to work and ground and remain"hot" several seconds after the gun trigger is released.

NOTE: Check that drive rolls, guide plates and gun parts areproper for the wire size and type being used. Refer to Table C.1 inAccessories section.

1. Turn the Readi-Reel or spool until the free end of the electrodeis accessible.

2. While securely holding the electrode, cut off the bent end andstraighten the first six inches. (If the electrode is not properlystraightened, it may not feed properly through the wire drivesystem).

3. Release the pressure on the idle roll by swinging the adjustablepressure arm down toward the back of the machine. Lift thecast idle roll assembly and allow it to sit in an uprightposition. Leave the outer wire guide plate installed. Manuallyfeed the wire through the incoming guide bushing andthrough the guide plates (over the drive roll groove). Push asufficient wire length to assure that the wire has fed into thegun and cable assembly without restriction. Reposition theadjustable pressure arm to its original position to applypressure to the wire.

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

IdLE ROLL PRESSURE SETTING

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

power source before installation or changingdrive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drivemechanism are "hot" to work and ground and couldremain energized several seconds after the gun triggeris released.

• Only qualified personnel should perform maintenancework.

The pressure arm controls the amount of force the drive rolls exerton the wire. Proper adjustment of both pressure arm gives thebest welding performance. For best results, set both pressurearms to the same value.

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

FIGURE B.4WARNING

WARNING

ALUMINUMOUTERSHIELD

METALSHIELD

INNERSHIELD STEEL

STAINLESS

COREDWIRES SOLID WIRES

6

132

54

B-6


WIRE dRIVE CONFIGURATION

(See Figure B.5)

CHANGING THE GUN RECEIVER BUSHING

Tools required:

• 1/4" hex key wrench.

Note: Some gun bushings do not require the use of the thumbscrew.

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.

5. Loosen the socket head cap screw that holds the connector baragainst the gun bushing.

Important: Do not attempt to completely remove the sockethead cap screw.

6. Remove the outer wire guide, and push the gun bushing out ofthe wire drive. Because of the precision fit, light tapping maybe required to remove the gun bushing.

7. Disconnect the shielding gas hose from the gun bushing, ifrequired.

8. Connect the shielding gas hose to the new gun bushing, ifrequired.

9. Rotate the gun bushing until the thumb screw hole aligns withthe thumb screw hole in the feed plate. Slide the gun receiverbushing into the wire drive and verify the thumb screw holesare aligned.

10. Tighten the socket head cap screw.

11. Insert the welding gun into the gun bushing and tighten thethumb screw.

GUN RECEIVER BUSHING

THUMB SCREW

OUTER WIRE GUIDE

SOCKET HEADCAP SCREW

CONNECTOR BLOCK

Figure B.5

B-7


dISPLAY OPERATION:FIG B.2 - 7” STARTUP SCREEN

1. Main Display2. Back Button/Knob --- rotate adjust value, push to move back

to previous selection

3. Select Button/Knob --- rotate adjusts value, push confirmsthe selected value or choice

4. Home/Mode Button --- brings up the home screen

FIG B.3 - HOME SCREEN

1. Current Settings Tool Bar --- It displays the weld settingsused

2. Selected Welding Mode Type --- It gives a description of thecurrently selected function/welding mode

3. Wire Feed Speed 4. Voltage5. ARCFX™ --- provides a way to graphically communicate

instant feedback of how the end user settings affect the weldoutcome when adjusting wire feed speed and voltage.

FIG B.4 - WELDING SCREEN

1. Current Settings Tool Bar --- It displays the weld settingsused


3. Setup Wire Feed Speed4. Actual Voltage5. Actual Current6. Setup Voltage

FIG B.5 - SELECT MODE SCREEN

1. Welding Mode Setup Diagram --- The diagram shows themajor component settings needed to perform a weld. Thesynergic software will take the user through the necessarysteps for a proper welding parameter setup.


3. Manual Mode --- The synergic mode is disengaged. Allwelding parameters have to be selected/set by user.

4. GMAW Mode --- metal inert gas (MIG) welding

5. FCAW-S Mode --- flux cored arc welding - self shielded

6. FCAW-G Mode --- flux cored arc welding - gas shielded

7. Spool Mode --- spool welding guns mode

8. Push-Pull Mode --- Push-pull guns mode

9. Memory Recall --- It allows the recall of prior weld settingssaved under the Memory Save function

10. Configuration --- Select to open the System Settings menu

A V

1

4

2 3

Select Process

Steel Ø0.025

Ar/CO2 22ga MIG

Weld Settings

90 15.0A V

Vin

min

12

3 4

5

Select Process

Steel Ø0.025

Ar/CO2 22ga MIG

Weld Settings

90144 14.9

15.0A V

V

VAin

min

12

3

5

6

4

MIG 2

3 4 5 6 7 8 9 10

1

B-8


FIG B.6 - ADVANCE OPTIONS SCREEN

1. Material Thickness --- Select welding material thickness

2. Selected Function Name3. Trigger ---Select the desired mode with the toggle switch:

• Normal Welding mode (2 Step) provides weld power onlywhile the trigger switch is depressed.

• 4-Step Trigger interlock mode eliminates the need tohold the gun trigger while welding. It operates in 4 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, the machine willreset to the "trigger off" condition automatically.Note: 4 Step Trigger interlock mode does not function with aSpool Gun.

4. Spot Time ---The spot time option permits adjusting theduration of the welding arc. This is used for tack welds orspot welds. The spot-time option is available in GMAW andFCAW modes.

5. Run-In --- The run-in option permits adjusting the wire feedspeed prior to the arc being established. A lower run-in speedpermits smooth arc starts. After the arc is established therun-in value is inactive and the set wire feed speed ispresent. The run-in option is available in GMAW and FCAWmodes.

6. Burnback --- Setting the Burnback means setting theadjustable time delay between turning off the wire feedingand turning off the arc. Burnback helps to prevent wiresticking to the puddle. The Burnback feature will allowcurrent to continue to flow for a specified time period at theend of a weld after wire feeding has stopped.

7. Memory Save --- Power MIG™ 260 is capable of storing upto 25 sets of welding setting. To save a desired weld setting,select a location, preferable an empty slot (Note: The latestsaving will override any prior saved settings), push and holdthe right knob for 3 seconds. The saved welding settings canbe recalled through the Memory Recall function.

FIG B.6 - SETTING SCREEN

1. Remote Gun Pot --- Disable or Enable Remote Gun Pot

2. Setting Mode ID --- Selected mode name/identification

3. Brightness --- The brightness of the display can be adjustedwithin the settings option.

4. Measurement System --- The units of measure can bechosen by the user. The units can be selected as metric orEnglish. The default units are English.

5. Language --- The language of the text present in the userinterface software can be modified. The available languageoptions are English, French and Spanish. The defaultlanguage is English.

6. Factory Reset --- The user interface software settings can bereset to the original factory settings.

7. System Info. --- Information regarding the software revisionof the user interface and the software revision of the inverterboard is present in the information section.

8. Demo Mode --- Selecting demo mode enables a series ofautomated transitions through the display screen that willprovide the user a visual overview of the user interface andthe machine’s capabilities. In demo mode the output isdisabled. To permit welding, the user must exit demo modeor power cycle the machine.

Thickness

3 4 5 6

1

2

7

HomeBack Select

22ga

A V

Remote Gun Pot

3 4 5 6

1

2

8

7

HomeBack Select

A V

B-9


MAkING A WELd

1. Check that the electrode polarity is correct for the processbeing 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.

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

4. Press the trigger to feed the wire electrode through the gunand cable and then cut the electrode within approximately3/8" (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, the wirefeeder feeds wire at low speed regardless of the set wire feedspeed until the welding arc starts or 1 second has elapsed.This feature enhances starting and makes it easier to set thestickout. The 1 second limit permits high speed loading of thegun and cable. To change run-in mode, see "Run-In Mode" inDescription 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; 12-16 liters/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 clamp mustmake good electrical contact to the work. The work must alsobe grounded as stated in "Arc Welding Safety Precautions".

When using an open arc process, it is necessary to usecorrect eye, head, and body protection.

8. Position electrode over joint. End of electrode may be lightlytouching the work.

9. Lower welding helmet, close gun trigger, and begin welding.Hold the gun so the contact tip to work distance is about 3/8"(10 mm) [3/4" (20 mm) for Outershield].

10. To stop welding, release the gun trigger and then pull the gunaway from the work after the arc goes out.

11. When no more welding is to be done, close valve on gascylinder (if used), momentarily operate gun trigger to releasegas pressure, and turn off POWER MIG® 260.

AVOIdING WIRE FEEdING PROBLEMS

Wire feeding problems can be avoided by observing the followinggun handling procedures:

• Do not kink or pull cable around sharp corners.

• Keep the gun cable as straight as possible when welding orloading electrode through cable.

• Do not allow dolly wheels or trucks to run over cables.

• Keep cable clean by following maintenance instructions.

• Use only clean, rust-free electrode. The Lincoln electrodes

have proper surface lubrication.

• Replace contact tip when the arc starts to become unstable orthe contact tip end is fused or deformed.

• Keep wire reel spindle brake tension to minimum required toprevent excess reel over-travel which may cause wire "loop-offs" from coil.

• Use proper drive rolls and wire drive idle roll pressure for wiresize and type being used.

FAN CONTROL

The fan is designed to come on automatically when a weld arc isestablished. The fan will also stay on when the machine’s weldingand feeding are disabled during thermostatic over temperatureprotection. (See Welding Thermal Overload Protection)

INPUT LINE VOLTAGE PROTECTION

High Line Voltage — If the line voltage exceeds 110% of ratedinput voltage, the output will be reduced to the lower level toprotect voltage rating of the capacitor bank.

Low Line Voltage — You may not be able to get maximum outputfrom the machine if the line voltage is less than rated input. Theunit will continue to weld, but the output may be less than what isset.

WIRE FEEd OVERLOAd PROTECTION

The POWER MIG® 260 has solid state overload protection of thewire drive motor. If the motor becomes overloaded, the protectioncircuitry turns off the wire feed speed weld output and gassolenoid. Check for proper size tip, liner, and drive rolls, for anyobstructions or bends in the gun cable, and any other factors thatwould impede the wire feeding.

To resume welding, simply pull the trigger. There is no circuitbreaker to reset, as the protection is done with reliable solid stateelectronics.

WELdING THERMAL OVERLOAd PROTECTION

The POWER MIG® 260 has built-in protective thermostats thatrespond to excessive temperature. They open the wire feed andwelder output circuits if the machine exceeds the maximum safeoperating temperature because of a frequent overload, or highambient temperature plus overload. The thermostats automaticallyreset when the temperature reaches a safe operating level andwelding and feeding are allowed again, when gun is retriggered.

OVERCURRENT PROTECTION

The machine will automatically reduce the output if the load onthe machine exceeds 300 to 320 amperes. This protects thewelding machine from excessive short circuit currents and fromexceeding their temperature rating before the thermostats canreact.

WARNING

C-1

ACCESSORIESPOWER MIG® 260

OPTIONS / ACCESSORIESdRIVE ROLL kITS

Refer to Table C.1 for various drive roll kits that are available forthe POWER MIG® 260.The item in Bold is supplied standard withthe POWER MIG® 260.

TABLE C.1

K3675-1 Canvas Cover

K1738-1 Spool Gun Holder for Power MIG - provide neat storageof spool gun cable, and gas hose for Power MIG. Also providehardware for routing gas inside Power MIG when using a PrinceXL gun. (Note: included in K1809-1 and K2310-1)

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

K363P READI-REEL™ ADAPTER - The K363P Readi-Reel Adaptermounts to the 2" spindle. It is needed to mount the 22-30 lb.Readi-Reels.

K435 Spindle Adapter for 14 lbs. coils - the K435 spindle adapterallows 14lbs. (6kg.) Innershield coils to be mounted on 2” (51mm)O.D. spindle.

K3676-1 Dual Cylinder

ALTERNATIVE MAGNUM GMAW GUN ANd CABLEASSEMBLIES

The following Magnum® PRO 250L gun and cable assembly isseparately available for use with the POWER MIG® 260. Each israted 200 amps 60% duty cycle (or 250 amps 40% duty) and isequipped with the integrated connector, twist-lock triggerconnector, fixed nozzle and insulator, and includes a liner,diffuser, and contact tips for the wire sizes specified:

1 Optional liners for different wire diameters are sold separately,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 for thePOWER MIG permits use of standard Magnum® 200, 300 or 400gun and cable assemblies.

SPOOL GUN

Remove all input power to the POWER MIG® 260 beforeproceeding.

The POWER MIG® 260 provides direct connection and use of theSpool Gun (with remote speed control).

It also provides gun trigger switch transfer between the machine’suse with its feeder gun or the spool gun for same polarity weldingwith different wire and gas processes.

K2490-1 Magnum® 250LX

K487-25 Magnum® SG Spool Gun (requires K2445-1 CableAdapter)

K2445-1 Magnum® SG Spool gun Control Cable Adapter. Allowsthe K487-25 Magnum® SG spool gun’s 6-pin control cable plug toconnect to the POWER MIG® 260’s 7-pin spool gun control cablereceptacle.

Wire Wire Size Drive Roll KitSolid Steel .023”-.030” (0.6-0.8 mm)

.035” (0.9 mm)

.045” (1.1 mm)

.035”-.045” (0.9-1.1mm)

.040” (1.0mm)

KP1696-030S

KP1696-035S

KP1696-045S

KP1696-1

KP1696-2

Cored .035” (0.9 mm)

.045” (1.1 mm)

KP1697-035C

KP1697-045C

Aluminum 3/64” (1.2 mm)

.035” (0.9 mm)

KP1695-3/64A

KP1695-035A

WARNING

Length Part No. English WireSize1

Metric WireSize

15' (4.6 m) K3081-2 .035 – .045" 0.9 – 1.2 mm

C-2


CONNECTING THE SPOOL GUN TO THEPOWER MIG® 260

(See Figure C.1)

1. Connect the Spool Gun control cable to the mating 7-pinreceptacle in the Power MIG wire drive compartment. K487-25Magnum SG Spool Gun requires K2445-1 cable 7-pin to 6-pinadapter.

2. Connect the Spool Gun electrode lead to the (+)positive studwith the Spool Gun electrode lead sandwiched between the(+)positive power source electrode lead and the (+)positivestud. Tighten and be careful not to strip the threads.

3. Attach the Spool Gun gas line to the 5/8 Gas fitting on the frontof the machine.

4. Attach a Gas hose from the Gas supply to the rear inlet gasfitting marked “Spool” on the POWER MIG® 260.

MAkING A WELd WITH THE SPOOL GUN

The POWER MIG® 260 control circuitry is designed to sense eitherthe spool gun or (built in) wire feeder trigger circuitry. The spoolgun can easily be plugged in and will be ready to use.

Closing either gun trigger will cause the electrode of bothguns to be electrically "HOT". Be sure unused gun ispositioned so electrode or tip will not contact metal case orother metal common to work.

1. Pulling the trigger for the built-in feeder gun:

• Disables spool gun operation.

• Closing feeder gun trigger starts feeder gun welding andmakes both electrodes electrically "HOT".

2. Pulling SPOOL GUN Trigger:

• Disables built-in feeder gun operation.

• Closing spool gun trigger starts spool gun weld-ing andmakes both electrodes electrically "HOT".

3. Operation with POWER MIG® 260:

• Turn the POWER MIG® 260 input power ON.

• Adjusting the voltage control will increase or decrease yourwelding voltage.

• Adjusting the wire speed control on the spool gun willincrease or decrease the spool gun wire feed speed.Calibration is available on the procedure menu.

• To aid in set-up, the POWER MIG® 260 wire feedspeed(WFS) meter will display the approximate WFS of thegun. Actual WFS at the gun may vary from the displayedvalue due to tension setting, liner condition or gunvariation.

4. The following procedure settings for Aluminum 4043 can beused as initial settings for making test welds to determinefinal settings:

5. To return to normal POWER MIG® 260 welding, release thespool gun trigger and reset feeder gun voltage proceduresetting if necessary.

CAUTION

Wire Diameter In. (mm)

Wire Feed Speed Display

Arc voltageSetting

.030” (.8mm) 270 15V

.035” (.9mm) 250 16V

3/64” (1.2mm) 240 20V

C-3


MAkING A WELd WITH THE MAGNUM® SG SPOOLGUN

The POWER MIG® 260 control circuitry is designed to sense eitherthe spool gun or (built in) wire feeder trigger circuitry. The spoolgun can easily be plugged in and will be ready to use.

Closing either gun trigger will cause the electrode of bothguns to be electrically "HOT". Be sure unused gun ispositioned so electrode or tip will not contact metal case orother metal common to work.

1. Pulling the trigger for the built-in feeder gun:

• Disables spool gun operation.

• Closing feeder gun trigger starts feeder gun weldingand makes both electrodes electrically "HOT".

2. Pulling SPOOL GUN Trigger:

• Disables built-in feeder gun operation.

• Closing spool gun trigger starts spool gun welding andmakes both electrodes electrically "HOT".

3. Operation with POWER MIG® 260:

• Turn the POWER MIG® 260 input power ON.

• Adjusting the voltage control will increase or decreaseyour welding voltage.

• Adjusting the wire speed control on the spool gun willincrease or decrease the spool gun wire feed speed.

4. To return to normal POWER MIG® 260 welding, release thespool gun trigger and reset feeder gun welding procedures.

CONNECTING THE PUSH-PULL GUN

Magnum® PRO Al

Magnum® PRO Pistol

Magnum® PRO Cougar

Custom

See lincolnelectric.com for latest K#

WELdING WITH THE PUSH-PULL GUN

• Set the idle roll pressure on the wire drive between anindicator reading of 0-2. A recommended start point is 1.5.

• Select from the main menu "PUSH-PULL GUN."

• Depending on the weld mode, set the Voltage at the POWERMIG® 260 using the right control knob located on the uppercase front panel.

• The Wire Feed Speed (WFS) is set using the control knob onthe Torch. The left control knob on the POWER MIG® 260 isinactive. The actual WFS being set at the torch is displayed onthe POWER MIG® 260. Note: disables the push-pull gunadjustments.

• All weld parameters normally available for the active weldmode are available during push-pull operation. Refer to theOperation Section of this manual.

PUSH-PULL CALIBRATIONMagnum® PRO AL, Magnum® PRO Pistol and Magnum® PROCougar

Auto Calibration: This procedure provides an automatic means tosynchronize the speeds of the rear push motor and front pullmotor. Before running the auto calibration procedure, make surethe machine and the gun cable are set up and ready for welding.Pull the gun trigger and hold it closed throughout the procedure.Wire will feed out of the gun while the calibration is beingperformed, however the welding output will NOT be energized.Wire will stop feeding when the calibration is complete. Autocalibration should be performed whenever the wire or gun ischanged.

Manual Calibration: this procedure allows a direct adjustment onthe pull motor speed by Offset value. The default is 90. A wirenesting or tangling issue can be resolved by increasing this value,and a wire slipping or shaving issue can be resolved bydecreasing this value.

Custom push-pull guns

Only Manual calibration is available, its operation is as describedabove.

CAUTION

MAINTENANCESafety Precautions

ELECTRIC SHOCK can kill.• Have an electrician install and service this

equipment.

• Turn the input power OFF at the fuse boxbefore working on equipment

• Do not touch electrically hot parts.

See additional warning information throughoutthis Operator’s Manual

GENERAL MAINTENANCE

In extremely dusty locations, dirt may clog the air passagescausing the welder to run hot. Blow dirt out of the welder withlow-pressure air at regular intervals to eliminate excessive dirtand dust build-up on internal parts.

The fan motors have sealed ball bearings which require noservice.

dRIVE ROLLS ANd GUIdE PLATES

After every coil of wire, inspect the wire drive mechanism. Clean itas necessary by blowing with low pressure compressed air. Donot use solvents for cleaning the idle roll because it may wash thelubricant out of the bearing.

All drive rolls are stamped with the wire sizes they will feed. If awire size other than that stamped on the roll is used, the drive rollmust be changed.

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

CONTACT TIP ANd GAS NOZZLE INSTALLATION

1. Choose the correct size contact tip for the electrode beingused (wire size is stenciled on the side of the contact tip) andscrew it snugly into the gas diffuser.

2. Screw the appropriate fixed gas nozzle fully onto the diffuser.Either the standard .50" (12.7 mm) flush nozzle or otheroptional flush or recessed (spray arc) nozzle sizes may beused. (Refer to www.lincolnelectric.com)

3. If using optional adjustable slip-on nozzles. (Refer towww.lincolnelectric.com)

• Be sure the nozzle insulator is fully screwed onto thegun tube and does not block the gas holes in thediffuser.

• Slip the appropriate gas nozzle onto the nozzle insulator.Either a standard .50" (12.7 mm) or optional .62" (15.9mm) I.D. slip-on gas nozzle may be used and should beselected based on the welding application.

• Adjust the gas nozzle as appropriate for the GMAWprocess to be used. Typically, the contact tip end shouldbe flush to .12" (3.2 mm) extended for the short-circuiting transfer process and .12" (3.2 mm) recessedfor spray transfer.

GUN TUBES ANd NOZZLES

1. Replace worn contact tips as required.

2. Remove spatter from inside of gas nozzle and from tip aftereach 10 minutes of arc time or as required.

GUN CABLE CLEANING

To help prevent feeding problems, clean cable liner after usingapproximately 300 pounds (136 kg) of electrode. Remove thecable from the wire feeder and lay it out straight on the floor.Remove the contact tip from the gun. Using an air hose and onlypartial pressure, gently blow out the cable liner from the gasdiffuser end.

Excessive pressure at the beginning of the cleaningprocedure may cause the dirt to form a plug.

Flex the cable over its entire length and again blow out the cable.Repeat this procedure until no further dirt comes out. If this hasbeen done and feed problems are experienced, try linerreplacement, and refer to trouble shooting section on rough wirefeeding.

LINER REMOVAL ANd REPLACEMENT

NOTE: Changing the liner for a different wire size requiresreplacement of the gas diffuser per Table D.1 to properly securethe different liner.

WARNING

CAUTION

Diameter of Electrodes Used

ReplacementLiner Part Number

Size Stencilled onEnd of Liner

Bushing

.025”-.030" Steel(0.6-0.8 mm)

KP42-25-15 .030” (0.8 mm)

.035”-.045" Steel (0.9-1.1 mm)

KP42-4045-15 .045” (1.1 mm)

3/64" Aluminum(1.2 mm)

KP42N-3545-15 3/64" (1.2 mm)

d-1

MAINTENANCEPOWER MIG® 260

d-2

MAINTENANCEPOWER MIG® 260

LINER REMOVAL, INSTALLATION ANd TRIMMINGINSTRUCTIONS FOR MAGNUM® PRO 250L

NOTE: The variation in cable lengths prevents the interchange-ability of liners between guns. Once a liner has been cut for aparticular gun, it should not be installed in another gun unless itcan meet the liner cutoff length requirement. Liners are shippedwith the jacket of the liner extended the proper amount.

1. Remove the gas nozzle and nozzle insulator, if used, to locatethe set screw in the gas diffuser which is used to hold the oldliner in place. Loosen the 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. Loosenthe set screw located in the brass connector at the feeder endof the cable and pull the liner out of the cable.

4. Insert a new untrimmed liner into the connector end of thecable. Be sure the liner bushing is stencilled appropriately forthe wire size being used.

Note: For liners KP45-3545-15 and KP45-3545-25

Before fully seating the liner bushing, it will be necessary to trimthe liner’s inner tube flush with the liner bushing using a sharpblade. After trimming, remove any burrs from inner tube andinsure that the opening is fully open.

5. Fully seat the liner bushing into the connector. tighten the setscrew on the brass cable connector. The gas diffuser, at thistime, should not be installed onto the end of the gun tube.

6. With the gas diffuser still removed from the gun tube, be surethe cable is straight, and then trim the liner to the lengthshown in Figure D.1. Remove any burrs from the end of theliner.

7. Screw the gas diffuser onto the end of the gun tube andsecurely tighten.

8. Tighten the set screw in the side of the gas diffuser againstthe cable liner using a 5/64" (2.0 mm) Allen wrench.

FIGURE D.1

This screw should only be gently tightened. Overtighteningwill split or collapse the liner and cause poor wire feeding.

GUN HANdLE dISASSEMBLY

The internal parts of the gun handle may be inspected or servicedif necessary.

The gun handle consists of two halves that are held together witha collar on each end. To open up the handle, turn the collarsapproximately 60 degrees counterclockwise (the same directionas removing a right hand thread) until the collar reaches a stop.Then pull the collar off the gun handle. If the collars are difficult toturn, position the gun handle against a corner, place a screwdriveragainst the tab on the collar and give the screwdriver a sharp blowto turn the collar past an internal locking rib.

SET SCREW

SET SCREW

BRASS CABLE CONNECTOR

GAS DIFFUSER

NOZZLE INSULATOR (IF USED)

GAS NOZZLE

.56"(14.2mm)

LINERTRIM

LENGTH

CAUTION

Counterclockwise

E-1

TROUBLESHOOTINGPOWER MIG® 260

TROUBLESHOOTINGHOW TO USE TROUBLESHOOTING GUIdE

Service and Repair should only be performed by LincolnElectric Factory Trained Personnel. Unauthorized repairsperformed on this equipment may result in danger to thetechnician and machine operator and will invalidate yourfactory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautionsdetailed throughout this manual.

This Troubleshooting Guide is provided to help you locate andrepair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. Thiscolumn describes possible symptoms that the machine mayexhibit. Find the listing that best describes the symptom that themachine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obviousexternal possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause,generally it states to contact your local Lincoln Authorized FieldService Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact your local LincolnAuthorized Field Service Facility.

WARNING

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

WWW.LINCOLNELECTRIC.COM/LOCATOR

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENTS(S)

RECOMMENDEDCOURSE OF ACTION

E-2


OUTPUT PROBLEMS

Major physical or electrical damageis evident.

Do not plug in machine or turn it on. Contact yourlocal Lincoln Authorized Field Service Facility.

If all recommended possible areas ofmisadjustment have been checked and theproblem persists, Contact your local LincolnAuthorized Field Service Facility.

No wire feed, Weld output or gas flowwhen gun trigger is pulled. Fans doesNOT operate.

1. Make sure correct voltage is applied to themachine.

2. Make certain that the power switch is in ONposition.

3. Make sure circuit breaker is reset.

No wire feed, Weld output or gas flowwhen gun trigger is pulled. Fansoperate normally.

1. The thermostat may be tripped due tooverheating. Let machine cool. Weld at lowerduty cycle.

2. Check for obstructions in air flow. Check guntrigger connections. See installation section.

3. Gun trigger may be faulty.

Arc is unstable – Poor starting. 1. Check for correct input voltage to machine.

2. Check machine reconnect panel is configuredproperly for the applied voltage.

3. Check gun tip for wear or damage and propersize – Replace.

4. Check for proper gas and flow rate for process.

5. Check work cable or loose or faultyconnections.

6. Check gun for damage or breaks.

7. Check for proper drive roll orientation andalignment.

8. Check liner for proper size.




PROBLEMS(SYMPTOMS)



E-3


Output voltage and wire feed is presentwhen gun trigger is not pulled (notactivated).

1. Remove gun assembly from machine. Ifproblem is solved, gun assembly isfaulty. Repair or replace.


2. If problem persists when gun assemblyis removed from machine, then theproblem is within the POWER MIG®

260.

Machine output is low. Welds are “cold”,weld bead is rounded or bumped updemonstrating poor wetting into plate.

1. Check input voltage. Make sure inputvoltage matches nameplate rating andreconnect panel configuration.

2. Make sure settings for wire feed speedand voltage are correct for the processbeing used.

3. Make sure output polarity is correct forprocess being used.

4. Check welding cables and gun assemblyfor loose or faulty connections.

FEEDING PROBLEMS

No wire feed when gun trigger is pulled.Fans run, gas flows and machine hascorrect open circuit voltage (38V Max.) –weld output.

1. If the wire drive motor is running, makesure that the correct drive rolls areinstalled in the machine.


2. Check for clogged cable liner or contacttip.

3. Check for proper size cable liner andcontact tip.

4. Check if the spool gun mode is selectedon the screen.

5. Check wire spindle for ease of rotationand adjust break tension knob ifnecessary.




PROBLEMS(SYMPTOMS)



E-4


The wire feed stops while welding. Whentrigger is released and pulled again thewire feed starts.

1. Check the wire feed drive rolls and motorfor smooth operation.

2. Check for restrictions in the wire feedpath.

3. Make sure gun liner and tip are correctfor wire size being used.

4. Check spindle for ease of rotation.

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

No control of wire feed speed. Othermachine functions are normal.

1. The wire feed speed control may bedirty. Rotate several times and check ifproblem is resolved.

GAS FLOW PROBLEMS

Gas does not flow when gun trigger ispulled.

1. Make sure gas supply is connectedproperly and turned “ON”.


2. If the gas solenoid does not actuate(click) when the gun trigger is pulled,there may be a restriction in the gassupply line.

3. The gun cable assembly may be faulty.Check or replace.

4. If gas solenoid does not operate whengun trigger is pulled, the problem iswithin the POWER MIG® 260.

5. Make sure the gun is pushed all the wayinto gun mount and is properly seated.

SCREEN PROBLEMS

Error code 213 is displayed on screen 1. Communication between display P.C.board and power control board.

1. Cycle power to machine.

ERROR CODE 36, Thermal trip 1. Machine is overloaded 1. Welding duty should not exceed machinerating

2. Poor airflow 2. Not enough space behind the back of themachine

ERROR CODE 81, Main motor overload 1. Drive rolls don’t match wire size or wiretype

1. Check drive rolls

2. Bad gun liner 2. Try different gun

ERROR 95, Gun motor overload 1. Drive rolls don’t match wire size or wiretype

1. Check drive rolls

2. Bad gun liner 2. Try different gun

ERROR CODE 213, Control board offline No communication between UI & Control PCB 1. Check UI & Control board connection

2. Replace Control PCB



G-1

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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 manufacturingand selling high quality welding equipment, consumables, andcutting equipment. Our challenge is to meet the needs of ourcustomers and to exceed their expectations. On occasion,purchasers may ask Lincoln Electric for advice or informationabout their use of our products. We respond to our customersbased on the best information in our possession at that time.Lincoln Electric is not in a position to warrant or guarantee suchadvice, and assumes no liability, with respect to such informationor advice. We expressly disclaim any warranty of any kind,including any warranty of fitness for any customer’s particularpurpose, with respect to such information or advice. As a matterof practical consideration, we also cannot assume any respon-sibility for updating or correcting any such information or adviceonce it has been given, nor does the provision of information oradvice create, expand or alter any warranty with respect to thesale of our products.

Lincoln Electric is a responsive manufacturer, but the selectionand use of specific products sold by Lincoln Electric is solelywithin the control of, and remains the sole responsibility of thecustomer. Many variables beyond the control of Lincoln Electricaffect the results obtained in applying these types of fabricationmethods and service requirements.

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.

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IM10464 Power MIG 260 - Lincoln Electric · 5/16/2018 · Power MIG ®260 Need Help? Call 1.888.935.3877 to talk to a Service Representative Hours of Operation: 8:00 AM to 6:00 PM