Lincoln Electric Welder IM10096 User Manual
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IM10096  
POWER MIG® 256  
July, 2011  
For use with machine Code Numbers  
11780, 11781  
For use with machine Code Numbers  
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 thoughtful operation on  
your part. DO NOT INSTALL,  
OPERATE OR REPAIR THIS  
EQUIPMENT WITHOUT READ-  
ING THIS MANUAL AND THE  
SAFETY PRECAUTIONS CON-  
TAINED THROUGHOUT. And,  
most importantly, think before  
you act and be careful.  
OPERATORʼSꢀMANUAL  
Copyright © 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 WEBꢀSITE: www.lincolnelectric.com  
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SAFETY  
ELECTRIC SHOCK can  
ARC RAYS can burn.  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
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  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
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  
themselves to the arc rays or to hot spatter or metal.  
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:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases. When welding, keep  
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  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) 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. In confined spaces or in some circum-  
stances, outdoors, a respirator may be required.  
Additional precautions are also required when welding  
on galvanized steel.  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be 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 and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5. b. The operation of welding fume control equipment is affected  
by various factors including proper use and positioning of  
the equipment, maintenance of the equipment and the spe-  
cific welding procedure and application involved. Worker  
exposure level should be checked upon installation and  
periodically thereafter to be certain it is within applicable  
OSHA PEL and ACGIH TLV limits.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
5.d. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
5.e. Read and understand the manufacturerʼs instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employerʼs safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.f. Also see item 1.b.  
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SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can  
cause fire or explosion.  
6.a. Remove fire hazards from the welding area.  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
If this is not possible, cover them to prevent  
process used and properly operating  
the welding sparks from starting a fire.  
regulators designed for the gas and  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions 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.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact  
can cause overheating and create a fire hazard.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper 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  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except 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 for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturerʼs  
recommendations.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturerʼs recommendations.  
6.h. Also see item 1.c.  
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention  
During Welding, Cutting and Other Hot Work”, available  
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma  
022690-9101.  
6.j. Do not use a welding power source for pipe thawing.  
Refer to http://www.lincolnelectric.com/safety for additional safety information.  
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SAFETY  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque dʼincendie dû aux étincelles.  
Pour votre propre protection lire et observer toutes les instructions  
et les précautions de sûreté specifiques qui parraissent dans ce  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque dʼincendie.  
Sûreté Pour Soudage A LʼArc  
8. Sʼassurer que la masse est connectée le plus prés possible  
de la zone de travail quʼil est pratique de le faire. Si on place  
la masse sur la charpente de la construction ou dʼautres  
endroits éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques dʼincendie ou dʼechauffement des chaines et des  
câbles jusquʼà ce quʼils se rompent.  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à lʼélectrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien sʼisoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher  
metallique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
d.Ne jamais plonger le porte-électrode dans lʼeau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode sʼapplicuent aussi au pistolet de  
soudage.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
dʼopérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de nʼimporte quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi quʼun verre blanc afin de se protéger les yeux du ray-  
onnement de lʼarc et des projections quand on soude ou  
quand on regarde lʼarc.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
lʻarc.  
c. Protéger lʼautre personnel travaillant à proximité au  
soudage à lʼaide dʼécrans appropriés et non-inflammables.  
1. Relier à la terre le chassis du poste conformement au code de  
lʼélectricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront  
effectués par un électricien qualifié.  
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-  
er à lʼinterrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de lʼarc de  
soudage. Se protéger avec des vêtements de protection libres  
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où lʼon pique le laitier.  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
CUSTOMER ASSISTANCE POLICY  
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-  
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln  
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-  
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-  
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,  
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or  
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any  
warranty with respect to the sale of our products.  
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control  
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in  
applying these types of fabrication methods and service requirements.  
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com  
for any updated information.  
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 “Support” and then “Register  
Your Product”. 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.  
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TABLE OF CONTENTS  
Page  
________________________________________________________________________  
Installation .......................................................................................................Section A  
Technical Specifications ........................................................................................A-1  
Safety Precautions.................................................................................................A-2  
®
Uncrating the POWER MIG 256 ..........................................................................A-2  
Location .................................................................................................................A-2  
Input Power, Grounding and Connection Diagram ........................................A-2, A-3  
Output Polarity Connections..................................................................................A-3  
Gun and Cable Installation ....................................................................................A-3  
Shielding Gas ........................................................................................................A-4  
Auxiliary Power Receptacle...................................................................................A-4  
Coil Claw™ Installation..........................................................................................A-4  
________________________________________________________________________  
Operation .........................................................................................................Section B  
Safety Precautions.................................................................................................B-1  
Product Description ...............................................................................................B-2  
Recommended Processes and Equipment ...........................................................B-2  
Welding Capability.................................................................................................B-2  
Limitations..............................................................................................................B-2  
Description of Controls ..........................................................................................B-2  
Wire Size Conversion Parts...................................................................................B-3  
Procedure for Changing Drive Roll........................................................................B-3  
Wire Reel Loading .................................................................................................B-4  
Mounting of 10 to 44 lb. Spools .............................................................................B-4  
To Start the Welder................................................................................................B-4  
Feeding Electrode..................................................................................................B-5  
Idle Roll Pressure Setting ......................................................................................B-5  
Wire Drive Configuration....................................................................................... B-6  
Making a Weld.......................................................................................................B-7  
Avoiding Wire Feeding Problems ..........................................................................B-7  
Fan Control............................................................................................................B-7  
Input Line Voltage Protection.................................................................................B-7  
Wire Feed Overload Protection .............................................................................B-7  
Welding Thermal Overload Protection...................................................................B-8  
Overcurrent Protection...........................................................................................B-8  
Welding Procedure Information .............................................................................B-8  
________________________________________________________________________  
Accessories.....................................................................................................Section C  
Drive Roll Kits........................................................................................................C-1  
Dual Cylinder Mounting Kit ...................................................................................C-1  
Alternative Magnum GMAW Gun and Cable Assemblies .....................................C-1  
Magnum Gun Connection Kit ...............................................................................C-1  
Spool Gun..............................................................................................................C-1  
®
Connecting the Spool Gun to the POWER MIG 256 ....................................................C-2  
Making a Weld with the Spool Gun .......................................................................C-2  
Making a Weld with the Magnum SG Spool Gun ..................................................C-3  
________________________________________________________________________  
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TABLE OF CONTENTS  
Page  
________________________________________________________________________  
Maintenance ....................................................................................................Section D  
Safety Precautions ................................................................................................D-1  
General Maintenance ............................................................................................D-1  
Drive Rolls and Guide Plates.................................................................................D-1  
Contact Tip and Gas Nozzle Installation ...............................................................D-1  
Gun Tubes and Nozzles........................................................................................D-1  
Gun Cable Cleaning ..............................................................................................D-1  
Liner Removal and Replacement ..........................................................................D-2  
Liner Removal, Installation and Trimming Instructions for Magnum® PRO 250L..D-2  
Gun Handle Disassembly......................................................................................D-3  
________________________________________________________________________  
Troubleshooting..............................................................................................Section E  
How to Use Troubleshooting Guide.......................................................................E-1  
Troubleshooting Guide ............................................................................E-2 thru E-4  
________________________________________________________________________  
Wiring Diagram and Dimension Print............................................................Section F  
________________________________________________________________________  
Parts Manual....................................................................................................Appendix  
®
POWER MIG 256 ...................................................................................................P-680  
Magnum® PRO 250L Gun .........................................................................P-202-H.2  
________________________________________________________________________  
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A-1  
A-1  
INSTALLATION  
®
TECHNICAL SPECIFICATIONS – POWER MIG 256  
INPUT – SINGLE PHASE ONLY  
Standard Voltage/Phase/Frequency  
208/230/1/60 Hz  
Input Current @ 200 Amp Rated Output Input Current @ 250 Amp Rated Output  
*47/44 Amps  
41/20/16 Amps  
*56/52 Amps  
47/24/19 Amps  
230/460/575/1/60 Hz  
RATED OUTPUT  
Duty Cycle  
40%  
Amps  
Volts at Rated Amperes  
26 Volts  
250 Amps  
200 Amps  
145 Amps  
60%  
28 Volts  
100%  
26 Volts  
OUTPUT  
Welding Current Range (Continuous) Maximum Open Circuit Voltage  
Welding Voltage Range  
30 – 300 Amps 40 Volts  
10-28 Volts  
RECOMMENDED INPUT WIRE AND FUSE SIZES  
Input Ampere  
Rating On  
Type S, SO, ST, STO or extra  
hard usage input cord  
AWG (IEC) Sizes  
Input Voltage  
Fuse or Breaker  
Size (Super Lag)  
Frequency (Hz)  
Nameplate  
208/60  
230/60  
60  
60  
56A  
52A  
8
10  
230/60  
460/60  
575/60  
60  
30  
25  
47A  
24A  
19A  
10  
14  
14  
WIRE SPEED RANGE  
Wire Speed  
50 – 700 IPM (1.27 – 17.8 m/minute)  
PHYSICAL DIMENSIONS  
Height  
Width  
With Coil Claw™ Without Coil Claw™  
Depth  
Weight  
220 lbs  
100 kg.  
32.56 in.  
827 mm  
20.12 in.  
512 mm  
19.15 in.  
487 mm  
39.9in.  
1014 mm  
TEMPERATURE RANGES  
OPERATING TEMPERATURE RANGE  
STORAGE TEMPERATURE RANGE  
-4°F to 104°F(-20°C to +40°C)  
-40°F to 185°F(-40°C to +85°C)  
* With 115V receptacle loaded to 15A.  
®
POWER MIG 256  
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A-2  
A-2  
INSTALLATION  
Read entire installation section before starting  
INPUT POWER, GROUNDING AND  
CONNECTION DIAGRAM  
installation.  
SAFETY PRECAUTIONS  
WARNING  
WARNING  
ELECTRIC SHOCK can kill.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts such as  
• Only qualified personnel should  
output terminals or internal wiring.  
perform this installation.  
• All input power must be electrically dis-  
connected before proceeding.  
• Only personnel that have read  
®
and understood the POWER MIG  
256 Operatorʼs Manual should  
install and operate this equip-  
ment.  
1. Before starting the installation, check with the local  
power company if there is any question about  
whether your power supply is adequate for the volt-  
age, amperes, phase, and frequency specified on  
the welder rating plate. Also be sure the planned  
installation will meet the U.S. National Electrical  
Code and local code requirements. This welder  
may be operated from a single phase line or from  
one phase of a two or three phase line.  
• Machine must be grounded per  
any national, local or other applic-  
able electrical codes.  
®
• The POWER MIG 256 power  
switch is to be in the OFF posi-  
tion when installing work cable  
and gun and when connecting  
other equipment.  
®
UNCRATING THE POWER MIG 256  
2. Models that have multiple input voltages specified  
on the nameplate (e.g. 208/230) are shipped con-  
nected for the highest voltage. If the welder is to be  
operated on lower voltage, it must be reconnected  
according to the instructions in Figure A.1 for dual  
voltage machines and Figure A.2 for triple voltage  
machines.  
Cut banding and lift off cardboard carton. Cut banding  
holding the machine to the skid. Remove foam and  
corrugated packing material. Untape accessories from  
Gas Bottle Platform. Unscrew the two wood screws  
(at the Gas Bottle Platform) holding the machine to  
the skid. Roll the machine off the skid assembly.  
LOCATION  
WARNING  
Locate the welder in a dry location where there is free  
circulation of clean air into the louvers in the back and  
the louvers out the front. A location that minimizes the  
amount of smoke and dirt drawn into the rear louvers  
reduces the chance of dirt accumulation that can  
block air passages and cause overheating.  
Make certain that the input power is electrically  
disconnected before removing the screw on the  
reconnect panel access cover.  
------------------------------------------------------------------------  
FIGURE A.1 — Dual Voltage Machine Input  
Connections  
®
POWER MIG 256  
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A-3  
A-3  
INSTALLATION  
OUTPUT POLARITY CONNECTIONS  
The welder, as shipped from the factory, is connected  
for electrode positive (+) polarity. This is the normal  
polarity for GMAW.  
3. The 208/230 volt 60 Hz model POWER MIG is  
shipped with a 10 ft. input cable and plug connect-  
ed to the welder. Obtain a receptacle and mount it  
in a suitable location. Be sure it can be reached by  
the plug on the input cable attached to the welder.  
Mount with the grounding terminal at the top to  
allow the power cable to hang down without bend-  
ing.  
If negative (–) polarity is required, interchange the  
connection of the two cables located in the wire drive  
compartment near the front panel. The electrode  
cable, which is attached to the wire drive, is to be con-  
nected to the negative (–) labeled terminal and the  
work lead, which is attached to the work clamp, is to  
be connected to the positive (+) labeled terminal.  
The 230/460/575 volt 60 Hz model is not equipped  
with a plug, an input cable or a receptacle.  
FIGURE A.2 — Triple Voltage Machine Input  
Connection  
GUN AND CABLE INSTALLATION  
The Magnum® PRO 250L gun and cable provided with the  
®
POWER MIG 256 is factory installed with a liner for .035-  
.045" (0.9-1.1 mm) electrode and an .035" (0.9 mm) contact  
tip. Install the .045” tip (also provided) if this wire size  
is being used.  
WARNING  
Turn the welder power switch off before installing  
gun and cable.  
(See Figure A.4)  
4. Using the instructions in Figure A.3, have a quali-  
fied electrician connect the receptacle or cable to  
the input power lines and the system ground per the  
U.S. National Electrical Code and any applicable  
local codes. See "Technical Specifications" at the  
beginning of this chapter for proper wire sizes. For  
long runs over 100 feet, larger copper wires should  
be used. Fuse the two hot lines with super lag type  
fuses as shown in the following diagram. The center  
contact in the receptacle is for the grounding  
connection. A green wire in the input cable  
connects this contact to the frame of the welder.  
This ensures proper grounding of the welder frame  
when the welder plug is inserted into the receptacle.  
1. Lay the cable out straight.  
2. Unscrew the Hand Screw on the drive unit front  
end (inside wire feed compartment) until tip of  
screw no longer protrudes into Gun Adapter open-  
ing as seen from front of machine. (See Figure A.4)  
3. Insert the male end of gun cable into the Gun  
Adapter through the opening in front panel. Make  
sure connector is fully inserted and tighten Hand  
Screw.  
4. Connect the Gun Trigger Connector from the gun  
and cable to the mating Receptacle inside the  
compartment located left just inside the opening on  
the Front Panel. Make sure that the keyways are  
aligned, insert and tighten retaining ring.  
FIGURE A.3 —Receptacle Diagram  
FIGURE A.4  
YSTEM  
CONNECT TO A S  
E THE  
ND/OR  
GROUNDING WIRE. SE  
UNITED STATES NATIONAL  
ELECTRICAL CODE A  
LOCAL CODES FOR OTHER  
DETAILS AND MEANS FOR  
PROPER GROUNDING.  
Hand Screw  
F
CONNECT TO HOT WIRES O  
Receptacle  
INGLE  
A THREE-WIRE, S  
PHASE SYSTEM OR TO ONE  
PHASE OF A TWO OR  
Gun Adapter  
Gun Trigger  
Connector  
THREE PHASE SYSTEM.  
Male End  
Gun and Cable  
®
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A-4  
A-4  
INSTALLATION  
7. Standing to one side, open the cylinder valve slowly a  
fraction of a turn. When the cylinder pressure gauge  
pointer stops moving, open the valve fully.  
SHIELDING GAS  
[For Gas Metal Arc Welding(GMAW) Processes]  
Customer must provide cylinder of appropriate type shield-  
ing gas for the process being used.  
WARNING  
Never stand directly in front of or behind the flow regu-  
lator when opening the cylinder valve. Always stand to  
one side.  
A gas flow regulator, for Argon blend gas, an inlet gas hose,  
and a regulator adapter are factory provided with the  
®
POWER MIG 256. When using 100% CO2, the regulator  
--------------------------------------------------------------------------------  
8. The flow regulator is adjustable. Adjust it to the flow rate  
recommended for the procedure and process being used  
before making the weld.  
adapter will be required to connect the regulator to the gas  
bottle.  
CYLINDER may explode if  
damaged.  
AUXILIARY POWER RECEPTACLES  
(For 208/230V Models only)  
• Gas under pressure is explosive.  
Always keep gas cylinders in an upright  
position and always keep chained to  
undercarriage or stationary support.  
See American National Standard Z49.1, “Safety in  
Welding and Cutting” published by the American  
Welding Society.  
This machine is equipped with 15Amp 120V receptacle with  
15Amp Circuit Breaker. The receptacle is UL and CSA  
approved.  
------------------------------------------------------------------------  
COIL CLAW™ INSTALLATION  
INSTALL SHIELDING GAS SUPPLY AS FOLLOWS:  
®
The Coil Claw™ and mounting screws are provided  
1. Set gas cylinder on rear platform of POWER MIG 256.  
®
as an optional accessory for the POWER MIG 256  
.
Hook chain in place to secure cylinder to rear of welder.  
2. Remove the cylinder cap. Inspect the cylinder valves and  
regulator for damaged threads, dirt, dust, oil or grease.  
Remove dust and dirt with a clean cloth.  
This user-install accessory provides cable manage-  
ment for the machine.  
DO NOT ATTACH THE REGULATOR IF OIL, GREASE  
OR DAMAGE IS PRESENT! Inform your gas supplier of  
this condition. Oil or grease in the presence of high pres-  
sure oxygen is explosive.  
WARNING  
Turn the welder power switch OFF  
before installing Coil Claw™.  
3. Stand to one side away from the outlet and open the  
cylinder valve for an instant. This blows away any dust or  
dirt which may have accumulated in the valve outlet.  
------------------------------------------------------------------------  
1. Unwrap Coil Claw™ from its protective paper and  
remove the bag of mounting screws from the back  
of the Coil Claw™.  
WARNING  
Be sure to keep your face away from the valve  
outlet when “cracking” the valve.  
2. Mount the Coil Claw™ using the provided mount-  
ing screws to the left side of the machine, when  
viewed from the front. Make sure the Coil Claw™ is  
firmly mounted. (See Figure A.5)  
--------------------------------------------------------------------------------  
4. Attach the flow regulator to the cylinder valve and tighten  
the union nut(s) securely with a wrench.  
NOTE: If connecting to 100% CO2 cylinder, the regulator  
adapter provided must be installed between the regulator  
and cylinder valve.  
FIGURE A.5  
5. Attach one end of the inlet gas hose to the outlet fitting of  
MOUNTING  
SCREWS  
®
the flow regulator, the other end to the POWER MIG  
256 rear fitting marked “Feeder” and tighten the union  
nuts securely with a wrench.  
6. Before opening the cylinder valve, turn the regulator  
adjusting knob counterclockwise until the adjusting  
spring pressure is released.  
COIL CLAW™  
®
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B-1  
B-1  
OPERATION  
Read entire Operation section before  
®
operating the POWER MIG 256.  
WARNING  
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  
dangerous.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to  
remove fumes from breathing  
zone.  
WELDING SPARKS can  
cause fire or explosion.  
• Keep flammable material away.  
• Do not weld on closed contain-  
ers.  
ARC RAYS can burn eyes  
and skin.  
• Wear eye, ear and body protec-  
tion.  
Observe all safety information throughout  
this manual.  
------------------------------------------------------------  
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B-2  
B-2  
OPERATION  
PRODUCT DESCRIPTION  
The POWER MIG 256 is a complete semiautomatic  
LIMITATIONS  
®
®
POWER MIG 256 WILL NOT operate satisfactorily if  
constant voltage DC arc welding machine built to meet  
NEMA specifications. It combines a constant voltage  
power source and a constant speed wire feeder with a  
microcomputer-based controller to form a reliable high-  
performance welding system. A simple control  
scheme, consisting of continuous full range voltage  
and wire feed speed controls, provides versatility with  
powered with a portable or in-plant generating system.  
DESCRIPTION OF CONTROLS  
See Figure B.1  
1. Power ON/OFF Switch — Place the lever in the  
®
"ON" position to energize the POWER MIG 256.  
When the power is on, the red LED display lights  
illuminate.  
®
ease of use and accuracy. The POWER MIG 256 is  
Spool Gun ready and includes a second Gas Solenoid  
for Spool Gun use. Refer to Accessories Section for  
Applicable Spool Guns.  
2. Voltage Control - This is a continuous control that  
gives full range adjustment of power source output  
voltage. It can be adjusted while welding over its 10  
to 28 volt range.  
Other features include a 2" (51 mm) O.D. wire reel  
spindle with adjustable brake, an integral gas cylinder  
mounting undercarriage, an adjustable CO2 or Argon  
blend flow regulator with cylinder pressure gauge and  
inlet hose, a 15 ft. (4.6 m) Magnum® PRO 250L GMAW  
gun and cable, a 10 ft. (3.1 m) power cable with plug  
(208/230V models only) and a 10ft. (3.1 m) work cable  
with clamp.  
3. Wire Speed Control - This controls the wire feed  
speed from 50 – 700 inches per minute (1.2 – 17.8  
m/min). The control can be preset on the dial to the  
setting specified on the Procedure Decal on the  
inside of the wire compartment door. Wire speed is  
not affected when changes are made in the voltage  
control.  
®
The POWER MIG 256 features built in timer functions  
4. Trigger Switch - Select the desired mode with the  
that provide variable burnback control, a spot function,  
a selectable 4-step trigger interlock and adjustable  
"Run In" for wire starting optimization. Optional  
features include a Dual Cylinder Mounting kit.  
toggle switch:  
• Normal Welding mode (2 Step) provides weld  
power only while the trigger switch is depressed.  
• 4-Step Trigger interlock mode eliminates the need  
to hold the gun trigger while welding. It operates in 4  
steps:  
RECOMMENDED PROCESSES AND  
EQUIPMENT  
®
1. Close trigger and establish welding arc.  
2. Release trigger and continue welding.  
3. Reclose trigger near end of weld.  
The POWER MIG 256 is recommended for GMA  
welding processes using 10 to 44 lb (4.5 to 20 kg)  
®
2"(51 mm) I.D. spools or 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)  
4. Release trigger again to stop welding.  
®
If the arc is broken while using this feature, the  
machine will reset to the "trigger off" condition  
automatically.  
aluminum and .045" (1.1 mm) Outershield and  
®
Ultracore ; as well as .035" (0.9 mm) and .045" (1.1  
mm) Innershield® self-shielding electrodes.  
Note: 4 Step Trigger interlock mode does not function  
with a Spool Gun.  
®
The POWER MIG 256 is factory equipped to feed .035"  
(0.9 mm) and .045(1.1mm) electrode. It also includes a  
200A, 60% duty cycle (or 250A, 40% duty cycle) rated,  
15 ft. (4.6 m) GMAW gun and cable assembly  
equipped for these wire sizes. Use of GMAW  
processes requires a supply of shielding gas.  
5. Spot Time - Spot Weld Mode is used for tack  
welding parts into position or for spot plug welds to  
hold thin sheet metal together prior to manual stitch  
or continuous welding. To use this feature, adjust  
the On-Time (0-25 seconds) as appropriate to  
obtain the desired results. Closing the trigger  
initiates a single timed spot weld cycle.  
WELDING CAPABILITY  
®
The POWER MIG 256 is rated at 250 amps @ 26 volts,  
Plug welds are made by using a punch to make a  
3/16" (5 mm) diameter hole in the top sheet and arc  
welding through the hole into the back sheet.  
at a 40% duty cycle based on a ten minute cycle time.  
It is capable of higher duty cycles at lower output  
currents and capable of up to 300 Amps at lower duty  
cycles.  
®
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B-3  
B-3  
OPERATION  
The drive rolls installed with the POWER MIG® 256  
have two grooves one for .035(0.9mm) wire Solid  
Steel electrode and the other for .045(1.1mm) wire.  
Drive roll size is stenciled on each side of the drive  
roll. If feeding problems occur, check to make sure  
that the wire size and the drive roll size matches. See  
"Procedure for Changing Drive Roll" in this section.  
This information also appears on the Procedure Decal  
on the door inside the wire compartment.  
To make spot plug welds, punch 3/16" (5 mm) holes  
in the top sheet. Set the Spot Time control to  
approximately 1.2 seconds and set the procedure for  
the metal thickness to be welded. Install spot weld  
nozzle (if available) on gun and press it against the  
top sheet so the top and bottom sheets are tight  
together. Close trigger and hold it closed until the arc  
goes out. If a spot weld nozzle is not used, smoother  
welds will result by moving the welding wire in a  
small circle during the weld.  
WIRE SIZE CONVERSION PARTS  
The POWER MIG® 256 is rated to feed .025 through  
.045" (0.6-1.1 mm) solid or cored electrode sizes.  
6. Run-In Mode - is used to adjust the starting wire  
feed speed. Starting conditions for certain welding  
applications can be improved with adjustment to the  
Run-In speed. The control allows for initial starting  
speeds from 50 - 150 IPM. After the arc is started,  
the set point on the wire feed speed control will  
dominate. Note that the Run-in is not functional with  
the spool gun. Also note that if Run-in is set fully  
counter clockwise to "OFF", Run-in speed will equal  
the preset WFS on the machine.  
The drive roll kits and Magnum® PRO 250L gun and  
cable parts are available to feed different sizes and  
types of electrodes. See Accessories section.  
PROCEDURE FOR CHANGING  
DRIVE AND IDLE ROLL SETS  
1. Turn off the power source.  
7. Burnback Time - Provides manual adjustment of  
the burnback time (0-250 milliseconds) for any  
selected welding mode. this control should be set as  
low as possible without the wire "sticking" in the  
puddle after each weld. Too long of a burnback time  
may form a "ball" on the end of the wire, or may  
"flash back" to the gun tip.  
2. Release the pressure on the idle roll by swinging  
the adjustable pressure arm down toward the back  
of the machine. Lift the cast idle roll assembly and  
allow it to sit in an upright position.  
3. Remove the outside wire guide retaining plate by  
loosening the two large knurled screws.  
4. Twist the drive roll retaining mechanism to the  
unlocked position as shown below and remove the  
drive roll. (See Figure B.2)  
8. Spool Gun Gas Connection  
FIGURE B.1  
FIGURE B.2  
LOCKED POSITION  
UNLOCKED POSITION  
4
5
5. Remove the inside wire guide plate.  
6. Replace the drive and idle rolls and inside wire  
guide with a set marked for the new wire size.  
NOTE: Be sure that the gun liner and contact tip  
are also sized to match the selected wire size.  
7. Manually feed the wire from the wire reel, over the  
drive roll groove and through the wire guide and  
then into the brass bushing of the gun and cable  
assembly.  
6
3
7
2
8
8. Replace the outside wire guide retaining plate by  
tightening the two large knurled screws. Reposition  
the adjustable pressure arm to its original position  
to apply pressure. Adjust pressure as necessary.  
1
®
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B-4  
B-4  
OPERATION  
WIRE REEL LOADING - READI  
FIGURE B.3  
ADAPTER  
REELS, SPOOLS OR COILS  
2 IN. O.D.  
SPINDLE  
RETAINING  
SPRING  
To Mount a 30 Lb. (14 kg) Readi-Reel Package  
(Using the Molded Plastic K363-P Readi-Reel  
Adapter:)  
RETAINING  
COLLAR  
(See Figure B.3)  
BRAKE  
HOLDING  
PIN  
GROOVES  
1. Open the Wire Drive Compartment Door.  
READI-REEL  
2. Depress the Release Bar on the Retaining Collar  
and remove it from the spindle.  
INSIDE  
CAGE  
RELEASE  
BAR  
WIRES  
3. Place the Optional Adapter on the spindle.  
To Mount 10 to 44 Lb. (4.5-20 kg) Spools (12"/300  
mm Diameter) or 14Lb.(6 Kg) Innershield Coils:  
4. Re-install the Retaining Collar. Make sure that the  
Release Bar "pops up" and that the collar retainers  
fully engage the retaining ring groove on the spindle.  
(For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil  
Adapter must be used).  
5. Rotate the spindle and adapter so the retaining  
spring is at the 12 o'clock position.  
(For 10 lb.(4.5 Kg) 8 inch(203mm) diameter spools, a  
K468 spindle adapter must be used).  
6. Position the Readi-Reel so that it will rotate in a  
direction when feeding so as to be de- reeled from  
top of the coil.  
1. Open the Wire Drive Compartment Door.  
2. Depress the Release Bar on the Retaining Collar  
and remove it from the spindle.  
7. Set one of the Readi-Reel inside cage wires on the  
slot in the retaining spring tab.  
3. Place the spool on the spindle making certain the  
spindle brake pin enters one of the holes in the  
back side of the spool (Note: an arrow mark on the  
spindle lines up with the brake holding pin to assist  
in lining up a hole). Be certain the wire comes off  
the reel in a direction so as to de-reel from the top  
of the coil.  
8. Lower the Readi-Reel to depress the retaining  
spring and align the other inside cage wires with the  
grooves in the molded adapter.  
9. Slide cage all the way onto the adapter until the  
retaining spring "pops up" fully.  
4. Re-install the Retaining Collar. Make sure that the  
Release Bar "pops up" and that the collar retainers  
fully engage the retaining ring groove on the spin-  
dle.  
CAUTION  
CHECK TO BE SURE THE RETAINING SPRING  
HAS FULLY RETURNED TO THE LOCKING  
POSITION AND HAS SECURELY LOCKED THE  
READI-REEL CAGE IN PLACE. RETAINING  
SPRING MUST REST ON THE CAGE, NOT THE  
WELDING ELECTRODE.  
TO START THE WELDER  
Turn the "Power Switch" switch to "ON". This lights  
the red LED display lights. With the desired voltage  
and wire speed selected, operate the gun trigger for  
welder output and to energize the wire feed motor.  
-----------------------------------------------------------------------  
10. To remove Readi-Reel from Adapter, depress  
retaining spring tab with thumb while pulling the  
Readi-Reel cage from the molded adapter with  
both hands. Do not remove adapter from spindle.  
®
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B-5  
B-5  
OPERATION  
FEEDING WIRE ELECTRODE  
The pressure arm controls the amount of force the  
drive rolls exert on the wire. Proper adjustment of both  
pressure arm gives the best welding performance. For  
best results, set both pressure arms to the same  
value.  
WARNING  
When triggering, the electrode and drive mecha-  
nism are electrically "hot" relative to work and  
ground and remain "hot" several seconds after  
the gun trigger is released.  
Set the pressure arm as follows (See Figure B.4):  
Aluminum wires  
Cored wires  
between 1 and 3  
between 3 and 4  
-----------------------------------------------------------------------  
Steel, Stainless wires between 4 and 6  
NOTE: Check that drive rolls, guide plates and gun  
parts are proper for the wire size and type being used.  
Refer to Table C.1 in Accessories section.  
FIGURE B.4  
1. Turn the Readi-Reel or spool until the free end of  
the electrode is accessible.  
2. While securely holding the electrode, cut off the  
bent end and straighten the first six inches. (If the  
electrode is not properly straightened, it may not  
feed properly through the wire drive system).  
CORED WIRES  
SOLID WIRES  
1
3
5
ALUMINUM  
2
4
6
OU TER SHIELD  
METALSHIELD  
INNERSHIELD  
STEEL  
STAINLESS  
3. Release the pressure on the idle roll by swinging the  
adjustable pressure arm down toward the back of  
the machine. Lift the cast idle roll assembly and  
allow it to sit in an upright position. Leave the outer  
wire guide plate installed. Manually feed the wire  
through the incoming guide bushing and through the  
guide plates (over the drive roll groove). Push a  
sufficient wire length to assure that the wire has fed  
into the gun and cable assembly without restriction.  
Reposition the adjustable pressure arm to its origi-  
nal position to apply pressure to the wire.  
4. Press gun trigger to feed the electrode wire through  
the gun.  
IDLE ROLL PRESSURE SETTING  
WARNING  
ELECTRIC SHOCK can kill.  
• Turn the input power OFF at the weld-  
ing power source before installation or  
changing drive rolls and/or guides.  
• Do not touch electrically live parts.  
• When inching with the gun trigger, electrode  
and drive mechanism are "hot" to work and  
ground and could remain energized several sec-  
onds after the gun trigger is released.  
• Only qualified personnel should perform mainte-  
nance work.  
------------------------------------------------------------------------  
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B-6  
B-6  
OPERATION  
5. Loosen the socket head cap screw that holds the  
connector bar against the gun bushing.  
WIRE DRIVE CONFIGURATION  
Important: Do not attempt to completely  
remove the socket head cap screw.  
(See Figure B.5)  
Changing the Gun Receiver Bushing  
WARNING  
6. Remove the outer wire guide, and push the gun  
bushing out of the wire drive. Because of the pre-  
cision fit, light tapping may be required to remove  
the gun bushing.  
ELECTRIC SHOCK can kill.  
• Turn the input power OFF at the weld-  
ing power source before installation  
or changing drive rolls and/or guides.  
• Do not touch electrically live parts.  
• When inching with the gun trigger, electrode and  
drive mechanism are "hot" to work and ground  
and could remain energized several seconds  
after the gun trigger is released.  
7. Disconnect the shielding gas hose from the gun  
bushing, if required.  
8. Connect the shielding gas hose to the new gun  
bushing, if required.  
• Only qualified personnel should perform mainte-  
nance work.  
9. Rotate the gun bushing until the thumb screw hole  
aligns with the thumb screw hole in the feed plate.  
Slide the gun receiver bushing into the wire drive  
and verify the thumb screw holes are aligned.  
------------------------------------------------------------------------  
Tools required:  
• 1/4" hex key wrench.  
10. Tighten the socket head cap screw.  
Note: Some gun bushings do not require the use of  
the thumb screw.  
11. Insert the welding gun into the gun bushing and  
tighten the thumb screw.  
1. Turn power off at the welding power source.  
2. Remove the welding wire from the wire drive.  
3. Remove the thumb screw from the wire drive.  
4. Remove the welding gun from the wire drive.  
Figure B.5  
THUMB SCREW  
GUN RECEIVER BUSHING  
OUTER WIRE GUIDE  
CONNECTOR BLOCK  
SOCKET HEAD  
CAP SCREW  
LOOSEN  
TIGHTEN  
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B-7  
B-7  
OPERATION  
11. When no more welding is to be done, close valve on  
gas cylinder (if used), momentarily operate gun trig-  
ger to release gas pressure, and turn off POWER  
MAKING A WELD  
1. Check that the electrode polarity is correct for the process  
®
MIG 256.  
being used, then turn the power switch ON.  
AVOIDING WIRE FEEDING  
PROBLEMS  
Wire feeding problems can be avoided by observing the  
following gun handling procedures:  
2. Set desired arc voltage and wire speed for the particular  
electrode wire, material type and thickness, and gas (for  
GMAW) being used. Use the Application Chart on the door  
inside the wire compartment as a quick reference for some  
common welding procedures.  
3. Select the desired mode as described in "Description of  
Controls” Section.  
• Do not kink or pull cable around sharp corners.  
• Keep the gun cable as straight as possible when weld-  
ing or loading electrode through cable.  
4. Press the trigger to feed the wire electrode through the  
gun and cable and then cut the electrode within  
approximately 3/8" (10 mm) of the end of the contact tip  
[3/4" (20 mm) Outershield®].  
• Do not allow dolly wheels or trucks to run over cables.  
• Keep cable clean by following maintenance instruc-  
tions.  
• Use only clean, rust-free electrode. The Lincoln elec-  
trodes have proper surface lubrication.  
NOTE: If set for slow run-in when the trigger is pulled, the  
wire feeder feeds wire at low speed regardless of the set wire  
feed speed until the welding arc starts or 1 second has  
elapsed. This feature enhances starting and makes it easier  
to set the stickout. The 1 second limit permits high speed  
loading of the gun and cable. To change run-in mode, see  
"Run-In Mode" in Description of Controls Section.  
• Replace contact tip when the arc starts to become  
unstable or the contact tip end is fused or deformed.  
• Keep wire reel spindle brake tension to minimum  
required to prevent excess reel over-travel which may  
cause wire "loop-offs" from coil.  
• Use proper drive rolls and wire drive idle roll pressure  
for wire size and type being used.  
5. If welding gas is to be used, turn on the gas supply and set  
the required flow rate (typically 25-35 CFH; 12-16  
liters/min).  
FAN CONTROL  
The fan is designed to come on automatically when a  
weld arc is established. The fan will stay on for a minimum  
of 6 minutes after the weld arc is terminated. The fan will  
also stay on when the machineʼs welding and feeding are  
disabled during thermostatic over temperature protection.  
(See Welding Thermal Overload Protection)  
6. When using Innershield electrode, the gas nozzle may be  
removed from the insulation on the end of the gun and  
replaced with the gasless nozzle. This will give improved  
visibility and eliminate the possibility of the gas nozzle  
overheating.  
7. Connect work cable to metal to be welded. Work clamp  
must make good electrical contact to the work. The work  
must also be grounded as stated in "Arc Welding Safety  
Precautions".  
INPUT LINE VOLTAGE PROTECTION  
High Line Voltage — If the line voltage exceeds 125% of  
rated input voltage, the output will be reduced to the lower  
level to protect voltage rating of the capacitor bank.  
WARNING  
When using an open arc process, it is necessary  
to use correct eye, head, and body protection.  
------------------------------------------------------------------------  
Low Line Voltage — You may not be able to get  
maximum output from the machine if the line voltage is  
less than rated input. The unit will continue to weld, but  
the output may be less than what is set.  
8. Position electrode over joint. End of electrode may  
be lightly touching the work.  
WIRE FEED OVERLOAD PROTECTION  
®
The POWER MIG 256 has solid state overload  
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].  
protection of the wire drive motor. If the motor becomes  
overloaded, the protection circuitry turns off the wire feed  
speed weld outputi and gas solenoid. Check for proper  
size tip, liner, and drive rolls, for any obstructions or bends  
in the gun cable, and any other factors that would impede  
the wire feeding.  
10. To stop welding, release the gun trigger and then  
pull the gun away from the work after the arc goes  
out.  
To resume welding, simply pull the trigger. There is no  
circuit breaker to reset, as the protection is done with  
reliable solid state electronics.  
®
POWER MIG 256  
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B-8  
B-8  
OPERATION  
WELDING THERMAL OVERLOAD  
PROTECTION  
®
The POWER MIG 256 has built-in protective  
thermostats that respond to excessive temperature.  
They open the wire feed and welder output circuits if  
the machine exceeds the maximum safe operating  
temperature because of a frequent overload, or high  
ambient temperature plus overload. The thermostats  
automatically reset when the temperature reaches a  
safe operating level and welding and feeding are  
allowed again, when gun is retriggered.  
OVERCURRENT PROTECTION  
The machine will automatically reduce the output if the  
load on the machine exceeds 300 to 320 amperes.  
This protects the welding power SCRʼs from excessive  
short circuit currents and from exceeding their  
temperature rating before the thermostats can react.  
WELDING PROCEDURE  
INFORMATION  
NOTE: See inside cover of machine for additional,  
commonly used welding procedure  
.
®
POWER MIG 256  
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C-1  
C-1  
ACCESSORIES  
DRIVE ROLL KITS  
ALTERNATIVE MAGNUM GMAW  
GUN AND CABLE ASSEMBLIES  
Refer to Table C.1 for various drive roll kits that are  
®
available for the POWER MIG 256.The item in Bold  
The following Magnum® PRO 250L gun and cable  
assembly is separately available for use with the  
®
is supplied standard with the POWER MIG 256.  
®
POWER MIG 256. Each is rated 200 amps 60% duty  
TABLE C.1  
cycle (or 250 amps 40% duty) and is equipped with the  
integrated connector, twist-lock trigger connector, fixed  
nozzle and insulator, and includes a liner, diffuser, and  
contact tips for the wire sizes specified:  
Wire  
Wire Size  
Drive Roll Kit  
.023”-.030” (0.6-0.8 mm)  
.035” (0.9 mm)  
KP1696-030S  
KP1696-035S  
KP1696-045S  
KP1696-1  
Solid  
Steel  
English Wire  
Metric Wire  
Size  
0.9–1.2mm  
.045” (1.1 mm)  
1
Length  
15' (4.6 m)  
Part No.  
K3081-2  
Size  
.035”-.045” (0.9-1.1mm)  
.040” (1.0mm)  
.035 – .045"  
KP1696-2  
.035” (0.9 mm)  
.045” (1.1 mm)  
KP1697-035C  
KP1697-045C  
Cored  
1
Optional liners for different wire diameters are sold  
separately, see table D.1 Maintenance Section.  
Aluminum  
3/64” (1.2 mm)  
.035” (0.9 mm)  
KP1695-3/64A  
KP1695-035A  
MAGNUM GUN CONNECTION KIT  
(Optional K466-6)  
Using the optional K466-6 Magnum Connection kit for  
the POWER MIG permits use of standard Magnum  
200, 300 or 400 gun and cable assemblies.  
K2378-1 Canvas Cover  
K468 Spindle Adapter - for 8” (203.2mm) O.D. spool.  
K363P READI-REEL™ ADAPTER  
SPOOL GUN  
The K363P Readi-Reel Adapter mounts to the 2"  
spindle. It is needed to mount the 22-30 lb. Readi-  
Reels.  
®
Remove all input power to the POWER MIG 256  
before proceeding.  
--------------------------------------------------------------------------------  
®
DUAL CYLINDER MOUNTING KIT  
(K1702-1)  
Permits stable side-by-side mounting of two full size  
228.6mm dia x 1.524m high(9" dia. x 5' high) gas  
cylinders with “no lift” loading. Simple installation and  
easy instructions provided. Includes upper and lower  
cylinder supports, wheel axles and mounting hard-  
ware.  
The POWER MIG 256 provides direct connection and  
use of the Spool Gun (with remote speed control).  
It also provides gun trigger switch transfer between the  
machineʼs use with its feeder gun or the spool gun for  
same polarity welding with different wire and gas  
processes.  
®
K2490-1  
Magnum 250LX  
®
K487-25  
Magnum SG Spool Gun (requires  
K2445-1 Cable Adapter)  
K2445-1 Magnum SG Spool gun Control Cable  
Adapter. Allows the K487-25 Magnum SG spool gunʼs  
6-pin control cable plug to connect to the POWER  
®
MIG 256ʼs 7-pin spool gun control cable receptacle.  
®
POWER MIG 256  
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C-2  
C-2  
ACCESSORIES  
CONNECTING THE SPOOL GUN TO  
CAUTION  
®
THE POWER MIG 256  
(See Figure C.1)  
Closing either gun trigger will cause the electrode  
of both guns to be electrically "HOT". Be sure  
unused gun is positioned so electrode or tip will  
not contact metal case or other metal common to  
1
. Connect the Spool Gun control cable to the mating  
7-pin receptacle in the Power MIG wire drive  
compartment. K487-25 Magnum SG Spool Gun  
requires K2445-1 cable 7-pin to 6-pin adapter.  
work.  
------------------------------------------------------------------------  
1. Pulling the trigger for the built-in feeder gun:  
2. Connect the Spool Gun electrode lead to the  
(+)positive stud with the Spool Gun electrode lead  
sandwiched between the (+)positive power source  
electrode lead and the (+)positive stud. Tighten and  
be careful not to strip the threads.  
• Disables spool gun operation.  
• Closing feeder gun trigger starts feeder gun  
welding and makes both electrodes electrically  
"HOT".  
2. Pulling SPOOL GUN Trigger:  
3. Attach the Spool Gun gas line to the 5/8 Gas fitting  
on the front of the machine.  
• Disables built-in feeder gun operation.  
• Closing spool gun trigger starts spool gun weld-  
ing and makes both electrodes electrically  
"HOT".  
4. Attach a Gas hose from the Gas supply to the rear  
®
inlet gas fitting marked “Spool” on the POWER MIG  
256.  
®
POWER MIG 256  
3. Operation with  
:
®
POWER MIG 256  
• Turn the  
input power ON.  
MAKING A WELD WITH THE SPOOL  
GUN  
• Adjusting the voltage control will increase or  
decrease your welding voltage.  
• Adjusting the wire speed control on the spool  
gun will increase or decrease the spool gun wire  
®
The POWER MIG 256 control circuitry is designed to  
feed speed.  
sense either the spool gun or (built in) wire feeder  
trigger circuitry. The spool gun can easily be plugged  
in and will be ready to use.  
®
POWER MIG 256  
• To aid in set-up, the  
wire feed  
speed(WFS) meter will display the approximate  
WFS of the gun. Actual WFS at the gun may vary  
from the displayed value due to tension setting,  
liner condition or gun variation.  
FIGURE C.1  
7-PIN  
SPOOL GUN  
RECEPTACLE  
K2445-1  
ADAPTER  
CABLE  
(7-pin to 6-pin)  
Note:This adapter is only  
forThe Magnum SG  
Spool Gun.  
+ POSITIVE  
CABLE AND STUD  
GAS LINE  
AND 5/8 FITTING  
®
POWER MIG 256  
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C-3  
C-3  
ACCESSORIES  
4. The following procedure settings for Aluminum  
4043 can be used as initial settings for making test  
welds to determine final settings:  
See the following procedure for setting the Wire  
Speed Feed using the Magnum SG Spool Gun:  
Wire Feed Speed  
Display  
SG Spool Gun Wire Feed Speed  
Approximate Range  
Wire Diameter  
Wire Feed Speed Arc voltage  
In. (mm)  
Display  
270  
250  
240  
Setting  
50  
50-200  
200-400  
300-600  
300  
700  
.030” (.8mm)  
.035” (.9mm)  
3/64” (1.2mm)  
15V  
16V  
20V  
To determine spool gun wire feed speed use a hand  
tachometer, or calculate the speed using the following  
equation:  
®
5. To return to normal POWER MIG 256 welding,  
release the spool gun trigger and reset feeder gun  
voltage procedure setting if necessary.  
IPM= Length of wire fed (inches) x 60  
Time fed (seconds)  
®
4. To return to normal POWER MIG 256 welding,  
release the spool gun trigger and reset feeder gun  
welding procedures.  
MAKING A WELD WITH THE  
MAGNUM SG SPOOL GUN  
®
The POWER MIG 256 control circuitry is designed to  
sense either the spool gun or (built in) wire feeder  
trigger circuitry. The spool gun can easily be plugged  
in and will be ready to use.  
CAUTION  
Closing either gun trigger will cause the electrode  
of both guns to be electrically "HOT". Be sure  
unused gun is positioned so electrode or tip will  
not contact metal case or other 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 and makes both electrodes electrically  
"HOT".  
2. Pulling SPOOL GUN Trigger:  
• Disables built-in feeder gun operation.  
• Closing spool gun trigger starts spool gun weld-  
ing and makes both electrodes electrically  
"HOT".  
®
3. Operation with POWER MIG 256:  
®
• Turn the POWER MIG 256 input power ON.  
• Adjusting the voltage control will increase or  
decrease your welding voltage.  
• Adjusting the wire speed control on the spool gun  
will increase or decrease the spool gun wire feed  
speed.  
• For the Magnum SG Spool Gun, the wire feed  
speed is controlled by combination of the wire  
®
feed speed displayed on the POWER MIG 256  
and the wire speed control on the spool gun.  
®
POWER MIG 256  
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D-1  
D-1  
MAINTENANCE  
3. If using optional adjustable slip-on nozzles. (Refer  
SAFETY PRECAUTIONS  
to www.lincolnelectric.com)  
WARNING  
•
Be sure the nozzle insulator is fully screwed  
onto the gun tube and does not block the gas  
holes in the diffuser.  
ELECTRIC SHOCK can kill.  
• Have an electrician install and  
service this equipment.  
•
Slip the appropriate gas nozzle onto the nozzle  
insulator. Either a standard .50" (12.7 mm) or  
optional .62" (15.9 mm) I.D. slip-on gas nozzle  
may be used and should be selected based on  
the welding application.  
• Turn the input power OFF at the  
fuse box before working on  
equipment  
• Do not touch electrically hot  
parts.  
• Adjust the gas nozzle as appropriate for the  
GMAW process to be used. Typically, the con-  
tact tip end should be flush to .12" (3.2 mm)  
extended for the short-circuiting transfer  
process and .12" (3.2 mm) recessed for spray  
transfer.  
GENERAL MAINTENANCE  
In extremely dusty locations, dirt may clog the air pas-  
sages causing the welder to run hot. Blow dirt out of  
the welder with low-pressure air at regular intervals to  
eliminate excessive dirt and dust build-up on internal  
parts.  
GUN TUBES AND NOZZLES  
1. Replace worn contact tips as required.  
The fan motors have sealed ball bearings which  
require no service.  
2. Remove spatter from inside of gas nozzle and from  
tip after each 10 minutes of arc time or as required.  
DRIVE ROLLS AND GUIDE PLATES  
GUN CABLE CLEANING  
After every coil of wire, inspect the wire drive mecha-  
nism. Clean it as necessary by blowing with low pres-  
sure compressed air. Do not use solvents for cleaning  
the idle roll because it may wash the lubricant out of  
the bearing.  
To help prevent feeding problems, clean cable liner  
after using approximately 300 pounds (136 kg) of  
electrode. Remove the cable from the wire feeder and  
lay it out straight on the floor. Remove the contact tip  
from the gun. Using an air hose and only partial pres-  
sure, gently blow out the cable liner from the gas dif-  
fuser end.  
All drive rolls are stamped with the wire sizes they will  
feed. If a wire size other than that stamped on the roll  
is used, the drive roll must be changed.  
CAUTION  
For instructions on replacing or changing drive roll,  
see “Wire Drive Rolls” in Operation section.  
Excessive pressure at the beginning of the clean-  
ing procedure may cause the dirt to form a plug.  
-----------------------------------------------------------------------  
Flex the cable over its entire length and again blow  
out the cable. Repeat this procedure until no further  
dirt comes out. If this has been done and feed prob-  
lems are experienced, try liner replacement, and refer  
to trouble shooting section on rough wire feeding.  
CONTACT TIP AND GAS NOZZLE  
INSTALLATION  
1. Choose the correct size contact tip for the elec-  
trode being used (wire size is stenciled on the side  
of the contact tip) and screw 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 other optional flush or recessed  
(spray arc) nozzle sizes may be used. (Refer to  
www.lincolnelectric.com)  
®
POWER MIG 256  
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D-2  
D-2  
MAINTENANCE  
5. Fully seat the liner bushing into the connector.  
tighten the set screw on the brass cable connector.  
The gas diffuser, at this time, should not be  
installed onto the end of the gun tube.  
LINER REMOVAL AND REPLACE-  
MENT  
NOTE: Changing the liner for a different wire size  
requires replacement of the gas diffuser per Table D.1  
to properly secure the different liner.  
6. With the gas diffuser still removed from the gun  
tube, be sure the cable is straight, and then trim  
the liner to the length shown in Figure D.1.  
Remove any burrs from the end of the liner.  
TABLE D.1  
Replacement Size Stencilled  
7. Screw the gas diffuser onto the end of the gun tube  
and securely tighten.  
Diameter of  
Liner Part  
on End of  
Electrodes Used  
Number  
Liner Bushing  
.025”-.030" Steel  
KP42-25-15  
.030” (0.8 mm)  
(0.6-0.8 mm)  
8. Tighten the set screw in the side of the gas diffuser  
against the cable liner using a 5/64" (2.0 mm) Allen  
wrench.  
.035”-.045" Steel  
(0.9-1.1 mm)  
KP42-4045-15  
.045” (1.1 mm)  
3/64" Aluminum  
KP42N-3545-15 3/64" (1.2 mm)  
(1.2 mm)  
FIGURE D.1  
LINER REMOVAL, INSTALLATION  
AND TRIMMING INSTRUCTIONS  
FOR MAGNUM® PRO 250L  
NOTE: The variation in cable lengths prevents the  
interchangeability of liners between guns. Once a liner  
has been cut for a particular gun, it should not be  
installed in another gun unless it can meet the liner  
cutoff length requirement. Liners are shipped with the  
jacket of the liner extended the proper amount.  
SET SCREW  
BRASS CABLE CONNECTOR  
.56"  
(14.2mm)  
LINER  
TRIM  
LENGTH  
SET SCREW  
GAS DIFFUSER  
NOZZLE INSULATOR (IF USED)  
GAS NOZZLE  
1. Remove the gas nozzle and nozzle insulator, if  
used, to locate the set screw in the gas diffuser  
which is used to hold the old liner in place. Loosen  
the set screw with a 5/64" (2.0 mm) Allen wrench.  
CAUTION  
2. Remove the gas diffuser from the gun tube.  
This screw should only be gently tightened.  
Overtightening will split or collapse the liner and  
cause poor wire feeding.  
3. Lay the gun and cable out straight on a flat surface.  
Loosen the set screw located in the brass connec-  
tor at the feeder end of the cable and pull the liner  
out of the cable.  
------------------------------------------------------------------------  
4. Insert a new untrimmed liner into the connector  
end of the cable. Be sure the liner bushing is sten-  
cilled appropriately for the wire size being used.  
Note: For liners KP45-3545-15 and KP45-3545-25  
Before fully seating the liner bushing, it will be neces-  
sary to trim the linerʼs inner tube flush with the liner  
bushing using a sharp blade. After trimming, remove  
any burrs from inner tube and insure that the opening  
is fully open.  
®
POWER MIG 256  
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D-3  
D-3  
MAINTENANCE  
GUN HANDLE DISASSEMBLY  
The internal parts of the gun handle may be  
inspected or serviced if necessary.  
The gun handle consists of two halves that are  
held together with a collar on each end. To  
open up the handle, turn the collars approxi-  
mately 60 degrees counterclockwise (the same  
direction as removing a right hand thread) until  
the collar reaches a stop. Then pull the collar  
off the gun handle. If the collars are difficult to  
turn, position the gun handle against a corner,  
place a screwdriver against the tab on the col-  
lar and give the screwdriver a sharp blow to  
turn the collar past an internal locking rib.  
Counterclockwise  
®
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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  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
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 Field Service Facility.  
Step 1. LOCATE PROBLEMꢀ(SYMPTOM).  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that  
best describes the symptom that the machine is  
exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
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.  
®
POWER MIG 256  
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E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
(SYMPTOMS)  
OUTPUT PROBLEMS  
Major Physical or Electrical  
Damage is Evident  
1. Contact your Local Lincoln  
Authorized Field Service Facility.  
There is no wire feed or open cir-  
cuit voltage when the gun trigger is  
pulled. Input power is applied to  
1 The gun trigger or cable may be  
faulty. Check or replace gun  
assembly.  
®
POWER MIG 256.  
2. The thermal protection circuit  
may be activated. If this is the  
case, allowing the machine to  
cool will clear the error condition.  
3. Make sure input voltage is cor-  
rect and matches nameplate rat-  
ing and reconnect panel configu-  
ration.  
4. If spool gun option kit is in-  
stalled, check to see that it is set  
to “Push Gun” if pulling the gun  
trigger associated with built in  
feeder, and “Spool Gun” if pulling  
spool gun trigger.  
If all recommended possible areas  
of misadjustment have been  
Output voltage and wire feed is pre- 1. Remove gun assembly from checked and the problem persists,  
sent when gun trigger is not pulled  
(not activated).  
machine. If problem is solved, Contact your local Lincoln  
gun assembly is faulty. Repair or Authorized Field Service Facility.  
replace.  
2. If problem persists when gun  
assembly is removed from  
machine, then the problem is  
®
within the POWER MIG 256.  
Machine output is low. Welds are  
“cold”, weld bead is rounded or  
bumped up demonstrating poor  
wetting into plate.  
1. Check input voltage. Make sure  
input voltage matches name-  
plate rating and reconnect panel  
configuration.  
2. Make sure settings for wire feed  
speed and voltage are correct  
for process being used.  
3. Make sure output polarity is cor-  
rect for process being used.  
4. Check welding cables and gun  
assembly for loose or faulty con-  
nections.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.  
®
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
(SYMPTOMS)  
OUTPUT PROBLEMS  
Poor arc striking with electrode  
sticking or blasting off.  
1. Make sure settings for wire feed  
speed and voltage are correct  
for process being used.  
2. The gas shielding may be  
improper for process being used.  
3. Check input line voltage to be  
within machineʼs recommended  
rating range.  
4. Check that the machine recon-  
nect panel is configured properly  
for the applied voltage.  
FEEDING PROBLEMS  
Rough wire feeding or wire will not 1. The gun cable may be kinked or twisted.  
feed but drive rolls are turning.  
2. The wire may be jammed in the gun  
cable, or gun cable may be dirty.  
3. Check drive roll tension and  
position of grooves.  
4. Check for worn or loose drive rolls.  
5. The electrode may be rusty or dirty.  
If all recommended possible areas  
of misadjustment have been  
6. Check for damaged or incorrect  
checked and the problem persists,  
Contact your local Lincoln  
contact tip.  
7. Check wire spindle for ease of  
rotation and adjust break ten-  
sion knob if necessary.  
Authorized Field Service Facility.  
8. Check that the gun is pushed all  
the way into gun mount and  
properly seated.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.  
®
POWER MIG 256  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
POSSIBLE  
RECOMMENDED  
COURSE OF ACTION  
PROBLEMS  
CAUSE  
(SYMPTOMS)  
FEEDING PROBLEMS  
1. Check the wire feed drive rolls  
and motor for smooth operation.  
2. Check for restrictions in the wire  
feed path. Check the gun and  
cable for restrictions.  
The wire feed stops while welding.  
When trigger is released and  
pulled again the wire feed starts.  
3. Make sure gun liner and tip are  
correct for wire size being used.  
4. Make sure drive rolls and guide plates  
are clean and are the correct size.  
5. Check spindle for ease of rotation.  
1. The wire feed speed control may  
be dirty. Rotate several times  
and check if problem is resolved.  
No control of wire feed speed.  
Other machine functions are nor-  
mal.  
GAS FLOW PROBLEMS  
If all recommended possible areas  
of misadjustment have been  
1. Make sure gas supply is con-  
nected properly and turned  
“ON”.  
Gas does not flow when gun trigger  
is pulled.  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service Facility.  
2. If the gas solenoid does actuate  
(click) when the gun trigger is  
pulled, there may be a restriction  
in the gas supply line.  
3. The gun cable assembly may be  
faulty. Check or replace.  
4. If gas solenoid does not operate  
when gun trigger is pulled, the  
problem is within the POWER  
®
MIG 256.  
5. Make sure the gun is pushed all  
the way into gun mount and is  
properly seated.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.  
®
POWER MIG 256  
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F-1  
F-1  
WIRING DIAGRAMS  
500  
515  
550  
551  
552  
8
7
6
5
4
3
2
1 R  
+
-
-
+
®
POWER MIG 256  
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F-2  
F-2  
WIRING DIAGRAMS  
500  
515  
550  
551  
552  
8
7
6
5
4
3
2
1 R  
+
-
-
+
®
POWER MIG 256  
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F-3  
F-3  
DIMENSION PRINT  
®
POWER MIG 256  
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NOTES  
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•
•
Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground.  
•
•
Keep flammable materials away.  
•
•
Wear eye, ear and body protection.  
WARNING  
Spanish  
•
No toque las partes o los electrodos  
bajo carga con la piel o ropa moja-  
da.  
Mantenga el material combustible  
fuera del área de trabajo.  
Protéjase los ojos, los oídos y el  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
•
•
Aislese del trabajo y de la tierra.  
Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
Isolez-vous du travail et de la terre.  
•
•
Gardez à l’écart de tout matériel  
inflammable.  
•
•
Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
•
•
German  
Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
Isolieren Sie sich von den  
Entfernen Sie brennbarres Material!  
Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
•
Elektroden und dem Erdboden!  
Portuguese  
•
•
Não toque partes elétricas e electro-  
dos com a pele ou roupa molhada.  
Isole-se da peça e terra.  
•
Mantenha inflamáveis bem guarda-  
dos.  
•
Use proteção para a vista, ouvido e  
corpo.  
ATENÇÃO  
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 ELEKTRO-  
DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS  
SIND EBENFALLS ZU BEACHTEN.  
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•
•
Keep your head out of fumes.  
Use ventilation or exhaust to  
remove fumes from breathing zone.  
•
•
Turn power off before servicing.  
•
•
Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
•
•
Los humos fuera de la zona de res-  
piración.  
Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
•
•
Débranchez le courant avant l’entre-  
tien.  
•
•
N’opérez pas avec les panneaux  
ouverts ou avec les dispositifs de  
protection enlevés.  
•
•
Gardez la tête à l’écart des fumées.  
Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ATTENTION  
German  
Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öffnen;  
Maschine anhalten!)  
Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
•
•
Vermeiden Sie das Einatmen von  
Schweibrauch!  
Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
•
•
Não opere com as tampas removidas.  
Desligue a corrente antes de fazer  
serviço.  
•
•
Mantenha-se afastado das partes  
moventes.  
Não opere com os paineis abertos  
ou guardas removidas.  
•
•
Mantenha seu rosto da fumaça.  
Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
•
Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES  
DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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• 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 WEBꢀSITE: www.lincolnelectric.com  
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