Lincoln Electric IM822 User's Manual
Contents
1. idl erue D 1 Items Requiring No Maintenance eeeseeene enm emen D 1 Fouine MAIMLONANCO tete eren d ce net died Laer Pe usd e ru D 1 Cleaning the Gun entrent senes D 2 Cleaning Components as Required D 2 Component Replacement Procedures D 2 Changing Contact D 2 Changing the Drive D 2 Gun Assembly 22 es sine Ped eds D 3 Work Cable Installation D 3 Troubleshooting ss Section E Safety Precaution S isigi des te ca nudes epe ire all Fl lao ER dre draco E 1 How to Use Troubleshooting E 1 Troubleshooting Guide E 2 THRU E 4 Wiring Diagrams ss nnne nnne nennen nnne Section F Wirmo NAGA etc 1 Parts LISS E E E E EAE E EE EEE P437 Series n INSTALLATION m TECHNICAL SPECIFICATIONS MIG PAK HD INPUT SINGLE PHASE ONLY Standard Voltage Frequency Input Current 120V 60Hz 20 Amps Rated Output RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 20 Duty Cycle 70 17 OUTPUT RANGE Welding Current Range Maximum Open Circuit Voltage No Load 0 450 in min DC OUTPUT 35 88 Amps 29V 0 17 7 mm min While welding 0 300 in min 0 11 8 mm min RECOMMENDED INPUT CABLE AND FUSE SIZES Fuse or AT RATED 1202. B 1 OPERATION B 1 Read entire operation section before operating the machine A 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 2 Observe all safety information throughout this manual GENERAL DESCRIPTION The machine is a semiautomatic constant voltage DC arc welder The machine uses a single phase con stant voltage transformer solid state rectifier and a DC permanent magnet motor for feeding and welding solid steel electrode and flux cored electrode The machine is ideally suited for individuals having access to 115 volt AC input power and wanting the ease of use quality and dependability of both metal inert gas MIG welding and the Innershield electrode process self shielded flux cored welding The machine will handle reels of wire up to 2 Ibs 1 kg RECOMMENDED PROCESSES The machine can be used for welding carbon and low alloy steel with CO or argon CO mixture shielding gas The welder can also be used without gas
3. output terminal and the work cable to the Negative terminal This is the typical configuration for the Metal Inert Gas MIG process Make sure that both thumbscrews are tight FIGURE A 3 WORK CABLE CABLE GUN CABLE WORK CABLE INSTALLATION INPUT CONNECTIONS FIGURE A 4 GAS INLET FITTING POWER INPUT CABLE Refer to Figure A 4 The machine has two input connections the power input cable and the gas inlet fitting The power input cable and gas inlet fitting are located on the rear GAS CONNECTION When using the MIG process a cylinder of shielding gas appropriate for the metal being welded must be obtained A WARNING CYLINDER may explode if damaged Keep cylinder upright and chained to support Keep cylinder away from areas where it may be damaged Never lift welder with cylinder attached Never allow welding electrode to touch cylinder Keep cylinder away from welding or other live electrical circuits BUILDUP OF SHIELDING GAS may harm health or kill Shut off shielding gas supply when not in use SEE AMERICAN NATIONAL STANDARD Z 49 1 SAFETY IN WELDING AND CUTTING PUB LISHED BY THE AMERICAN WELDING SOCIETY MIG PAK HD LINCOLN 4 INSTALLATION A 4 SHIELDING GAS CONNECTION FIGURE A 5 REGULATOR CYLINDER VALV
4. 20 MIG PAK HD LINCOLN 13 MACHINE SET UP FOR THE GMAW PROCESS 1 See PROCESS GUIDELINES in the OPERATION section for selection of welding wire and shielding gas and for range of metal thicknesses that can be welded 2 See the Application Guide on the inside of wire feed section door for information on setting the controls 3 Set the Voltage and Wire Speed controls to the settings suggested on the Application Guide for the welding wire and base metal thickness being used The voltage control is marked V and the wire feed speed is marked olo 4 Check that the polarity is correct for the welding wire being used Set the polarity for DC when welding with the GMAW MIG process See Work Cable Installation in the INSTALLATION section for instructions for changing polarity 5 Check that the gas nozzle and proper size liner and contact tip are being used and that the gas supply is turned on If adjustable set for 15 to 20 cubic feet per hour 7 to 10 l min under normal conditions increase to as high as 35 CFH 17 l min under drafty slightly windy conditions 6 Connect work clamp to metal to be welded Work clamp must make good electrical contact to the work piece The work piece must also be grounded as stated in the Arc Welding Safety Precautions at the beginning of this manual WELDING TECHNIQUES FOR THE GMAW MIG PROCESS Four simple manipulations are of prime importanc
5. A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans laterau
6. DC Constant Voltage Wire Welder DC Manual Stick Welder Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 2 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 487 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays
7. 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 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough 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 below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 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 Read and understand the manufacturer s instructions
8. electrode 6 Replace contact tip when it becomes worn or the end is fused or deformed MIG PAK HD LINCOLN B 16 1 ACCESSORIES C 1 ACCESSORIES INNERSHIELD WELDING WIRE NR 211 MP Innershield welding wire 035 0 9 mm diameter flux cored electrode MIG WELDING WIRE Lincoln L56 025 0 6mm diameter solid steel elec trode CONSUMABLE PARTS The following items are consumed over the life of the welder and may need to be ordered See the complete parts list at the end of this manual for machine replacement parts ITEM DESCRIPTION PART NO Chipping Hammer Brush S24355 12 Face Shield G3364 Filter Lens Clear Cover Lens G3364 C amp D Drive Roll 023 035 0 6 0 9 mm KP2315 1 Contact Tip 023 025 0 6 mm KH710 Contact Tip 035 0 9 mm KH712 Flux Nozzle Gasless KH726 Gas Nozzle KH725 Gas Hose T10642 120 Gas Diffuser 525351 1 PAK HD LINCOLN 8 D 1 MAINTENANCE D 1 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Disconnect input power by removing plug from receptacle before working inside machine Use only grounded receptacle Do not touch electrically hot parts inside machine Have qualified personnel do the mainte nance and trouble shooting work ITEMS REQUIRING NO MAINTENANCE Drive Motor and Gearbox Lifetime lubrication Wire Reel Spindle Do NO
9. for the self shielded Innershield electrode process The machine is configured for the Flux Cored Arc Welding process as delivered from the factory OPERATIONAL FEATURES AND CONTROLS The machine has the following controls as standard Power ON OFF Switch Heat Range Switch e 1 2 Fine Heat Adjustment Switch Wire Speed Control DESIGN FEATURES AND ADVANTAGES Operates on 115 volt input Solid state output control Overload protection incorporates a thermostat to protect the welder from overheating caused by mal functions or overly heavy use Permanent magnet wire drive motor Easy to set controls for arc voltage and wire speed Thumbscrew release idle roll pressure arm is easily adjusted Reversible dual groove drive roll will feed 023 035 0 6 0 9 mm diameter wire Accommodates spools of wire up to 4 102mm diameter No external shielding gas is required when used with Lincoln Innershield 035 0 9 mm NR 211 MP electrode Easy to change polarity MIG PAK HD LINCOLN P B 2 OPERATION B 2 WELDING CAPABILITY The machine is rated at 70 amps 17 volts at 20 duty cycle on a ten minute basis It is capable of high er output currents at lower duty cycles LIMITATIONS The machine is recommended for welding on mild steel up to 1 8 thick CONTROLS AND SETTINGS FIGURE B 1 Refer to Figure B 1 1 Power ON OFF Switch When the power is ON the welding output and wire f
10. for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer 5 e Also see item 1 b Mar 95 SAFETY 7 WELDING SPARKS can lt gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire 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 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 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 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
11. may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY PRECAUTIONS DE SURETE 2 Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage
12. panel abierto 0 guardas quitadas e N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas e 5 x 052 amp WRUA4L7I 6 CRRATEELEWTFSEU CHEAT DO SUUS eS MSR edo Bel OMA 2 ils 15 jual Ide Je ye Age aug gll Aaa Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Hx BIR Chinese ons LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR HDRHRVE NOX H OIEREE A CL TRHOKRSME HITE AAA Mee QUE AO REA RS FIR SR IURI MHRTRANARSORERE 0 HYAA FAP GM spect 48 ud al gli LINCOLN B World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
13. similar devices that can be damaged See Figure B 6 Always disconnect electrical devices before welding upon them FIGURE B 6 Bearings Electrical Components CORRECT CURRENT PATH For best results position work clamp approximantely 12 inches 294mm from the welded area A WARNING Fumes and slag generated from Innershield type electrodes recom mended for use with this welding machine can be toxic Avoid contact with eyes and skin Do not take internally Keep out of reach of children Follow all safety precautions found in this operating manual The gun and cable assembly is held by the operator who guides the automatically fed wire along the joint maintaining a contact tip to work distance of about 3 8 to 1 2 inch 10 12 mm This is called electrical stick out This electrical stickout ESO must be properly maintained by the operator The electric arc is made in the gap between the work and the tip end of a small diameter wire When the power source is properly set the arc gap is maintained automatically Arc welding is a manual skill requiring a steady hand good physical condition and good eyesight The oper ator controls the welding arc and therefore the quali ty of the weld made THE SELF SHIELDED FCAW FLUX CORE WELDING ARC Figure B 7 illustrates the action taking place in the self shielded FCAW Innershield welding arc It closely resembles what is actually seen while
14. spool lock turning it clockwise to lock the spool assembly onto the spindle FIGURE B 2 SPOOL SPACER 2 SPOOL LOCK SPRING MIG PAK HD LINCOLN P 3 FIGURE WIRE THREADING DETAILS SPRING LOADED THUMSCREW E Hr IDLER ROLL ARM E iw Der A WIRE pa A WIRE FEED INGOING GUIDE TUBE LOWER DRIVE ROLL Refer to Figure B 3 4 Release the spring loaded thumbscrew and rotate the idle roll arm away from the wire feed drive roll Ensure that the visible stenciled size on the drive roll side facing you matches the wire size being used Carefully detach the end of the wire from the spool maintain tension on the wire To prevent the spool from unwinding and do not release the wire until after step 5 Cut the bent portion of wire off and straighten the first 4 102 mm Thread the wire through the incoming guide tube over the drive roll and into the gun liner Close the idle roll arm and turn down the thumb screw until the idle roller presses down firmly on the wire Now you may release the welding wire Make sure the wire is positioned in the groove of the lower drive roll The spring loaded thumbscrew on the idle roll arm adjusts the pressure on the wire Adjust pressure by turning the thumbscrew to pr
15. welding Burning of core materials inside wire electrode results in shield of gas Cored Wire Protective Slag Arc Stream Weld Metal FIGURE B 7 MIG PAK HD LINCOLN P B 7 OPERATION B 7 The arc stream is seen in the middle of the picture This is the electric arc created by the electric current flowing through the space between the end of the wire electrode and the base metal The temperature of this arc is about 6000 F which is more than enough to melt metal The arc is very bright as well as hot and cannot be looked at with the naked eye without risking painful injury The very dark lens specifically designed for arc welding must be used with the hand or face shield whenever viewing the arc The arc melts the base metal and actually digs into it much as water through a nozzle on a garden hose digs into the earth The molten metal forms a molten pool or crater and tends to flow away from the arc As it moves away from the arc it cools and solidifies The function of the Innershield cored wire electrode is much more than simply to carry current to the arc The wire core is composed of fluxes and or alloying ingre dients around which a steel sheath has been formed It is simply a stick electrode turned inside out in a con tinuous wire form The cored wire melts in the arc and tiny droplets of molten metal shoot across the arc into the molten pool The wire sheath provides additional filler metal for
16. wire after welding For easier restrikes the ball may be removed by feeding out a few inches of wire and cutting off the end of the wire with wire cutters 6 When no more welding is to be done close the valve on the gas cylinder momentarily operate the gun trigger to release gas pressure then turn off the machine MIG PAK HD LINCOLN 14 Contact Wire Electrode ESO FIGURE B 22 3 The Correct Electrical Stickout ESO The electrical stickout ESO is the distance from the end of the contact tip to the end of the wire See Figure B 22 Once the arc has been established maintaining the correct ESO becomes extremely important The ESO should be approximately 3 8 to 1 2 inch 10 to 12 mm long The easiest way to tell whether the ESO is the cor rect length is by listening to its sound The correct ESO has a distinctive crackling sound very much like eggs frying in a pan A long ESO has a hollow blowing or hissing sound If the ESO is too short you may stick the contact tip or nozzle to the weld puddle and or fuse the wire to the contact tip 4 The Correct Welding Speed The important thing to watch while welding is the puddle of molten metal right behind the arc See Figure B 23 Do not watch the arc itself It is the appearance of the puddle and the ridge where the molten Puddle solidifies that indicates correct weld ing speed The ridge should be approximately 3 8 10 mm behind the w
17. 2 Decrease drag angle 3 Increase stickout 4 Decrease travel speed Arc blow is the effect of a magnetic field which forces the arc from its normal path visual results are concave face uneven leg lengths heavy spatter and porosity To Eliminate Stubbing In order of priority 1 Check or reset WFS amp Volts on chart inside door 2 Decrease stickout 3 Increase drag angle Stubbing occurs when the electrode drives through the molten puddle and hits the bottom plate tending to push the gun up Proper Gun Handling Most feeding problems are caused by improper han dling of the gun cable or electrodes 1 Do not kink or pull the gun around sharp corners 2 Keep the gun cable as straight as practical when welding 3 Do not allow dolly wheels or trucks to run over the cables 4 Keep the cable clean 5 Innershield electrode has proper surface lubrica tion Use only clean rust free electrode 6 Replace contact tip when it becomes worn or the end is fused or deformed MIG PAK HD LINCOLN P 16 OPERATION Proper Gun Handling Most feeding problems are caused by improper han dling of the gun cable or electrodes 1 Do not kink or pull the gun around sharp corners 2 Keep the gun cable as straight as practical when welding 3 Do not allow dolly wheels or trucks to run over the cables 4 Keep the cable clean 5 Innershield electrode has proper surface lubrica tion Use only clean rust free
18. 5 Refer to Figure B 5 Connect the work clamp to the metal to be welded The work clamp must make good electrical contact to the work piece The work piece must also be grounded as stated in Arc Welding Safety Precautions in the beginning of this manual 6 Based on the welding process type and material thickness of the work piece use the chart below or on the procedure decal located on the wire drive door to set the correct wire feed speed and heat range setting 7 Based on the weld joint type and orientation of the weld joint position the gun into the joint at the cor rect angle Refer to the LEARNING TO WELD sec tion of this manual 8 To begin welding raise your hand shield to protect your eyes and pull the trigger 9 While welding travel at a constant speed and main tain an electrode stickout of 3 8 Follow the correct direction of travel for the process and joint type and orientation as detailed in the LEARNING TO WELD section of this manual 10 To stop welding release the gun trigger 11 When no more welding is to be done close the valve on the gas cylinder if used momentarily operate the gun trigger to release gas pressure and turn off the machine TABLE B 1 Process FCAW Gasless Flux Cored Optimum for 16 gauge and heavier material Can be used for Selecting the lighter gauge material Mig with 75 25 Gas kk 5 Ar 25 CO2 Mig w CO2 Gas Excellent Finished VVeld appearance Exc
19. E HOSE lt GAS CYLINDER esse J Refer to Figure A 5 1 Chain the cylinder to a wall or other stationary sup port to prevent the cylinder from falling over Insulate the cylinder from the work circuit work ground 2 With the cylinder securely installed remove the cylinder cap Stand to one side away from the out let and open the cylinder valve very slightly for an instant This blows away any dust or dirt which may have accumulated in the valve outlet A WARNING BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN CRACKING THE VALVE Never stand directly in front of or behind the flow regulator when opening the cylinder valve Always stand to one side 3 Attach one end of the inlet gas hose to the outlet fit ting of the gas cylinder secure with hose clamp Connect the other end to the Gas Inlet Fitting on the machine and secure with hose clamp Make certain the gas inlet hose is not kinked or twisted 4 The machine is supplied with a regulator suitable for a mixed shielding gas CO2 Argon For welding with 100 a suitable regulator or adapter must be purchased separately from a welding gas suppli er To prevent leakage if welding with 10096 CO2 shielding gas the regulator for carbon dioxide must have a plastic adapter washer seated in the fitting that attaches to the cylinder This adapter is avail able from your local gas supplier CODE REQUIREMENTS FOR ELECTRI CAL INPUT CONNECT
20. IAGRAMS F 1 01 20242 WIRING DIAGRAM NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels MIG PAK HD LINCOLN P Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Japanese Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes 0 los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra eoHmRogasme 7 bnfdcomn amp oect OMIMPT APSSereRe NHTUVSHRELTFSAU e K RRR DENVER e 5 Be NOM MI HEAR eHza SHES Xe se sE Su e 22 HAS Jui gay ui el ja oa Y O coe oe il gS Gaal DU du Ule Yo pue Keep flammable mat
21. IONS A WARNING This welding machine must be connected to a power source in accordance with applicable elec trical codes The United States National Electrical Code Article 630 B 1990 Edition provides standards for amperage handling capability of supply conductors based on duty cycle of the welding source If there is any question about the installation meeting applicable electrical code requirements consult a qualified electrician CAUTION Do not connect the machine to an input power supply with a rated voltage that is greater than 125 volts Do not remove the power cord ground prong REQUIREMENTS FOR MAXIMUM OUTPUT A line cord with a 15 amp 125 volt three prong plug NEMA Type 5 15P is factory installed on the machine Connect this plug to a mating grounded receptacle which is connected to a 20 amp branch cir cuit with a nominal voltage rating of 115 volts to 125 volts 60 hertz AC only If connected to a circuit pro tected by fuses use a time delay fuse marked D With this installation the machine can be used at an output of 70 amps 17 volts 20 duty cycle 2 min utes of every 10 minutes used for welding EXTENSION CORD USAGE If an extension cord is required use one that is rated for the application and is 3 conductor 14 AWG 2 1 mm or larger The recommended maximum lengths are 25 ft 7 5 m if 14 AWG 2 1 mm is used and 50 ft 15 m if 12 AWG 3 3 mm is used MIG PAK HD LINCOLN
22. RC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 hy h 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spi
23. RETURN TO MAIN MENU ER M822 MIG PAK HD ry 2000 For use with machine Code Number 11062 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Date of Purchase Serial Number Code Number Model Where Purchased E OPERATOR S MANUAL EU pue ISO 9001 ABS Quality Ev i Inc to ISO 9001 Re nts E EAE TES LI CO LN Copyright 2008 Lincoln Global Inc e World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines A
24. T lubricate shaft ROUTINE AND PERIODIC MAINTENANCE BEFORE EACH USE Check over machine and accessories for any obvious condi tion that may prevent safe performance or operation Repair or replace items as necessary to correct any abnormal con dition AFTER 5 MINUTES OF WELDING or when spatter accumulates in the gas nozzle Clean the contact tip and gas nozzle to avoid bridging between the nozzle and contact tip Bridging results in a shorted nozzle poor welds and overheated gun Hint Anti stick spray or gel available from a welding supplier may reduce buildup and aid in spatter removal MIG PAK HD LINCOLN 8 D 2 MAINTENANCE D 2 CLEANING THE GUN LINER Unplug the machine or turn the power switch to the OFF 0 position Remove the gas nozzle and contact tip from the gun Clean the inside diameter with a short piece of wire Clean the cable liner when rough and erratic wire feeding occur Lay the cable out straight Blow out gently with dry compressed air through the wire guide tube and check the condition of the tube Bend the cable back and forth then blow the tube out again Repeat until clean CAUTION Excessive pressure at start may cause the dirt to form a plug CLEANING COMPONENTS AS REQUIRED Unplug the machine or turn the power switch to the OFF 0 position Blow dirt out of the welder with low pressure air to eliminate excessive dirt and dust buildup that could c
25. TER TABLE CONTENTS FOR ALL SECTIONS Page Inistallatloh eire eine O a a Section Technical Specifications sssi sarot coe tete re LEE A 1 Identify and Locate Components A 2 Select Suitable Location ss A 3 Scd A 3 CGhanging TT A 3 Gun Installation aa dest ges lene nds ta sense titre a Eus Edda A 3 INPUT cedicest A 3 ECCE nce A 3 Shielding Gas Connections issu 4 Code Requirements iii 4 MEE Section B Dalely B 1 General Description issus B 1 Recommended PrOCOSS8658 erit cbe etus ter dert entente B 1 Operation Features and sss B 1 Design Features aeter Mate e Le lead B 1 Welding Capability E B 2 B 2 Controls and Settings 2 Welding nn anne Rs 2 Sha B 3 Making a Weld and Process Table B 4 Cleaning Tip and Gas Nozzle eene B 5 Changing Machine over to Feed Other Wire Sizes Overload Protection B 5 Learning to Weld trece xe tetes B 6 thru B 16 ACCESSOTIES Section C ACCO SSO E C 1 R plac ment Parts cacciani annn n e A NENS C 1 esate Seed ete este Section D Safely Precautions soisissa eenei
26. V 60Hz 15 Amp 125 Three Conductor OUTPUT Three Prong Plug 12 AWG NEMA Type 5 15P 3 3 mm or Larger Up to 50 Ft 15 2 mm PHYSICAL DIMENSIONS 11f connected to a circuit protected by fuses use Time Delay Fuse marked D MIG PAK HD LINCOLN 2 INSTALLATION A 2 Read entire installation section before starting installation SAFETY PRECAUTIONS WARNING nn ELECTRIC SHOCK can kill Only qualified personnel should perform this installation FIGURE A 1 Only personnel that have read under stood the Machine Operating Manual should install and operate this equipment Machine must be plugged into a receptacle which is grounded per any national local or other applicable electrical codes Machine power switch is to be in the OFF O position when installing work cable and gun and when connecting power cord to input power Co q oe N Ro NON NN E ee ccc MCCC d Md CE NSD OS c IDENTIFY AND LOCATE COMPONENTS If you have not already done so unpack the machine from its carton and remove all packing material around the machine The following items are shipped loose see Figure A 1 1 MIG PAK HD with work clamp Gun and cable assembly attached 2 This operator s manual 3 Two contact tips for 035 0 9mm diameter wire 4 Three contact tips for 025 0 6mm diameter wire 5 Gas No
27. When using Innershield electrode use the gasless nozzle instead of a gas nozzle to improve visibility of the arc 5 Connect work clamp to metal to be welded Work clamp must make good electrical contact to the work piece The work piece must also be grounded as stated in the Arc Welding Safety Precautions at the beginning of this manual WELDING TECHNIQUES FOR THE SELF SHIELDED FCAW PROCESS Four simple manipulations are of prime importance when welding With complete mastery of the four welding will be easy They are as follows 1 The Correct Welding Position Figure B 16 illustrates the correct welding position for right handed people For left handed people it is the opposite Hold the gun of the gun and cable assembly in your right hand and hold the shield with your left hand Left handers simply do the opposite When using the FCAW Process weld from left to right if you are right handed This enables you to clearly see what you are doing Left handers do the opposite Tilt the gun toward the direction of travel holding the electrode at an angle as shown in Figure B 18 MIG PAK HD LINCOLN 8 11 OPERATION B 11 Contact Tip Wire Electrode FIGURE B 16 3 8 10mm Electrical Stickout ESO WARNING FIGURE 17 ARC RAYS burn eyes and skin 2 The easiest way to tell whether the ESO is the cor 77 When using open arc process it rect length is by listening to it
28. al up or vertical down Vertical up is used whenever a larger stronger weld is desired Vertical down is used primarily on sheet metal WARNING Use of this unit on thicker materials than recom mended may result in welds of poor quality The welds may appear to be fine but may lack the fusion or bonding necessary to give a strong weld This is called Cold Casting or cold lap some what similar to a cold solder joint Weld failure may result Vertical up And Overhead Welding The problem when welding vertical up is to put the molten metal where it is wanted and make it stay there If too much molten metal is deposited gravity will pull it downwards and make it drip Therefore a certain technique has to be followed When welding out of position run stringer beads Don t whip break the arc move out of the puddle or move too fast in any direction Use Wire Feed Speed WFS in the low portion of the range The general technique and proper gun angle is illustrated in Figure B 14 Generally keep the electrode nearly perpendicular to the joint as illustrated The maximum angle above per pendicular may be required if porosity becomes a problem MIG PAK HD LINCOLN 10 lt lt PROPER GUN ANGLE PROPER GUN ANGLE FOR GMAW PROCESS FOR FCAW PROCESS WELDING IN THE VERTICAL UP POSITION WELDING IN THE VERTICAL UP POSITION FIGURE 14 Vertical down Welding Refer to Figure B 15 Verti
29. ange Thickness Speed 7 Heat Range 24 Ga Steel 24 Ga Steel 4 Low 1 24 GaSteel sd Suggeated 22 Ga Steel 22 Ga Steel 4 Low 1 22 Ga Steel 4 Low 2 ge 4 4 z 20 Ga Si aS Settings For 2 ss Low Pu Welding 8 Ga Steel Low Stee Ga Stee 16 Ga Steel 3 Low 2 16 Ga Steel 16 Ga Steel 14Ga Steel 3 High 1 14 Ga Steel 14 Ga Steel 12 Ga Steel 4 High 2 12 Ga Steel 12 Ga Steel 1 8 Steel 4 High 2 1 8 Steel 1 8 Steel MIG PAK HD LINCOLN P B 5 OPERATION CLEANING TIP AND GAS NOZZLE Keep the contact tip and nozzle clean to avoid arc bridging between them Bridging can result in a short ed nozzle poor welds and an overheated gun Hint Anti stick spray or gel available from a welding suppli er may reduce buildup and aid in spatter removal CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES The machine is shipped from the factory ready to feed 0 035 0 9 mm diameter wire To operate the machine with other sizes of wire it is necessary to change the contact tip and change the drive roll to other sizes Refer to Changing the Contact Tip and Changing the Drive Roll in the MAINTENANCE sec tion for specific information on these procedures OVERLOAD PROTECTION THERMAL PROTECTION The machine has a maximum output duty cycle of 20 If the duty cycle is exceeded a thermal protector will shut off the output until the machine cools to a normal operating temperature This is an automatic function of the machine and does no
30. ause the welder to run hot Vacuum accumulated dirt from the gear box and wire feed section Inspect the incoming guide tube and clean the inside diameter if necessary Replace when exces sively worn Replace Contact when the hole is enlarged or elongated Refer to Changing The Contact Tip in this section Check the condition of the wire feed rollers Remove any metallic dust deposited in the feed area rollers and entrance and outlet wire guide Check the gas hose and fittings for tightness COMPONENT REPLACEMENT PROCEDURES FIGURE D 1 CONTACT TIP REPLACEMENT CONTACT TIP NOZZLE CHANGING THE CONTACT TIP 1 Refer to Figure D 1 Remove the gas nozzle from the gun by unscrewing it counter clockwise 2 Remove the existing contact tip from the gun by unscrewing it counter clockwise 3 Insert and tighten the desired contact tip Do not overtighten 4 Replace the gas nozzle CHANGING THE DRIVE ROLL FIGURE D 2 DRIVE ROLL REPLACEMENT SPRING LOADED HANDLE SCREW wnel IE 8 UPPER IDLER ROLL ARM INGOING GUIDE TUBE WIRE FEED LOWER DRIVE ROLL The machine Wire Feed Drive Roll has two grooves one for 0 023 0 025 0 6 mm solid steel electrode and the other for 0 030 0 8 mm solid and 0 035 0 9 mm flux cored steel electrode See Figure D 2 Use the appropriate sized groove f
31. cal down welds are applied at a fast pace These welds are therefore shallow and narrow and as such are excellent for sheet metal Suggested settings for welding Vertical down welds are found in table b 1 Use stringer beads and tip the gun in the direction of travel so the arc force helps hold the molten metal in the joint Move as fast as possible consistent with desired bead shape The important thing is to continue lowering the entire arm as the weld is made so the angle of the gun does not change Move the electrode wire fast enough that the slag does not catch up with the arc Vertical down welding gives thin shallow welds It should not be used on heavy material where large welds are required FIGURE B 15 OPERATION B 10 MACHINE SET UP FOR THE SELF SHIELDED FCAW PROCESS 1 See the Application Guide on the inside of wire feed section door for information on setting the controls based on wire type and metal thickness being welded 2 Set the Voltage and Wire Speed controls to the settings suggested on the Application Guide for the welding wire and base metal thickness being used The voltage control is marked V and the wire feed speed is marked olo 3 Check that the polarity is correct for the welding wire being used Set the polarity for DC when welding with NR 211 MP Innershield electrode See Work Cable Installation in the INSTALLATION section for instructions on changing polarity 4
32. ding For easier restrikes with Innershield wire the ball may be removed by feeding out a few inches of wire and simply bending the wire back and forth until it breaks off Solidifying ridge Molt ddl 6 When no more welding is to be done turn off the machine 3 The Correct Electrical Stickout ESO The electrical stickout ESO is the distance from the end of the contact tip to the end of the wire FIGURE B 18 See Figure B 17 Once the arc has been established maintaining the correct ESO becomes extremely important The ESO should be approximately 3 8 10mm long MIG PAK HD LINCOLN 8 12 Helpful Hints 1 For general welding it is not necessary to weave the arc neither forward or backward nor sideways Weld along at a steady pace You will find it easier 2 When welding on thin plate you will find that you will have to increase the welding speed whereas when welding on heavy plate it is necessary to go more slowly in order to get good penetration 3 When welding sheet metal 16 gauge 1 5 mm and lighter heat buildup may cause part warpage and burn through One way to eliminate these problems is to use the back stepping method illustrated in Figure B 19 First weld from A to B then from C to A then from D to C then from E to D and so on 508 Back Stepping FIGURE B 19 Practice The best way of getting practice in the four skills that enable you to maintain 1 Correc
33. e when welding With complete mastery of the four welding will be easy They are as follows 1 The Correct Welding Position Figure B 21 illustrates the correct welding position for right handed people For left handed people it is the opposite When GMAW MIG welding on sheet metal it is important to use the forehand push technique Hold the gun of the gun and cable assembly in your right hand and hold the shield with your left hand Left handers simply do the opposite OPERATION B 13 FIGURE B 21 When using the GMAW process on light gauge mater ial weld from right to left if you are right handed This results in a colder weld and has less tendency for burn through 2 The Correct Way To Strike An Arc WARNING ARC RAYS can burn eyes and skin Y When using an open arc process it ae Is necessary to use correct eye head and body protection Protect yourself and others read ARC RAYS can burn at the front of this manual 1 Be sure the work clamp makes good electrical con tact to the work 2 Position gun over joint End of wire may be lightly touching the work 3 Position face shield to protect face and eyes close gun trigger and begin welding Hold the gun so that the contact tip to work distance is about 3 8 to 1 2 inch 10 12 mm 4 To stop welding release the gun trigger and pull the gun away from the work after the arc goes out 5 A ball may form at the tip end of the
34. e apart See Figure B 10 Now weld the two plates together Weld from left to right if right handed Point the wire electrode down in the crack between the two plates keeping the gun slightly tilted in the direction of travel Watch the molten metal to be sure it distributes itself evenly on both edges and in between the plates This is referred to as the pull technique On thin gauge sheet metal use the push technique See Welding Techniques for GMAW MIG Process FIGURE B 10 MIG PAK HD LINCOLN P B 9 OPERATION B 9 Penetration Unless a weld penetrates close to 100 of the metal thickness a butt joint will be weaker than the material welded together In the example shown in Figure 11 the total weld is only half the thickness of the material thus the weld is only approximately half as strong as the metal FIGURE 11 1 In the example shown Figure B 12 the joint has been welded so that 100 penetration could be achieved The weld if properly made is as strong as or stronger than the original metal FIGURE B 12 Fillet Welds When welding fillet welds it is very important to hold the wire electrode at a 45 angle between the two sides or the metal will not distribute itself evenly The gun nozzle is generally formed at an angle to facilitate this See Figure B 13 45 FIGURE B 13 Welding In The Vertical Position Welding in the vertical position can be done either ver tic
35. e end of the work cable with the terminal lug through the Work Cable Access Hole in the case front 3 Route the cable through the rubber grommet in the metal divider under and around the back of the Wire Feed Gearbox MIG PAK HD LINCOLN D 3 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A 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 1 LOCATE PROBLEM 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 Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external 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 Field Service Facility If you do not und
36. eeder are ON hot when the gun trigger is pressed 2 Low High Heat Range Switch A rocker switch control that gives low or high coarse range adjust ment of the power source output voltage 3 1 2 Fine Heat Adjustment Switch Allows fine AME of the voltage within the selected Low or High output range 4 Wire Speed Control Controls the wire feed speed Wire speed is not affected when changes are made in the voltage control WELDING OPERATIONS PROCESS GUIDELINES MIG WELDING Table B 1 shows the recommended material gas combinations for MIG welding with solid electrodes TABLE B 1 MIG WELDING MATERIAL GAS COMBINATIONS Material Gas Carbon Steel Low Alloy Steel 2 or Argon CO2 2 or Argon CO2 FLUX CORED INNERSHIELD WELDING The recommended electrode for the flux cored self shielded process is 0 035 0 9 mm diameter Lincoln Innershield NR 21 1 MP on 1 lbs 5 kg spools SEQUENCE OF OPERATIONS WIRE LOADING AND THREADING Refer to Figure B 2 Turn machine power switch to the OFF 0 position before working inside the wire feed enclosure Make sure that the wire feed drive roll and the contact tip of the gun match the diameter and type of wire used 1 Push the spool onto the spindle so that the wire feeds off the bottom of the spool toward the drive roll 2 Push the spool spacer onto the spindle against the spool 3 Slide the spring onto the spool then press on the
37. ellent Finished VVeld appearance Excellent performance on light gauge Excellent performance on light gauge Somewhat rusty or dirty material Right Process Work pieces must be clean Work pieces must be clean Outdoor Welding and or windy conditions Indoor and or no wind Indoor and or no wind Good Out of position vertical welding Drive Roll 4 0 9mm Knurled groove Electrode gun Welding Polarity 5 Work clamp Welding Wire 035 Lincoln NR 211 MP innershield Cored Wire 025 Lincoln L 56 Steel Wire Nozzle 2 Black Plastic Nozzle shipped installed on gun Copper Gas Shielding Nozzle shipped Copper Gas Shielding Nozzle shipped loose lbose Contact Tip 3 035 0 9mm 025 0 6mm 025 0 6mm 0 6mm V Groove 0 6mm V Groove The Veld Settings in the table below correspond to the following tension setting Tighten the tension arm completely then back off 2 complete CO2 for good penetration and speed 025 Lincoln L 56 Steel Wire 15125 for a smooth arc w little spatter Electrode gun Work clamp 2 Work clamp Wire Feed Tension revolutions The tension may be changed if required to Improve wire feeding however the WFS setting may have to be adjusted from the values in k 5 ___ table below 7 Steel Wire Feed Steel Wire Feed 8 Steet Tienes Wire Feed Speed Heat Range Thickness Speed Heat R
38. erformed on 16 gauge and heavier somewhat rusty or dirty materials 5 Weld must be cleaned prior to painting COMMON METALS Most metals found around the farm small shop or home are low carbon steel sometimes referred to as mild steel Typical items made with this type of steel include most sheet metal plate pipe and rolled shapes such as channels and angle irons This type of steel can usually be easily welded without special pre cautions Some steels however contain higher car bon levels or other alloys and are more difficult to weld Basically if a magnet sticks to the metal and you can easily cut the metal with a file chances are good that the metal is mild steel and that you will be able to weld the material Regardless of the type of metal being welded in order to get a quality weld it is important that the metal is free of oil paint rust or other contaminant s JOINT TYPES AND POSITIONS Five types of welding joints are Butt Joint Fillet Joint Lap Joint Edge Joint and Corner Joint See Figure B 9 Of these the Butt joint and Fillet joint are the two most common welds LILI Butt joint Lap joint Edge joint Fillet joint Corner joint FIGURE B 9 Butt Joint Place two plates side by side leaving a space approx imately one half the thickness of the metal between them in order to get deeper penetration Securely clamp or tack weld the plates at both ends otherwise the heat will cause the plates to mov
39. erials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos edmaivodv6008Rcosisets CiU EGA e 1 5 9 155 55 ZJE AIX Jui ALIM al yl 2 e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo HAUSH ERMRELTTF 85 emAEm HRSSUEGERHR 119 Fo sare 854 Ale ail le Lily ques cl gai pis e 3 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out
40. erstand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility 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 MIG PAK HD LINCOLN 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage None is evident Contact your local Authorized Field Service Facility No wire feed weld output or gas 1 Make sure correct voltage is flow when gun trigger is pulled applied to the machine 115vac Make certain that power switch is in the ON position The thermostat may be tripped due to overheating Letmachine If all recommended possible areas cool Weld within the duty cycle of misadjustment have been or remove any air obstruction to checked and the problem persists the machine Contact your local Lincoln Authorized Field Service No weld output when gun trigger is 1 Gun tip may be worn Replace Facility pulled Gun trigger may be faulty The gun or work cable may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the tes
41. event spool over run but still allow smooth and easy wire feeding Start with the pressure set to an intermediate value Readjust if necessary Slightly less pressure may be required when using 0 023 0 025 0 6 mm wire If the drive roll slips while feeding wire the pressure should be increased until the wire feeds properly OPERATION FIGURE B 4 WIRE STICKOUT 11 12 13 14 15 16 CONTACT TIP 3 8 WIRE ELECTRODE mondi m Remove the gas nozzle and contact tip from the gun Turn the machine ON 1 Straighten the gun cable assembly Depress the gun trigger switch and feed welding wire through the gun and cable Point the gun away from yourself and others while feeding wire Release the gun trigger after wire appears at the end of the gun Turn off the machine Replace the contact tip and nozzle Refer to Figure B 4 Cut the wire off so that 3 8 10mm protrudes from the end of the tip Turn on the machine The machine is now ready to weld SHIELDING GAS When using the MIG process you will need a cylinder of carbon dioxide CO2 or argon carbon dioxide mixed shielding gas The preset regulator supplied with the machine is designed for use with argon blend gas An adapter and plastic washer are needed for using 10096 CO2 gas This adapter is available from your local gas sup plier 1 Open the cylinder valve slowly a fraction of a turn When the cyli
42. ire electrode Most beginners tend to weld too fast resulting in a thin uneven wormy looking bead They are not watching the molten metal Weld metal ridge 22 Molten puddle FIGURE B 23 OPERATION B 14 Helpful Hints 1 For general welding it is not necessary to weave the arc neither forward or backward nor sideways Weld along at a steady pace You will find it easier When welding on thin plate you will find that you will have to increase the welding speed whereas when welding on heavy plate it is necessary to go more slowly in order to get good penetration When welding sheet metal 16 gauge 1 5 mm and lighter heat buildup may cause part warpage and burn through One way to eliminate these problems is to use the back stepping method illustrated in Figure B 21 Practice The best way of getting practice in the four skills that enable you to maintain 1 Correct welding position 2 Correct way to strike an arc 3 Correct electrical stickout 4 Correct welding speed Coarse Voltage Setting Fine Voltage Setting Wire Speed Feed Setting is to perform the following exercise For the MACHINE use the following Mild Steel 16 gauge or 1 16 inch 1 6 mm Lincolnweld 0 025 L 56 electrode 75Ar 25 CO 100 Electrode GAS TYPE Hi 77 Refer to Figure 20 1 Learn to strike an arc by positioning the gun over the joint and to
43. ll fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety MS E minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your bogy 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throt
44. nder pressure gauge pointer stops moving open the valve fully 2 Keep the cylinder valve closed except when weld WARNING ing When finished welding When feeding the welding wire Close the cylinder valve to stop gas flow through the gun the drive roll the Depress the gun trigger briefly to release the gun connector block and the gun pressure in the gas hose contact tip are always energized rela Turn off the machine tive to work and ground MIG PAK HD LINCOLN P 4 OPERATION B 4 MAKING A WELD FIGURE B 5 WELDING SETUP GUN CABLE WORK READ the LEARNING WELD section of this man ual prior to making your first weld Also refer to Table B 1 and the Procedure Decal located on the inside of the wire drive compartment door of your machine for process selection consumables and quick tips for welding 1 Select the right welding process based on the type and condition of the pieces to be welded the envi ronment in which welding is to be done and the desired finished appearance of the weld 2 Select and install the welding wire to match the process Use Genuine Lincoln Electric Brand wire Wire quality is essential for successful welding 3 Install the drive roll contact tip and nozzle appro priate for the weld process 4 Check that the polarity is correct for the welding wire being used and that the gas supply if required is turned on
45. of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 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 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 6 h Also see item 1 c LINCOLN CYLINDER may explode 22 NB s if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they
46. of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n 0 aspiraci n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o exhaust o para remover fumo da zona respirat ria ta LPSRMEBTLIILT Feu CRACHBICTARELTFSEU e cc EUR E fE Fish Bk AzzTEA SALE else SANACEFE 87I 8 amp HAPI Ash 21294214 SEIE A zSHMAS gaal oe le dul sui e pal Bia jja si igal e Ael uil Ge call aas ous e Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entretien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e xX TTLAGR UACRUPD PARKI EFBRAL YFE HFT F e HEMORRE e SH AHS X ChSHIAI J Jill abil e Do not operate with panel open or guards off No operar con
47. or selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for product registration on line or information on this equipment always supply the information you have recorded above 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment MAS
48. or the wire used as indicated by the stenciling on the side of the drive roll Reverse the drive roll as follows Refer to Figure D 2 1 Make certain the machine power switch is OFF 0 2 Open the spring loaded pressure arm Lift up the idle roll arm MID PAK HD LINCOLN 8 D 3 MAINTENANCE 3 Remove the Thumbscrew holding the drive roll 4 Replace the drive roll so that the desired size sten ciled on the side of the drive roll is toward the inside and visible 5 Replace the Thumbscrew and tighten GUN ASSEMBLY REMOVAL Unplug machine Remove wire drive door and right case side Remove gas line connections Remove gun connections from output studs Remove trigger leads The trigger leads are routed through the center panel and connected to the P C board X8 X9 Use care in removal as not to damage the P C board or adjoining connections 6 Unfasten the 2 retaining bolts and 1 screw securing the gun strain relief note the alignment of the gun in the wire drive 7 Installation is the reverse of removal 7 thru 1 WORK CABLE INSTALLATION O1 D The work cable and clamp comes already installed If you should ever need to replace or reinstall the cable do the following Refer to Figure D 3 FIGURE D 3 WORK CABLE AND GROMMET 1 Remove the case sides 2 Pass th
49. pal difference between the two lies in the type of shielding used GMAW uses gas for shielding thus we have Gas Metal Arc Welding FCAW uses the melting or burning of the core ingredi ents for shielding and is thus termed Self Shielded Flux Cored Arc Welding The recommended wire for Gas Metal Arc Welding MIG is Lincolnweld 0 025 0 6 mm L 56 electrode Lincolnweld L 56 is capable of welding a wide range of mild steels in all positions however more skill IS required for out of position welding with the GMAW process PROCESS SELECTION By gaining knowledge of the differences between the two processes you will be able to select the best process for the job you have at hand In selecting a process you should consider MIG PAK HD LINCOLN 8 8 OPERATION B 8 For GMAW MIG Process 1 Is most of my welding performed on 16 gauge and lighter materials 2 Can afford the extra expense space and lack of portability required for gas cylinders and gas sup ply 3 Do require clean finished looking welds If you have answered yes to all the above questions GMAW may be the process for you If you have answered no to any of the above questions then you should consider using the FCAW process For FCAW Innershield Process 1 Do want simplicity and portability 2 Will welding be performed outdoors or under windy conditions 3 Do require good all position welding capability 4 Will most welding be p
50. r le c ble lectrode autour de n importe quelle PR CAUTIONS DE S RET POUR partie du corps LES MACHINES SOUDER 3 Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN 2 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 V V f
51. s sound The correct Is necessary to use correct eye ESO has a distinctive crackling sound very much head and body protection like eggs frying in a pan A long ESO has a hollow blowing or hissing sound If the ESO is too short you may stick the contact tip or nozzle to the weld puddle and or fuse the wire to the contact tip Protect yourself and others read ARC RAYS can burn at the front of this manual 2 The Correct Way To Strike An Arc 1 Be sure the work clamp makes good electrical contact to the work 4 The Correct Welding Speed The important thing to watch while welding is the puddle of molten metal right behind the arc See Figure B 18 Do not watch the arc itself It is the appearance of the puddle and the ridge where the molten puddle solidifies that indicates correct weld ing speed The ridge should be approximately 3 8 10 mm behind the wire electrode 2 Position gun over joint End of wire may be lightly touching the work 3 Position face shield to protect face and eyes close gun trigger and begin welding Hold the gun so that the contact tip to work distance is about 3 8 to 1 2 inch 10 12 mm Most beginners tend to weld too fast resulting in a thin uneven wormy looking bead They are not watching the molten metal 4 To stop welding release the gun trigger and the pull the gun away from the work after the arc goes out 5 A ball may form at the tip end of the wire after wel
52. stant travel speed Output heat range is too low Set the Low High Heat Range switch to High or the Fine Heat Adjustment to MAX Travel speed is slow and or inconsistent Increase and main tain a constant travel speed Output heat range is too high If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility Set the Low High Heat Range switch to Low or the Fine Heat Adjustment to MIN Bead does not penetrate base 1 Travel speed is inconsistent metal Decrease and maintain a con stant travel speed Output heat range is too low Set the Low High Heat Range switch to High or the Fine Heat Adjustment to MAX Wire sputters and sticks to work 1 The wire is damp Change to dry piece wire Be sure wire is stored in a dry location Wire feed speed WFS is too fast Reduce WFS Edge of weld has ragged depres 1 Travel speed is too fast Reduce sions travel speed WFS is too fast Reduce WFS Output heat range is too high Set the Low High Heat Range switch to Low or the Fine Heat Adjustment to MIN CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MIG PAK HD LINCOLN F 1 D
53. t require user intervention MIG PAK HD LINCOLN B 6 OPERATION B 6 LEARNING TO WELD No one can learn to weld simply by reading about it Skill comes only with practice The following pages will help the operator to understand welding and develop this skill THE ARC WELDING CIRCUIT The operators knowledge of arc welding must go beyond the arc itself The operator must know how to control the arc and this requires a knowledge of the welding circuit and the equipment that provides the electric current used in the arc Figure B 5 illustrates the welding circuit for a typical welding machine The circuit begins where the gun cable is attached to the welding machine Current flows through the gun cable gun and contact tip to the wire and across the arc On the work side of the arc current flows through the base metal to the work cable and back to the welding machine This circuit must be complete for the current to flow This machine s welding circuit has a voltage output of 29 volts DC maximum This voltage is quite low and is only present when the gun trigger is depressed To weld the work clamp must be tightly connected to clean base metal Remove paint rust dirt or oil as necessary and connect the work clamp as close as possible to the area you wish to weld This helps pre vent current from going through an unwanted path Avoid allowing the welding circuit to pass through hinges bearings electronic components or
54. t welding position 2 Correct way to strike an arc 3 Correct electrical stickout 4 Correct welding speed is to perform the following exercise OPERATION For the MACHINE use the following Mild Steel 12 gauge or 1 8 inch 3 0 mm 0 035 0 9 mm NR 211 MP Innershield Wire Coarse Voltage Setting Hi Electrode Fine Voltage Setting Wire Speed Feed Seiting Refer to Figure B 20 1 Learn to strike an arc by positioning the gun over the joint and touching the wire to the work 2 Position face shield to protect face and eyes 3 Depress gun trigger hold gun so contact tip to work distance is about 3 8 to 1 2 inch 10 to 12 mm and the gun is at proper angle 4 After you strike the arc practice the correct electri cal stickout Learn to distinguish it by its sound 5 When you are sure that you can hold the correct electrical stickout with a smooth crackling arc start moving Look at the molten puddle constantly and look at the ridge where the metal solidifies 6 Run beads on a flat plate Run them parallel to the top edge the edge farthest away from you This gives you practice in running straight welds and also gives you an easy way to check your progress The 10th weld will look considerably bet ter than the first weld By constantly checking on your mistakes and your progress welding will soon be a matter of routine Contact CE gt LO Git nds CE gt FIGURE B
55. the joint to fill the groove or gap between the two pieces of base metal The core materials also melt or burn in the arc and perform several functions They make the arc stead ier provide a shield of smoke like gas around the arc to keep oxygen and nitrogen in the air away from the molten metal and provide a flux for the molten pool The flux picks up impurities and forms the protective slag on top of the weld during cooling After running a weld bead the slag may be removed with a chipping hammer and wire brush This improves appearance and allows for inspection of the finished weld Since machine size and output characteristics limit the size and type of wire electrode which can be used Lincoln 0 035 0 9 mm NR 211 MP Innershield elec trode is recommended for Self Shielded Flux Cored Arc Welding THE GMAW MIG WELDING ARC Figure B 8 illustrates the GMAW MIG welding arc Solid wire does not contain fluxes or ingredients to form its own shielding and no slag forms to protect the molten weld metal For this reason a continuous even flow of shielding gas is needed to protect the molten weld metal from atmospheric contaminant s such as oxygen and nitrogen Shielding gas is supplied through the gun and cable assembly through the gas nozzle and into the welding zone Gas nozzle Solid wire Shielding gas electrode fim Weld metal FIGURE B 8 When comparing the GMAW and FCAW processes you can see that the princi
56. tle control rods while the engine is running EN 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side AR IN Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 ILINCOLN SAFETY ELECTRIC SHOCK can 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 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 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
57. ts repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MIG PAK HD LINCOLN 8 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FEEDING PROBLEMS No wire feed when gun trigger is The thermostat may be tripped pulled due to overheating Let machine cool Weld within the duty cycle or remove any air obstruction to If all recommended possible areas the machine of misadjustment have been checked and the problem persists Gun trigger may be faulty Contact your local Lincoln Authorized Field Service Drive Roll tension is set too high Facility Wire be kinked or jammed Inspect Drive Roll and Guide Tubes CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MIG PAK HD LINCOLN 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION Bead is too thin intermittently Bead is too thick intermittently WELDING PROBLEMS Travel speed is inconsistent Decrease and maintain a con
58. uching the wire to the work Position face shield to protect face and eyes Depress gun trigger hold gun so contact tip to work distance Is about 3 8 to 1 2 inch 10 to 12 mm and the gun is at proper angle MIG PAK HD LINCOLN 5 15 TROUBLESHOOTING WELDS Good welds have excellent appearance To Eliminate Porosity In order of priority Check or reset WFS amp Volts on chart inside door Clean joints from moisture paint rust etc Increase stickout Decrease drag angle ar N gt Decrease travel speed NOTE Always be sure the joint is free from moisture oil rust paint or other contaminants To Eliminate a Ropy Convex Bead LIME ETC V CE 011 In order of priority Check or reset WFS amp Volts on chart inside door 1 2 Decrease stickout 3 Decrease travel speed 4 Decrease drag angle OPERATION B 15 To Reduce Spatter ICKL In order of priority 1 Check or reset WFS amp Volts on chart inside door 2 Increase drag angle 3 Decrease stickout 4 Decrease travel speed To Correct Poor Penetration In order of priority 1 Check or reset WFS amp Volts on chart inside door 2 Decrease stickout 3 Decrease speed 4 Decrease drag angle If Arc Blow Occurs In order of priority NOTE Try different work connection locations before adjusting procedures 1 Check or reset WFS amp Volts on chart inside door
59. x dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 jamais enroule
60. zzle NS 6 Chipping hammer and brush 7 Starter spool of 035 0 9mm NR211 MP flux cored wire 8 Starter spool of 025 0 6mm solid mig wire 9 Gas regulator and hose with hose clamps 10 Handshield with filter plate and lens For available options and accessories refer to the Accessories Section of this manual MIG PAK HD LINCOLN 3 SELECT SUITABLE LOCATION Place the machine on a secure level surface or rec ommended undercarriage The machine may topple over if this procedure is not followed To minimize over heating locate the welder in a dry location where there is free circulation of clean air Do not place on com bustible surfaces STACKING Machines cannot be stacked CHANGING POLARITY 1 For Negative Polarity Welding DC Refer to Figure A 2 As delivered the machine is wired for Negative polarity with the gun cable connected to the Negative output terminal and the work cable to the Positive output terminal Make sure that both thumbscrews are tight This is the typical con figuration for Flux Cored Welding FCAW FIGURE 2 WORK CABLE GUN CABLE 1 HO GUN CABLE S WORK CABLE Q 2 F ae U U 2 For Positive Polarity Welding DC Refer to Figure A 3 To wire for Positive polarity connect the gun cable to the Positive
Download Pdf Manuals
Related Search