Lincoln Electric PRO 100 manual GUN and Cable Maintenance, For Magnum 100L GUN

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D-2

MAINTENANCE

D-2

 

 

 

GUN AND CABLE

MAINTENANCE

FOR MAGNUM™ 100L GUN

Gun Cable Cleaning

Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using low pressure air, gently blow out the cable liner from the gas diffuser end.

Excessive pressure at the start 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.

Contact Tips, Nozzles, and Gun Tubes

1.Dirt can accumulate in the contact tip hole and restrict wire feeding. After each spool of wire is used, remove the contact tip and clean it by push- ing a short piece of wire through the tip repeatedly. Use the wire as a reamer to remove dirt that may be adhering to the wall of the hole through the tip.

2.Replace worn contact tips as required. A variable or “hunting” arc is a typical symptom of a worn con- tact tip. To install a new tip, choose the correct size contact tip for the electrode being used (wire size is stenciled on the side of the contact tip) and screw it snugly into the gas diffuser.

3.Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required.

4.Be sure the gas nozzle is fully screwed onto the

diffuser for gas shielded processes. For the Inner- shield® process, the gasless nozzle should be screws onto the diffuser.

5.To remove gun tube from gun, remove gas nozzle or gasless nozzle and remove diffuser from gun tube. Remove both collars from each end of the gun handle and separate the handle halves. Loosen the locking nut holding the gun tube in place against the gun end cable connector. Unscrew gun tube from cable connector. To install gun tube, screw the locking nut on the gun tube as far as possible. Then screw the gun tube into the cable connector until it bottoms. Then unscrew (no more than one turn) the gun tube until its axis is perpendicular to the flat sides of the cable connec- tor and pointed in the direction of the trigger. Tight- en the locking nut so as to maintain the proper relationship between the gun tube and the cable connector. Replace the gun handle, trigger and dif- fuser. Replace the gas nozzle or gasless nozzle.

CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM

 

Contact Tip

Cable Liner

Drive Roll

 

 

 

 

Components shipped with

S19726-3

M16291-6

M16190

PRO 100

.035” (0.9mm)

.035” (0.9mm)

Large Knurled, Small Smooth groove

 

 

 

Small .023-.025 (0.6mm)

 

 

 

Large .030/.035” (0.8/0.9mm)

 

 

 

 

K610-1 .023/.025”(0.6mm)

S19726-1

M16291-2

Use Standard Drive Roll

MIG Conversion Kit•

.025” (0.6mm)

.030 (0.8mm)

Small Smooth Groove

 

 

 

 

K664-2 .035 (0.9mm)

S24221-1

M18971-1

M19631

Aluminum or Stainless Kit*

.035A (0.9mm)

.035” (0.9mm)

 

 

 

 

 

 

 

 

 

•If .030 Solid wire feeding is desired obtain an S19726-2 Contact Tip.

*It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire. Failure to do so may result in contaminated welds when welding aluminum.

PRO 100

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Contents PRO Safety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcThank You Please Examine Carton and Equipment For Damage ImmediatelyTable of Contents Installation Technical Specifications PROInstallation Safety PrecautionsRead entire installation section before starting Identify and Locate ComponentsOutput Connections Work Clamp InstallationSelect Suitable Location StackingConnecting Gun Cable to the PRO GUN InstallationWork Cable Installation GAS Connection OptionalFigure A.5 Code Requirements for Input Connections Input ConnectionsRequirements For Rated Output Requirements For CSA Rated OutputFumes and Gases can be dangerous Observe all safety information throughout this manual1OPERATIONB-1 Welding Sparks can cause fire or explosionOperation Welding Operations Wire LoadingSequence of Operation Friction Brake Adjustments Wire ThreadingProcess Guidelines Cleaning Tip And NozzleMaking a Weld Welding with Gmaw MIG Changing Machine Over to Feed Other Wire SizesOverload Protection ARC-WELDING Circuit Learning to WeldLearning to Weld SELF-SHIELDED Fcaw Welding ARCProcess Selection Gmaw MIG Welding ARCFor Gmaw MIG Process For Fcaw Innershield Process Common MetalsJoint Types and Positions Butt WeldsPenetration Welding In The Vertical PositionFillet Welds Vertical-down Welding Machine SET UP for the SELF-SHIELDED Fcaw ProcessWelding Techniques for the SELF- Shielded Fcaw Process Correct Welding PositionCorrect Electrical Stickout ESO Correct Welding SpeedHelpful Hints PracticeMachine SET UP for the Gmaw MIG Process Welding Techniques for the Gmaw MIG ProcessFor the PRO 100, use the following To Correct Poor Penetration in order of impor- tance Troubleshooting WeldsTo Eliminate a Ropy Convex Bead in order of importance To Eliminate Stubbing* in order of importanceProper Gun Handling Application Chart MIG Conversion AccessoriesOptional Accessories K610-1 MIG Conversion Kit for the PROMaintenance Safety Precautions MaintenanceRoutine Maintenance For Magnum 100L GUN GUN and Cable MaintenanceConfiguration of Components in Wire Feeding System Contact Tip Cable Liner Drive RollChanging the Contact TIP Component Replacement ProceduresChanging Drive Roll Changing Liner Liner trim lengthGUN Handle Parts Figure D.31TROUBLESHOOTINGE-1 HOW to USE Troubleshooting GuideProblems Possible Areas Symptoms Misadjustments TroubleshootingTroubleshooting Guide Recommended Course of ActionFeeding Problems Welding Problems Diagrams PRO100 Wiring DiagramPRO Need Welding Training? How To Read Shop DrawingsNew Lessons in Arc Welding $700.00Precaucion Warnung

PRO 100 specifications

The Lincoln Electric PRO 100 is a compact and versatile multi-process welder designed to meet the needs of both novice and experienced welders. Known for its robust build quality and advanced features, the PRO 100 is engineered for tasks ranging from light fabrication to heavy-duty welding projects.

One of the standout features of the PRO 100 is its multi-process capability. It can seamlessly switch between MIG, Stick, and TIG welding, allowing users to tackle various materials including aluminum, stainless steel, and mild steel with ease. This versatility makes it an essential tool for welding professionals and hobbyists alike, enhancing productivity and efficiency on the job.

The machine is equipped with Lincoln Electric's unique Auto-Set technology, which simplifies the setup process for users. By automatically adjusting the voltage and wire feed speed based on the selected material and thickness, it enables welders to achieve optimal results without extensive experience or technical knowledge. This feature not only saves time but also reduces the likelihood of mistakes, making it ideal for beginners.

Powering the PRO 100 is a reliable inverter-based technology that ensures smooth and consistent arcs. This technology not only enhances performance but also improves energy efficiency, making the machine more cost-effective in the long run. The compact design allows for portability, making it convenient for job sites where space may be limited.

The PRO 100 also boasts several safety features that protect both the user and the machine. It includes an overload protection system that prevents overheating, ensuring the longevity of the welder. Additionally, the welder features a rugged construction that can withstand demanding work environments, further enhancing its durability.

Furthermore, the PRO 100 is designed for user comfort and control. The intuitive interface and large color display provide clear readability of settings and parameters, allowing for quick adjustments. The adjustable wire feed speed and voltage settings give welders the flexibility to customize their welding experience.

In summary, the Lincoln Electric PRO 100 stands out in the crowd of welding machines for its multi-process capabilities, Auto-Set technology, and inverter-based power system. Its combination of portability, durability, and user-friendly features makes it an excellent choice for a wide range of welding applications, whether at home, in the workshop, or on the field. This well-rounded welder can help elevate the quality of the work for both the novice and the seasoned professional.
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