Lincoln Electric IM546 manual Cylinder may explode if damaged

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SAFETY

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WELDING SPARKS can cause fire or explosion.

4.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.

4.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.

4.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.

4.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).

4.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

4.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.

4.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.

4.h. Also see item 7c.

CYLINDER may explode if damaged.

5.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.

5.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

5.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.

5.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

5.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

5.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

5.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.

FOR ELECTRICALLY powered equipment.

6.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations.

6.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturerʼs recommendations.

Mar. ʻ93

WELD-PAK 100

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Contents WELD-PAK 100 Plus Safety Depends on YouARC Welding can be hazardous SafetyCylinder may explode if damaged Iii Electric and Magnetic FieldsSûreté Pour Soudage a LʼArc Précautions DE SûretéPlease Examine Carton and Equipment For Damage Immediately Master Table of Contents for ALL Sections Vii Technical Specifications WELD-PAK INSTALLATIONA-12INSTALLATION Safety PrecautionsIdentify and Locate Components Stacking INSTALLATIONA-3Select Suitable Location Output ConnectionsConnecting Gun Cable to the WELD-PAK 4INSTALLATIONGUN Installation Work Cable InstallationFigure A.5 INSTALLATIONA-5Code Requirements for Input Connections 6INSTALLATIONInput Connections Requirements For Rated OutputWelding Sparks can cause fire or explosion Observe all safety information throughout this manualOPERATIONB-1 Fumes and Gases can be dangerous2OPERATION Sequence of Operation Wire LoadingOPERATIONB-3 Welding OperationsFriction Brake Adjustment Wire Threading4OPERATION Making a Weld Cleaning Tip And NozzleOPERATIONB-5 Process GuidelinesOverload Protection Changing Machine Over to Feed Other Wire Sizes6OPERATION Welding with Gmaw MIGSELF-SHIELDED Fcaw Welding ARC Learning to WeldLearning to Weld ARC-WELDING CircuitGmaw MIG Welding ARC Process SelectionFor Gmaw MIG Process For Fcaw Innershield Process Machine SET UP for the SELF-SHIELDED Fcaw ProcessCommon Metals Welding Techniques for the SELF- Shielded Fcaw ProcessCorrect Welding Speed Correct Electrical Stickout ESOBack-Stepping Electrode Voltage Setting Wire Feed Speed ooHelpful Hints PracticeWelding Techniques for the Gmaw MIG Process Machine SET UP for the Gmaw MIG ProcessVoltage Setting Wire Feed Speed oo Mild SteelElectrode Fillet Welds Joint Types and PositionsPenetration Butt WeldsVertical-down Welding Welding In The Vertical PositionTo Eliminate Stubbing* in order of importance Troubleshooting WeldsTo Eliminate a Ropy Convex Bead in order of importance To Correct Poor Penetration in order of impor- tanceProper Gun Handling Application Chart ACCESSORIESC-1 Optional AccessoriesMIG Conversion 2NOTES MAINTENANCED-1 Maintenance Safety PrecautionsRoutine Maintenance For Magnum 100L GUN 2MAINTENANCEGUN and Cable Maintenance Component Replacement ProceduresChanging Drive Roll MAINTENANCED-34MAINTENANCE Changing LinerLiner trim length GUN Handle Parts MAINTENANCED-56NOTES HOW to USE Troubleshooting Guide TROUBLESHOOTINGE-1Recommended Course of Action 2TROUBLESHOOTINGTroubleshooting Guide Problems Possible Areas Symptoms MisadjustmentsFeeding Problems TROUBLESHOOTINGE-3Welding Problems 4TROUBLESHOOTINGWiring Diagrams Weldpak 100 Wiring Diagram100 2NOTES Parts WELD-PAK2PARTS Main Exploded DiagramDescription Reqʼd 4PARTS Complete Drive ASSEMBLY/MOTORPARTS5 Case Front Assembly6PARTS RECTIFIER, FAN and Bracket AssemblyPARTS7 Center Panel Assembly8PARTS Magnum 100L AssemblySquare Wave TIG Square Wave TIG $700.00 How To Read Shop DrawingsNew Lessons in Arc Welding Need Welding Training?Precaucion Guards off Superseded