Lincoln Electric IM546 manual ACCESSORIESC-1, Optional Accessories, MIG Conversion

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ACCESSORIESC-1

OPTIONAL ACCESSORIES

1.K520 Utility Cart — Designed to trans- port the Lincoln family of small welders. Has provisions for mounting a single gas cylinder. Has front casters and large rear wheels. Handle height is easily adjustable. Bottom tray provided for tools and accessories. Easy assembly required; takes less than 15 minutes.

2.K664-1 Aluminum Feeding Kit — This kit required for welding with .035 Aluminum wire. This kit may also be used for feeding .035 stainless wire. Included with this kit are a drive roll, liner and contact tip. It is important when changing between welding with steel wire and aluminum to exchange these components due to the lubricant applied to steel wire. Failure to do so may result in contaminated welds when welding aluminum.

3.K610-1 MIG Conversion Kit for the WELD-PAK 100 — Complete kit for use with .025" (0.6 mm) electrode wire and

either CO2 or Argon-mixed gas. Includes

.025-.030" (0.6-0.8 mm) cable liner, two

.025" (0.6 mm) contact tips, gas nozzle, 2 lb. spool of .025" (0.6 mm) L-56 elec- trode, gas regulator, gas hose, regulator

adapter for CO2 cylinders and gas sole- noid assembly, with all necessary hard- ware and easy instructions for installing gas solenoid. Use with .030" (0.8 mm) wire requires additional .030" (0.8 mm) contact tip and electrode wire.

MIG CONVERSION

Several changes are needed to convert the unit for operation with the MIG (GMAW) process. The K610-1 MIG Conversion Kit for the WELD-PAK 100 includes all the nec- essary accessories for this conversion and is provided for this purpose. The following conversions should be made using the con- tents of this kit:

1.Install the gas solenoid. Complete instructions are included with the kit.

2.Change the output polarity to DC(+). See “Work Cable Installation” in Installation section for details.

3.Change drive roll orientation (if required) for the wire size selected. See “Changing Drive Roll” in Maintenance section for details.

4.Install the proper gun liner and tip for the wire size selected. See “Component Replacement” in Maintenance section for details.

5.Remove gasless nozzle (if installed) and install gas nozzle. To remove, simply unscrew.

6.Load wire into machine and thread into gun and cable per “Welding Wire Loading” section.

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 Select Suitable Location INSTALLATIONA-3Output Connections StackingGUN Installation 4INSTALLATIONWork Cable Installation Connecting Gun Cable to the WELD-PAKFigure A.5 INSTALLATIONA-5Input Connections 6INSTALLATIONRequirements For Rated Output Code Requirements for Input ConnectionsOPERATIONB-1 Observe all safety information throughout this manualFumes and Gases can be dangerous Welding Sparks can cause fire or explosion2OPERATION OPERATIONB-3 Wire LoadingWelding Operations Sequence of OperationFriction Brake Adjustment Wire Threading4OPERATION OPERATIONB-5 Cleaning Tip And NozzleProcess Guidelines Making a Weld6OPERATION Changing Machine Over to Feed Other Wire SizesWelding with Gmaw MIG Overload ProtectionLearning to Weld Learning to WeldARC-WELDING Circuit SELF-SHIELDED Fcaw Welding ARCGmaw MIG Welding ARC Process SelectionFor Gmaw MIG Process Common Metals Machine SET UP for the SELF-SHIELDED Fcaw ProcessWelding Techniques for the SELF- Shielded Fcaw Process For Fcaw Innershield ProcessCorrect Welding Speed Correct Electrical Stickout ESOHelpful Hints Electrode Voltage Setting Wire Feed Speed ooPractice Back-SteppingWelding Techniques for the Gmaw MIG Process Machine SET UP for the Gmaw MIG ProcessVoltage Setting Wire Feed Speed oo Mild SteelElectrode Penetration Joint Types and PositionsButt Welds Fillet WeldsVertical-down Welding Welding In The Vertical PositionTo Eliminate a Ropy Convex Bead in order of importance Troubleshooting WeldsTo Correct Poor Penetration in order of impor- tance To Eliminate Stubbing* in order of importanceProper Gun Handling Application Chart ACCESSORIESC-1 Optional AccessoriesMIG Conversion 2NOTES MAINTENANCED-1 Maintenance Safety PrecautionsRoutine Maintenance GUN and Cable Maintenance 2MAINTENANCEComponent Replacement Procedures For Magnum 100L GUNChanging Drive Roll MAINTENANCED-34MAINTENANCE Changing LinerLiner trim length GUN Handle Parts MAINTENANCED-56NOTES HOW to USE Troubleshooting Guide TROUBLESHOOTINGE-1Troubleshooting Guide 2TROUBLESHOOTINGProblems Possible Areas Symptoms Misadjustments Recommended Course of ActionFeeding 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 New Lessons in Arc Welding How To Read Shop DrawingsNeed Welding Training? $700.00Precaucion Guards off Superseded
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