Lincoln Electric IM546 2MAINTENANCE, GUN and Cable Maintenance, Component Replacement Procedures

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D-2MAINTENANCE

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.

CAUTION

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 proce- dure 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 pushing 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 contact tip. To install a new tip, choose the correct size con- tact tip for the electrode being used (wire size is stenciled on the side of the con- tact tip) and screw it snugly into the gas diffuser.

3.Remove spatter from inside of gas noz- zle 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 Innershield® 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 perpendicu- lar to the flat sides of the cable connector and pointed in the direction of the trigger. Tighten the locking nut so as to maintain the proper relationship between the gun tube and the cable connector. Replace the gun handle, trigger and diffuser. Replace the gas nozzle or gasless noz- zle.

COMPONENT

REPLACEMENT

PROCEDURES

CHANGING THE CONTACT TIP

1.Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise.

2.Remove the existing contact tip from the gun by unscrewing counter-clockwise.

3.Insert and hand tighten desired contact tip.

4.Replace gas nozzle.

WELD-PAK 100

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Contents Safety Depends on You WELD-PAK 100 PlusSafety ARC Welding can be hazardousCylinder may explode if damaged Electric and Magnetic Fields IiiPrécautions DE Sûreté Sûreté Pour Soudage a LʼArcPlease Examine Carton and Equipment For Damage Immediately Master Table of Contents for ALL Sections Vii INSTALLATIONA-1 Technical Specifications WELD-PAK2INSTALLATION Safety PrecautionsIdentify and Locate Components INSTALLATIONA-3 Select Suitable LocationOutput Connections Stacking4INSTALLATION GUN InstallationWork Cable Installation Connecting Gun Cable to the WELD-PAKINSTALLATIONA-5 Figure A.56INSTALLATION Input ConnectionsRequirements For Rated Output Code Requirements for Input ConnectionsObserve all safety information throughout this manual OPERATIONB-1Fumes and Gases can be dangerous Welding Sparks can cause fire or explosion2OPERATION Wire Loading OPERATIONB-3Welding Operations Sequence of OperationFriction Brake Adjustment Wire Threading4OPERATION Cleaning Tip And Nozzle OPERATIONB-5Process Guidelines Making a WeldChanging Machine Over to Feed Other Wire Sizes 6OPERATIONWelding 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 Machine SET UP for the SELF-SHIELDED Fcaw Process Common MetalsWelding Techniques for the SELF- Shielded Fcaw Process For Fcaw Innershield ProcessCorrect Electrical Stickout ESO Correct Welding SpeedElectrode Voltage Setting Wire Feed Speed oo Helpful HintsPractice Back-SteppingMachine SET UP for the Gmaw MIG Process Welding Techniques for the Gmaw MIG ProcessVoltage Setting Wire Feed Speed oo Mild SteelElectrode Joint Types and Positions PenetrationButt Welds Fillet WeldsWelding In The Vertical Position Vertical-down WeldingTroubleshooting Welds To Eliminate a Ropy Convex Bead in order of importanceTo 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 2MAINTENANCE GUN and Cable MaintenanceComponent Replacement Procedures For Magnum 100L GUNMAINTENANCED-3 Changing Drive Roll4MAINTENANCE Changing LinerLiner trim length MAINTENANCED-5 GUN Handle Parts6NOTES TROUBLESHOOTINGE-1 HOW to USE Troubleshooting Guide2TROUBLESHOOTING Troubleshooting GuideProblems Possible Areas Symptoms Misadjustments Recommended Course of ActionTROUBLESHOOTINGE-3 Feeding Problems4TROUBLESHOOTING Welding ProblemsWiring Diagrams Weldpak 100 Wiring Diagram100 2NOTES WELD-PAK PartsMain Exploded Diagram 2PARTSDescription Reqʼd Complete Drive ASSEMBLY/MOTOR 4PARTSCase Front Assembly PARTS5RECTIFIER, FAN and Bracket Assembly 6PARTSCenter Panel Assembly PARTS7Magnum 100L Assembly 8PARTSSquare Wave TIG Square Wave TIG How To Read Shop Drawings New Lessons in Arc WeldingNeed Welding Training? $700.00Precaucion Guards off Superseded
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