OPERATIONB-1

Read entire operation section before operating the WELD-PAK 100.

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.

Observe all safety information throughout this manual.

WELD-PAK 100

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Lincoln Electric IM546 manual OPERATIONB-1, Fumes and Gases can be dangerous, Welding Sparks can cause fire or explosion

Contents

WELD-PAK 100 Plus Safety Depends on You ARC Welding can be hazardous Safety Cylinder may explode if damaged Iii Electric and Magnetic Fields Sûreté Pour Soudage a LʼArc Précautions DE Sûreté Please Examine Carton and Equipment For Damage Immediately Master Table of Contents for ALL Sections Vii Technical Specifications WELD-PAK INSTALLATIONA-1 2INSTALLATION Safety PrecautionsIdentify and Locate Components Stacking INSTALLATIONA-3Select Suitable Location Output Connections Connecting Gun Cable to the WELD-PAK 4INSTALLATIONGUN Installation Work Cable Installation Figure A.5 INSTALLATIONA-5 Code Requirements for Input Connections 6INSTALLATIONInput Connections Requirements For Rated Output Welding Sparks can cause fire or explosion Observe all safety information throughout this manualOPERATIONB-1 Fumes and Gases can be dangerous 2OPERATION Sequence of Operation Wire LoadingOPERATIONB-3 Welding Operations Friction Brake Adjustment Wire Threading4OPERATION Making a Weld Cleaning Tip And NozzleOPERATIONB-5 Process Guidelines Overload Protection Changing Machine Over to Feed Other Wire Sizes6OPERATION Welding with Gmaw MIG SELF-SHIELDED Fcaw Welding ARC Learning to WeldLearning to Weld ARC-WELDING Circuit Gmaw 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 Process Correct Welding Speed Correct Electrical Stickout ESO Back-Stepping Electrode Voltage Setting Wire Feed Speed ooHelpful Hints Practice Welding Techniques for the Gmaw MIG Process Machine SET UP for the Gmaw MIG Process Voltage Setting Wire Feed Speed oo Mild SteelElectrode Fillet Welds Joint Types and PositionsPenetration Butt Welds Vertical-down Welding Welding In The Vertical Position To 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- tance Proper 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 Procedures Changing Drive Roll MAINTENANCED-3 4MAINTENANCE Changing LinerLiner trim length GUN Handle Parts MAINTENANCED-5 6NOTES HOW to USE Troubleshooting Guide TROUBLESHOOTINGE-1 Recommended Course of Action 2TROUBLESHOOTINGTroubleshooting Guide Problems Possible Areas Symptoms Misadjustments Feeding Problems TROUBLESHOOTINGE-3 Welding Problems 4TROUBLESHOOTING Wiring Diagrams Weldpak 100 Wiring Diagram100 2NOTES Parts WELD-PAK 2PARTS Main Exploded Diagram Description Reqʼd 4PARTS Complete Drive ASSEMBLY/MOTOR PARTS5 Case Front Assembly 6PARTS RECTIFIER, FAN and Bracket Assembly PARTS7 Center Panel Assembly 8PARTS Magnum 100L Assembly Square Wave TIG Square Wave TIG $700.00 How To Read Shop DrawingsNew Lessons in Arc Welding Need Welding Training? Precaucion Guards off Superseded