MAINTENANCED-1, Routine Maintenance | Lincoln Electric IM546

MAINTENANCED-1

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

•Disconnect input power by removing plug from receptacle before working inside WELD-PAK 100. Use only ground- ed receptacle. Do not touch electrically “hot” parts inside WELD-PAK 100.

•Have qualified personnel do the mainte- nance and trouble shooting work.

ROUTINE MAINTENANCE

POWER SOURCE COMPARTMENT

No user serviceable parts inside! Do not attempt to perform service in the power source (fixed) side of the WELD-PAK

100.Take the unit to an authorized Lincoln Service Center if you experience problems. NO maintenance is required.

WIRE FEED COMPARTMENT

1.When necessary, vacuum accumulated dirt from gearbox and wire feed section.

2.Occasionally inspect the incoming guide tube and clean inside diameter is necessary.

3.Motor and gearbox have lifetime lubrication and require no maintenance.

FAN MOTOR

Has lifetime lubrication — requires no maintenance.

WIRE REEL SPINDLE

Requires no maintenance. Do not lubricate shaft.

WELD-PAK 100

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Lincoln Electric IM546 manual MAINTENANCED-1, Maintenance Safety Precautions, Routine Maintenance

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 Identify and Locate Components 2INSTALLATIONSafety Precautions 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 4OPERATION Friction Brake AdjustmentWire Threading 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 For Gmaw MIG Process Gmaw MIG Welding ARCProcess Selection 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 Electrode Voltage Setting Wire Feed Speed ooMild Steel 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 MIG Conversion ACCESSORIESC-1Optional Accessories 2NOTES Routine Maintenance MAINTENANCED-1Maintenance Safety Precautions For Magnum 100L GUN 2MAINTENANCEGUN and Cable Maintenance Component Replacement Procedures Changing Drive Roll MAINTENANCED-3 Liner trim length 4MAINTENANCEChanging Liner 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 100 Wiring DiagramsWeldpak 100 Wiring Diagram 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