Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
For use with machine Code Numbers
For use with machine Code Numbers
For use with machine Code Numbers
For use with machine Code Numbers
For use with machine Code Numbers
For use with machine Code Numbers
• World's Leader in Welding and Cutting Products •
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i
SAFETY
WARNING
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can
kill.
1.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
1.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or Iying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
1.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
1.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
1.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
2.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
ARC RAYS can burn.
2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
FUMES AND GASES
can be dangerous.
3.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
1.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
1.g. Never dip the electrode in water for cooling.
1.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
1.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
1.j. Also see Items 4.c. and 6.
WELD-PAK 100
3.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.
3.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.d. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.e. Also see item 7b.
vapors
Apr. ʻ93
to
SAFETY
ii
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.
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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.
Sparks and spatter are thrown from the welding arc. Wear oil
4.f.
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 circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
4.h. Also see item 7c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
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
iii
SAFETY
FOR ENGINE
powered equipment.
7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
7.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not
start engine until fumes have been
eliminated.
7.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
ELECTRIC AND MAGNETIC
FIELDS
may be dangerous
8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
8.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
8d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
8.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
8.d.2. Never coil the electrode lead around your body.
8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
8.d.4. Connect the work cable to the workpiece as close as
7.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
Mar. ʻ93
WELD-PAK 100
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de nʼimporte quelle
partie du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du
rayonnement de lʼarc et des projections quand on soude
ou quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection
libres de lʼhuile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de lʼélectricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la
debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ʻ93
WELD-PAK 100
v
for selecting a QUALITY product by Lincoln Electric.
We want you to take pride in operating this Lincoln
Thank You
Electric Company product ••• as much pride as we
have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the time
the shipment is received.
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Code Number _____________________________________
Serial Number _____________________________________
Model Name_____________________________________
Date of Purchase __________________________________
Whenever you request replacement parts for or information on this equipment always supply the information you
have recorded above.
Read this Operatorʼs Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
WELD-PAK 100
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Installation .......................................................................................................Section A
12.0 in9.75 in16.5 in47 Ibs
305 mm248 mm419 mm21.4 kg
WELD-PAK 100
A-2
WELD
-
P
AK 10
0
1
2
3
4
5
6
7
8
10
9
INSTALLATION
Read entire installation section before starting
FIGURE A.1
installation.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform
this installation.
• Only personnel that have read and understood the WELD-PAK 100 Operating
Manual should install and operate this
equipment.
• Machine must be plugged into a receptacle
which is grounded per any national, local
or other applicable electrical codes.
• The WELD-PAK 100 power switch is to be
in the OFF (“O”) position when installing
work cable and gun and when connecting
power cord to input power.
WELD-PAK 100
IDENTIFY AND LOCATE
COMPONENTS
If you have not already done so, unpack the Weld-Pak
100 from its carton and remove all packing material
around the WELD-PAK 100. Remove the following
loose items from the carton (see Figure A.1):
For available options and accessories refer to the
Accessories Section of this manual.
(1)
The gun is ready to feed 0.035" (0,9 mm)
Innershield wire.
WELD-PAK 100JAN96
INSTALLATION
WELD-PAK 100
4
5
8
36
7
1
2
SCREW
PLASTIC HANDLE
WORK CABLE
BACKING PLATE & NUT
A-3
SELECT SUITABLE LOCATION
Locate the welder in a dry location where there is free
circulation of clean air into the louvers in the back and
out the front of the unit. A location that minimizes the
amount of smoke and dirt drawn into the rear louvers
reduces the chance of dirt accumulation that can block
air passages and cause overheating.
STACKING
WELD-PAK 100ʼs cannot be stacked.
TILTING
Each machine must be placed on a secure, level surface, either directly or on a recommended undercarriage. The machine may topple over if this procedure
is not followed.
OUTPUT CONNECTIONS
Refer to Figure A.2.
1. Work Cable Access Hole.
Work Clamp Installation
Attach the work clamp per the following: Refer to
Figure A-3.
FIGURE A.3
SCREW
1. Remove the screw, pressure plate and backing nut
from clamp.
2. Remove plastic handle from same side of clamp by
pulling steadily on handle until it slides off clamp.
3. Insert the work cable terminal lug with the larger
hole through the hole in the end of the plastic handle. Slide plastic handle several inches further onto
cable to allow easy and clear access to terminal
lug.
PLASTIC HANDLE
WORK CABLE
BACKING PLATE & NUT
2. Gun Cable and Control Lead Access Hole.
3. Connector Block.
4. Gun Trigger Lead Connectors.
5. Positive (+) and negative (–) output terminals.
WELD-PAK 100
4. Secure work cable to clamp by inserting screw
through hole in clamp, attaching cable lug on inside
of clamp, and installing pressure plate and backing
nut. make sure pressure plate is installed such that
it prevents nut from turning. tighten screw securely.
5. Slide plastic handle back onto clamp and into original position.
FIGURE A.2
+
-
WELD-PAK 100
1
2
4
3
A-4
INSTALLATION
Work Cable Installation
Refer to Figure A.2.
1. Open the wire feed section door on the right side of
the WELD-PAK 100.
2. Pass the end of the work cable that has the terminal lug with the smaller hole through the Work
Cable Access Hole (1) in the case front.
3. Route the cable under and around the back of the
Wire Feed Gearbox (6).
4. For Innershield Only: Refer to Figure A.2. As
delivered, the WELD-PAK 100 is connected for
negative electrode polarity. This is the appropriate
configuration for the Innershield process. To complete installation, use the provided wing nut to connect the work cableʼs terminal lug to the positive (+)
output terminal (5) located above the Wire Feed
Gearbox (6). Make sure that both wing nuts are
tight.
5. For GMAW Only: Refer to Figure A.4. To wire for
positive polarity (required for the MIG process),
connect the short cable attached to the connector
block (1) to the positive (+) output terminal (4) and
the work cable (3) to the negative (–) terminal (2).
FIGURE A.4
appropriate size. Additionally, the .023 – .030" (0.6 –
0.8 mm) gun liner included in the K610-1 MIG
Conversion Kit must be installed. Refer to the MAINTENANCE section for contact tip installation details.
Connecting Gun Cable to the WELD-PAK
100
1. Refer to Figure A.2. Unplug the machine or turn
power switch to the OFF “O” position.
2. Pass the insulated terminals of the gun trigger control leads, one at a time, through the Gun Cable
and Control Lead Access Slot (2) in the case front.
The leads are to be routed under the Wire Feed
Gearbox (6) and through the Cable Hanger (7) on
the inner panel.
3. Insert the connector on the gun conductor cable
through the Gun Cable Access Hole (2) in the
WELD-PAK 100 case front. Make sure the connector is all the way in the brass connector block.
Unscrew thumbscrew on the connector block a few
turns if gun connector will not insert fully. Rotate
the connector so control leads are on the underside and tighten the Thumbscrew (8) in the connector block.
4. Connect the gun trigger control lead terminals to
the two insulated 1/4" (6,4 mm) tab terminal connector bushings located above the “Gun Trigger
Connection” decal in the wire feed section (4).
Either lead can go to either connector. Form the
leads so that they are as close as possible to the
inside panel.
If the gun trigger switch being used is other than
that supplied with the WELD-PAK 100, the switch
must be a normally open, momentary switch. The
terminals of the switch must be insulated from the
welding circuit. Malfunction of the WELD-PAK 100
may result if this switch shorts to the WELD-PAK
100 welding output circuit or is common to any
electrical circuit other than the WELD-PAK 100
trigger circuit.
CAUTION
GUN INSTALLATION
As shipped from the factory, the WELD-PAK 100 gun
is ready to feed 0.035” (0,9 mm) wire. If .023" – .025"
(0,6 mm) or .030" (0.8 mm) wire is to be used for the
GMAW (MIG) process, change the contact tip to the
WELD-PAK 100
GAS CONNECTION (OPTIONAL)
When using the GMAW process, a K610-1 MIG conversion kit and a cylinder of carbon dioxide (CO
argon-carbon dioxide mixed shielding gas must be
obtained. For more information about the K610-1 MIG
Conversion Kit for use with the WELD-PAK 100, refer
to the ACCESSORIES section.
)or
2
INSTALLATION
A-5
WARNING
CYLINDER may explode if damaged. Keep cylinder upright and
chained to support
• Keep cylinder away from areas
where it may be damaged.
• Never lift welder with cylinder
attached.
• Never allow welding electrode to
touch cylinder.
• Keep cylinder away from welding
or other live electrical circuits.
WARNING
BUILDUP OF SHIELDING GAS may
harm health or kill.
• Shut off shielding gas supply
when not in use.
• SEE AMERICAN NATIONAL
STANDARD Z-49.1, “SAFETY IN
WELDING AND CUTTING” PUBLISHED BY THE AMERICAN
WELDING SOCIETY.
1. Chain the cylinder to a wall or other stationary support to prevent the cylinder from falling over.
Insulate the cylinder from the work circuit and earth
ground. Refer to Figure A.5.
2. With the cylinder securely installed, remove the
cylinder cap. Stand to one side away from the outlet and open the cylinder valve very slightly for an
instant. This blows away any dust or dirt which may
have accumulated in the valve outlet.
WARNING
BE SURE TO KEEP YOUR FACE AWAY FROM THE
VALVE OUTLET WHEN “CRACKING” THE VALVE.
Never stand directly in front of or behind the flow
regulator when opening the cylinder valve. Always
stand to one side.
3. Attach the flow regulator to the cylinder valve and
tighten the union nut securely with a wrench..
NOTE: If connecting to 100% CO
regulator adapter (provided with MIG Conversion
Kit for the WELD-PAK 100) between regulator and
cylinder valve. If adapter is equipped with a plastic
washer, be sure it is seated for connection to the
CO
cylinder.
2
4. Refer to Figure A.6. Attach one end of inlet gas
hose to the outlet fitting of the flow regulator and
tighten the union nut securely with a wrench.
Connect the other end to the WELD-PAK 100 Gas
Solenoid Inlet Fitting (5/8-18 female threads — for
CGA — 032 fitting). Make certain the gas hose is
not kinked or twisted.
cylinder, insert
2
Flow Regulator
Gas Hose
FIGURE A.5
Cylinder Valve
WELD-PAK 100
A-6
INSTALLATION
INPUT CONNECTIONS
FIGURE A.6
OPTIONAL GAS
SOLENOID INLET FITTING
POWER INPUT
CABLE
Refer to Figure A.6.
The WELD-PAK 100 has a power input cable located
on the rear of the machine.
CODE REQUIREMENTS FOR INPUT
CONNECTIONS
Requirements For Rated Output
A power cord with a 15 amp, 125 volt, three prong
plug (NEMA Type 5-15P) is factory installed on the
WELD-PAK 100. Connect this plug to a mating
grounded receptacle which is connected to a 20 amp
branch circuit with a nominal voltage rating of 115 to
125 volts, 60 Hertz, AC only.
The rated output with this installation is 88 amps, 18
Volts, 20% duty cycle (2 minutes of every 10 minutes
used for welding).
CAUTION
Do not connect the WELD-PAK 100 to an input
power supply with a rated voltage that is greater
than 125 volts.
Do not remove the power cord ground prong.
Requirements For CSA Rated Output
A line cord with a 15 amp, 125 volt, three-prong plug
(NEMA Type 5-15P) is factory installed. Connect this
plug to a mating grounded receptacle which is connected to a 15 amp branch circuit with a nominal voltage rating of 115 volts to 125 volts, 60 hertz, AC only.
With this installation, the WELD-PAK 100 can be used
at an output of 62 amps, 20 volts, 20% duty cycle.
WARNING
This welding machine must be connected to
power source in accordance with applicable electrical codes.
The United States National Electrical Code (Article
630-B, 1990 Edition) provides standards for
amperage handling capability of supply conductors based on duty cycle of the welding source.
If there is any question about the installation
meeting applicable electrical code requirements,
consult a qualified electrician.
WELD-PAK 100
OPERATION
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.
B-1
WELDING SPARKS can
cause fire or explosion.
• Keep flammable material away.
• Do not weld on closed containers.
ARC RAYS can burn eyes
and skin.
• Wear eye, ear and body protection.
Observe all safety information throughout
this manual.
WELD-PAK 100
B-2
OPERATION
GENERAL DESCRIPTION
The WELD-PAK 100 is a compact lightweight DC wire
feeder/power source. It has been designed for workshop, hobby, and light maintenance. It is capable of
general purpose welding with self-shielded flux-cored
(Innershield
K610-1 MIG Conversion Kit, the WELD-PAK 100 is
suitable for GMAW (MIG) welding applications.
The WELD-PAK 100 is ideally suited for individuals
having access to 115 volt AC input power, and wanting the ease of use, quality and dependability of both
gas metal arc welding or GMAW (also known as MIG
welding) and the Innershield electrode process (self
shielded flux cored or FCAW). The WELD-PAK 100 is
a rugged and reliable machine that has been
designed for dependable service and long life.
®
) wire. When combined with the optional
RECOMMENDED PROCESSES
The WELD-PAK 100 can be used for welding mild
steel using the self shielded, Innershield electrode
process (FCAW) or it can be used for the GMAW, single pass, process which requires a supply of shielding
gas and the K610-1 MIG Conversion Kit. The WELDPAK 100 is configured for use with the FCAW process
as delivered from the factory.
OPERATIONAL FEATURES AND
CONTROLS
The WELD-PAK 100 has the following controls as
standard: Power ON/OFF Switch, Voltage Control,
Wire Speed Control, Trigger Switch, and a Circuit
Breaker.
DESIGN FEATURES AND
ADVANTAGES
● Operates on 115 volt input — no special wiring
required.
● “Cold electrode” until gun trigger is pressed for an
added measure of safety.
● Overload protection — incorporates both a thermo-
stat and a circuit breaker.
● Quality wire drive with electronic overload protec-
tion.
● No external shielding gas is required when used
with Lincoln Innershield .035” (0,9 mm) NR®-211MP electrode.
● Accommodates 4” (100 mm) diameter spool of
wire. Will accommodate 8” (200 mm) diameter with
optional spindle.
WELDING CAPABILITY
The WELD-PAK 100 is rated at 88 amps, 18 volts, at
20% duty cycle on a ten minute basis. CSA rated output at 62 amps at 20 volts at 20% duty cycle. It is
capable of higher output currents at lower duty cycles.
LIMITATIONS
Arc Gouging cannot be performed with the WELDPAK 100. The WELD-PAK 100 is not recommended
for pipe thawing or TIG welding.
CONTROLS AND SETTINGS
Refer to Figure B.1a.
1. Power ON/OFF Switch —
When the power is on the
fan motor will run and air will
be exhausted out the louvers
in the front of the machine.
The welding output and wire
feeder remain off until the
gun trigger is pressed.
OFF
ON
2. Wire Speed Control —
Controls the wire feed speed
from 50 – 300 in /min (1.3 –
7.6 m/min). The control can
be preset on the dial to the
setting specified on the
WELD-PAK 100 Application
Chart located on the inside
of the wire feed section door.
3. Voltage Control — A 4-position tap selector switch gives
full range adjustment of
power source output voltage.
Do not switch while welding.
WIRE SPEED
ARC VOLTS
● “Quick Release” idle roll pressure arm is easily
adjusted.
● Reversible, dual groove drive roll. Drive roll will
feed .023 – .025” (0.6 mm) and .030" and .035"
(0.8 mm and 0.9 mm) diameter wire.
WELD-PAK 100JAN96
Refer to Figure B-1b.
4. Circuit Breaker – Protects machine from damage if
maximum output is exceeded. Button will extend
out when tripped (Manual reset).
WELD-PAK 100
3
2
1
WELD-PAK 100
OPERATION
Wire Spindle Shaft
to prevent overrun of the spool and excess slack in the
wire. The wing nut at the end of the shaft is used to
adjust the tension on the wire spool.
B-3
4" Wire Spool
Wing Nut
and Spacer
FIGURE B.2
FIGURE B.1a
FIGURE B.1b
4
WELDING OPERATIONS
SEQUENCE OF OPERATION
Wire Loading
Refer to Figure B.2 AND B3.
To use 8" (200 mm) diameter spools, the 2" (51 mm)
diameter M15445 spindle must be used. Remove the
spacer and wing nut at the end of the shaft. Insert
spindle as shown in figure B.3. Reattach spacer and
wing nut.
Note:When loading and removing the 8” Spools make
sure that the wing nut (inside the wire spool spindle
hub) is turned 90° from the wire spool spindle locking
tab. If the wing nut is positioned in line with the locking
tab, the tab cannot be depressed to load or unload the
wire spool.
Make certain the start end of the wire, which may protrude through the side of the spool, does not contact
any metallic case parts.
FIGURE B.3
Wire Spool Spindle
LOCKING TAB
8” Wire Spool
The machine power switch should be turned to the
OFF (“O”) position before working inside the wire feed
enclosure.
The machine is shipped from the factory ready to feed
4” (100 mm) diameter spools. A 4" (100 mm) diameter
spool is mounted directly on the 5/8" (16 mm) diameter spindle that has a built-in adjustable friction brake
Be sure that this stud engages
the hole in the wire spool.
To Wire Drive
Wire Spool must be pushed all the way on the spindle so that the
spindleʼs tab will hold it in place. The Wire Spool will rotate clockwise when wire is dereeled.
WELD-PAK 100
B-4
Friction Brake Adjustment
1. With wire spool installed, check free movement
and coast of the spool.
2. To tighten the brake turn the wing nut clockwise in
1/4 turn increments until coasting stops.
3. To loosen the brake turn the wing nut counterclockwise in 1/4 turn increments until the wire spool
moves freely without coasting.
Wire Threading
Refer to Figure B-4
1. Release the Spring Loaded Pressure Arm (1)
rotate the Idle Roll Arm (2) away from. the Wire
Feed Drive Roll (3). Ensure that the groove size in
the feeding position on the drive roll matches the
wire size being used.
OPERATION
FIGURE B.4
2
1
5
3
4
The Wire Drive Feed Roll can
accommodate two wire sizes by
flipping the wire drive feed roll
over.
2. Carefully detach the end of the wire from the
spool. To prevent the spool from unwinding,
maintain tension on the wire until after step 5.
3. Cut the bent portion of wire off and straighten the
first 4” (100 mm).
4. Thread the wire through the In-going guide tube
(4), over the drive roll (3), and into the out-going
guide tube (5).
5. Close the idle roll arm and latch the spring loaded
pressure arm (2) in place . Rotate the spool counterclockwise if required in order to take up extra
slack in the wire.
6. The idle roll pressure adjustment wing nut is normally set for mid-position on the pressure arm
threads. If feeding problems occur because the
wire is flattened excessively, turn the pressure
adjustment counter-clockwise to reduce distortion
of the wire. Slightly less pressure may be required
when using 0.023 – 0.025” (0,6 mm) wire. If the
drive roll slips while feeding wire, the pressure
should be increased until the wire feeds properly.
7. Refer to Figure B.5. Remove gas nozzle and contact tip from end of gun.
8. Turn the WELD-PAK 100 ON (“I”).
9. Straighten the gun cable assembly.
10. Depress the gun trigger switch and feed welding
wire through the gun and cable. (Point gun away
from yourself and others while feeding wire.)
Release gun trigger after wire appears at end of
gun.
11. Turn the WELD-PAK 100 OFF (“O”).
12. Replace contact tip and gas nozzle.
13. Refer to Figure B-6. Cut the wire off 1/4” – 3/8” (6
– 10 mm) from the end of the tip. The WELD-PAK
FIGURE B.5
WARNING
When inching the welding wire, the drive rolls, the
gun connector block and the gun contact tip are
electrically energized relative to work and ground
and remain energized for several seconds after
the gun trigger is released.
WELD-PAK 100
Gun Handle
Gas Diffuser/
Contact Tip
Gas Nozzle
Contact Tip
OPERATION
FIGURE B.6NANCE section for details on nozzle replacement.
6. Refer to Figure B.7. Connect work clamp to metal
to be welded. Work clamp must make good electrical contact to the workpiece. The workpiece
must also be grounded as stated in “Arc Welding
Safety Precautions” in the beginning of this manual.
B-5
Wire Electrode
3/8" – 1/2" Electrical Stickout
100 is now ready to weld.
Making A Weld
1. See “Process Guidelines” in this section for selection of welding wire and shielding gas and for
range of metal thicknesses that can be welded.
2. See the Application chart on the inside of the wire
feed compartment door for information on setting
the WELD-PAK 100 controls. Refer to Table B.1
for aluminum and stainless wire.
3. Set the Voltage (“V”) and Wire Speed (“oloʼ”) controls to the settings suggested for the welding wire
and base metal thickness being used, refer to
Applications chart on the inside of the wire drive
compartment door.
7. Position gun over joint. End of wire may be lightly
touching the work.
8. Lower welding helmet, close gun trigger, and
begin welding. Hold the gun so the contact tip to
work distance is about 3/8 inch (10 mm).
9. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.
10. When no more welding is to be done, close valve
on gas cylinder (if used), momentarily operate gun
trigger to release gas pressure, and turn off the
WELD-PAK 100.
Cleaning Tip And Nozzle
Clean the contact tip and nozzle to avoid arc bridging
between the nozzle and contact tip which can result in
a shorted nozzle, poor welds and an overheated gun.
Hint: Anti-stick spray or gel, available from a welding
supply distributor, may reduce buildup and aid in spatter removal.
4. Check that the polarity is correct for the welding
wire being used and that the gas supply, if
required, is turned on.
5. When using Innershield electrode, remove the gas
nozzle and install the gasless nozzle. This will
improve visibility of the arc and protect the gas diffuser from weld spatter. Refer to the MAINTE-
FIGURE B.7
WELD-PAK 100
GUN CABLE
WORKPIECE
ARC
WORK CLAMP
PROCESS GUIDELINES
The WELD-PAK 100 can be used for welding mild
steel using the self shielded, Innershield electrode
process or it can be used for the GMAW (MIG), single
pass, process which requires a supply of shielding gas
and the K610-1 MIG Conversion Kit.
The recommended electrode for the self-shielded
process is 0.035” (0,9 mm) diameter Lincoln
Innershield NR-211-MP on 10 Ib (4,5 kg) spools.
Requires optional spindle – refer to Accessories section. This electrode can be used for all position welding of 20 gauge through 5/16” (1,0 – 8,0 mm) thick
steel [multiple passes are required for 1/4” and 5/16”
(6,0 and 8,0 mm)].
The recommended gas and electrode for GMAW is
welding grade CO
Lincoln L-56 mild-steel welding wire [supplied on
12-1/2 Ib (6 kg) spools]. For 14 gauge (2,0 mm) and
gas and 0.025” (0 6 mm) diameter
2
WELD-PAK 100
B-6
OPERATION
thinner, CO2gas is recommended because it gives
equal or better performance than a blended gas at a
lower cost. A mixed gas consisting of 75 to 80% Argon
and 20 to 25% CO
is recommended for welding on
2
heavier gauge [12 gauge (2,5 mm) for example] steel.
The WELD-PAK 100 is suitable for .035" aluminum
wire and .030" stainless wire. Refer to Table B.1 for
recommended procedure settings.
Process Welding WireGas16 ga 14 ga 12 ga 10 ga
Shielding
MIG DC+ .035 Dia100% ArgonB-5D-7D-9D-9
4043 Aluminum
Wire
MIG DC+ .035 Dia100% ArgonB-5C-7D-9D-10
5356 Aluminum
Wire
MIG DC+ .030 Dia98% Argon/A-3C-6D-7.5 D-7.5
308L Stainless2% Oxygen
Steel Wire
Voltage/Wire Speed
TABLE B.1
CHANGING MACHINE OVER TO
FEED OTHER WIRE SIZES
The WELD-PAK 100 is shipped from the factory ready
to feed 0.035” (0,9 mm) diameter wire. To operate the
WELD-PAK 100 with other sizes of wire, it is necessary to change the contact tip and change the drive
roll over to other sizes. Refer to Changing the Contact
Tip and Changing the Drive Roll, in the MAINTENANCE section, for specific information on these procedures.
WELDING WITH GMAW (MIG)
stops moving, open the valve fully.
2. If using a regulator with an adjustable flow meter,
close the gun trigger and adjust the flow to give 15
– 20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20
– 25 CFH (10 – 12 I/min) when welding out of
position or in a drafty location for CO
]. For argon
2
mixed gas, trigger to release gas pressure, and
turn off the adjust the flow to give 25 – 30 CFH
(12–14I/min).
3. Keep the cylinder valve closed, except when using
the WELD-PAK 100. When finished welding:
a) Close the cylinder valve to stop gas flow.
b) Depress the gun trigger briefly to release the
pressure in the gas hose.
c) Turn off the WELD-PAK 100.
OVERLOAD PROTECTION
Output Overload
The WELD-PAK 100 is equipped with a circuit breaker
and a thermostat which protects the machine from
damage if maximum output is exceeded. The circuit
breaker button will extend out when tripped. The circuit breaker must be manually reset.
Thermal Protection
The WELD-PAK 100 has a rated output duty cycle of
20%. If the duty cycle is exceeded, a thermal protector
will shut off the output until the machine cools to a reasonable operating temperature. This is an automatic
function of the WELD-PAK 100 and does not require
user intervention. The fan continues to run during
cooling.
Shielding Gas
When using the GMAW process, obtain and install the
K610-1 MIG Conversion Kit and a cylinder of carbon
dioxide (CO
) or argon-carbon dioxide mixed shielding
2
gas. Refer to the ACCESSORIES section for more
information about installing the K610-1 Kit for use with
the WELD-PAK 100.
1. For CO
, open the cylinder very slowly. For argon-
2
mixed gas, open cylinder valve slowly a fraction of
a turn. When the cylinder pressure gauge pointer
WELD-PAK 100
Electronic Wire Drive Motor Protection
The WELD-PAK 100 has built-in protection for wire
drive motor overload.
LEARNING TO WELD
B-7
LEARNING TO WELD
No one can learn to weld simply by reading about it.
Skill comes only with practice. The following pages will
help the inexperienced operator to understand welding and develop this skill. For more detailed information, order a copy of “New Lessons in Arc Welding”
listed at the end of this manual.
THE ARC-WELDING CIRCUIT
The operatorʼs knowledge of arc welding must go
beyond the arc itself. The operator must know how to
control the arc, and this requires a knowledge of the
welding circuit and the equipment that provides the
electric current used in the arc. Figure B.7 illustrates
the welding circuit for a typical welding machine. The
circuit begins where the gun cable is attached to the
welding machine. Current flows through the gun cable,
gun, and contact tip, to the wire and across the arc.
On the work side of the arc, current flows through the
base metal to the work cable and back to the welding
machine. This circuit must be complete for the current
to flow.
This machineʼs welding circuit has a voltage output of
32 volts DC maximum. This voltage is quite low and is
only present when the gun triggers depressed.
To weld, the work clamp must be tightly connected to
clean base metal. Remove paint, rust, dirt or oil as
necessary and connect the work clamp as close as
possible to the area you wish to weld. This helps prevent current from going through an unwanted path.
Avoid allowing the welding circuit to pass through
hinges, bearings, electronic components, or similar
devices that can be damaged. See Figure B.8. Always
disconnect electrical devices before welding upon
them.
WARNING
Fumes and slag generated from
Innershield type electrodes recommended for use with this welding
machine can be toxic.
• Avoid contact with eyes and skin.
• Do not take internally.
• Keep out of reach of children.
• Follow all safety precautions
found in this operating manual.
The gun and cable assembly is held by the operator
who guides the automatically fed wire along the joint,
maintaining a contact tip to work distance of about 3/8
to 1/2 inch (10 – 12 mm) This is called electrical stickout. This electrical stickout (ESO) must be properly
maintained by the operator. The electric arc is made in
the gap between the work and the tip end of a small
diameter wire. When the power source is properly set,
the arc gap is maintained automatically.
Arc welding is a manual skill requiring a steady hand,
good physical condition, and good eyesight. The operator controls the welding arc, and, therefore, the quality of the weld made.
THE SELF-SHIELDED FCAW WELDING
ARC
Figure B.9 illustrates the action taking place in the self
shielded FCAW (Innershield) welding arc. It closely
resembles what is actually seen while welding.
FIGURE B.8
Hinges
Electronic Components
Bearings
Protective Slag
Weld Metal
Cored Wire
FIGURE B.9
Burning of core materials
inside wire electrode
results in shield of gas.
Arc Stream
WELD-PAK 100
B-8
LEARNING TO WELD
The “arc stream” is seen in the middle of the picture.
This is the electric arc created by the electric current
flowing through the space between the end of the wire
electrode and the base metal. The temperature of this
arc is about 6000°F, which is more than enough to
melt metal. The arc is very bright, as well as hot, and
cannot be looked at with the naked eye without risking
painful injury. The very dark lens, specifically designed
for arc welding must be used with the hand or face
shield whenever viewing the arc.
The arc melts the base metal and actually digs into it
much as water through a nozzle on a garden hose
digs into the earth. The molten metal forms a molten
pool or crater and tends to flow away from the arc. As
it moves away from the arc, it cools and solidifies.
The function of the Innershield cored wire electrode is
much more than simply to carry current to the arc. The
wire core is composed of fluxes and/or alloying ingredients around which a steel sheath has been formed.
It is simply a stick electrode turned inside out in a continuous wire form.
The cored wire melts in the arc and tiny droplets of
molten metal shoot across the arc into the molten
pool. The wire sheath provides additional filler metal
for the joint to fill the groove or gap between the two
pieces of base metal.
The core materials also melt or burn in the arc and
perform several functions. They make the arc steadier, provide a shield of smoke-like gas around the arc
to keep oxygen and nitrogen in the air away from the
molten metal, and provide a flux for the molten pool.
The flux picks up impurities and forms the protective
slag on top of the weld during cooling.
After running a weld bead, the slag may be removed
with a chipping hammer and wire brush. This
improves appearance and allows for inspection of the
finished weld.
THE GMAW (MIG) WELDING ARC
Figure B.10 illustrates the GMAW (MIG) welding arc.
Solid wire does not contain fluxes or ingredients to
form its own shielding and no slag forms to protect the
molten weld metal. For this reason, a continuous even
flow of shielding gas is needed to protect the molten
weld metal from atmospheric contaminants such as
oxygen and nitrogen. Shielding gas is supplied
through the gun and cable assembly, through the gas
nozzle and into the welding zone.
FIGURE B.10
Gas nozzle
Solid wire
electrode
Base metal
When comparing the GMAW and FCAW processes,
you can see that the principal difference between the
two lies in the type of shielding used. GMAW uses gas
for shielding, thus we have Gas Metal Arc Welding.
FCAW uses the melting or burning of the core ingredients for shielding, and is thus termed Self-Shielded
Flux Cored Arc Welding.
The recommended wire for Gas Metal Arc Welding
(MIG) is Lincolnweld 0.025” L-56 electrode.
Lincolnweld” L-56 is capable of welding a wide range
of mild steels in all positions, however, more skill IS
required for out-of-position welding with the GMAW
process.
Shielding gas
Weld metal
Since machine size and output characteristics limit the
size and type of wire electrode which can be used,
Lincoln 0.035ʼ (0.9 mm) NR-211-MP Innershield electrode is recommended for Self-Shielded Flux Cored
Arc Welding.
WELD-PAK 100
PROCESS SELECTION
By gaining knowledge of the differences between the
two processes, you will be able to select the best
process for the job you have at hand. In selecting a
process, you should consider:
For GMAW (MIG) Process
1. Is most of my welding performed on 16 gauge and
lighter materials?
LEARNING TO WELD
B-9
2. Can I afford the extra expense, space, and lack of
portability required for gas cylinders and gas supply?
3. Do I require clean, finished-looking welds?
If you have answered yes to all the above questions
GMAW may be the process for you. If you have
answered no to any of the above questions, then you
should consider using the FCAW process.
For FCAW (Innershield) Process
1. Do I want simplicity and portability?
2. Will welding be performed outdoors or under windy
conditions?
3. Do I require good all position welding capability?
4. Will most welding be performed on 16 gauge and
heavier, somewhat rusty or dirty materials?
5. Weld must be cleaned prior to painting.
COMMON METALS
Most metals found around the farm, small shop or
home are low carbon steel, sometimes referred to as
mild steel. Typical items made with this type of steel
include most sheet metal, plate, pipe and rolled
shapes such as channels and angle irons. This type of
steel can usually be easily welded without special precautions. Some steels, however, contain higher carbon levels or other alloys and are more difficult to
weld. Basically, if a magnet sticks to the metal and
you can easily cut the metal with a file, chances are
good that the metal is mild steel and that you will be
able to weld the material. In addition, aluminum and
stainless steel can be welded using the K664-1
Aluminum Welding Kit. For further information on identifying various types of steels and other metals, and
for proper procedures for welding them, we again suggest you purchase a copy of “New Lessons in Arc
Welding”.
Regardless of the type of metal being welded, in order
to get a quality weld, it is important that the metal is
free of oil, paint, rust or other contaminants.
MACHINE SET UP FOR THE
SELF-SHIELDED FCAW PROCESS
1. See PROCESS GUIDELINES in the OPERATION
section for selection of welding wire and shielding
gas, and for range of metal thicknesses that can be
welded.
2. See the Application Guide on the inside of wire
feed section door for information on setting the
controls.
3. Set the “Voltage” and “Wire Speed” controls to the
settings suggested on the Application Guide for the
welding wire and base metal thickness being used.
The voltage control is marked “V” and the wire feed
speed is marked ʻʼolo.ʼʼ
4. Check that the polarity is correct for the welding
wire being used. Set the polarity for DC(–) when
welding with NR-211-MP Innershield electrode.
See Work Cable Installation in the INSTALLATION
section for instructions on changing polarity.
5. When using Innershield electrode, the gasless nozzle may be used instead of a gas nozzle to improve
visibility of the arc.
6. Connect work clamp to metal to be welded. Work
clamp must make good electrical contact to the
work piece. The work piece must also be grounded
as stated in the “Arc Welding Safety Precautions”
at the beginning of this manual.
WELDING TECHNIQUES FOR THE SELFSHIELDED FCAW PROCESS
Four simple manipulations are of prime importance
when welding. With complete mastery of the four,
welding will be easy. They are as follows:
1. The Correct Welding Position
Figure B.11 illustrates the correct welding position
for right handed people. (For left handed people, it
is the opposite.)
Hold the gun (of the gun and cable assembly) in
your right hand and hold the shield with your left
hand. (Left handers simply do the opposite.)
When using the FCAW Process, weld from left to
right (if you are right handed). This enables you to
clearly see what you are doing. (Left handers do
the opposite.) Tilt the gun toward the direction of
travel holding the electrode at an angle as shown
in Figure B.11.
WELD-PAK 100
B-10
LEARNING TO WELD
FIGURE B.11FIGURE B.12
Contact Tip
Wire Electrode
3/8 – 1/2” (10 – 12 mm)
Electrical Stickout (ESO)
WARNING
ARC RAYS can burn eyes and skin.
When using an open arc process, it
Is necessary to use correct eye,
head and body protection.
Protect yourself and others, read
“ARC RAYS can burn” at the front
of this manual.
2. The Correct Way To Strike An Arc
1. Be sure the work clamp makes good electrical
contact to the work.
2. Position gun over joint. End of wire may be
lightly touching the work.
3. Position face shield to protect face and eyes,
close gun trigger, and begin welding. Hold the
gun so that the contact tip to work distance is
about 3/8 to 1/2 inch (10 – 12 mm).
4. To stop welding, release the gun trigger and
the pull the gun away from the work after the
arc goes out.
The easiest way to tell whether the ESO is the correct length is by listening to its sound. The correct
ESO has a distinctive “crackling” sound, very much
like eggs frying in a pan. A long ESO has a hollow,
blowing or hissing sound. If the ESO is too short,
you may stick the contact tip or nozzle to the weld
puddle and/or fuse the wire to the contact tip.
4. The Correct Welding Speed
The important thing to watch while welding is the
puddle of molten metal right behind the arc. See
Figure B.13. Do not watch the arc itself. It is the
appearance of the puddle and the ridge where the
molten puddle solidifies that indicates correct welding speed. The ridge should be approximately 3/8”
(10 mm) behind the wire electrode.
Most beginners tend to weld too fast, resulting in a
thin uneven, “wormy” looking bead. They are not
watching the molten metal.
FIGURE B.13
5. A ball may form at the tip end of the wire after
welding. For easier restrikes (with Innershield
wire) the ball may be removed by feeding out a
few inches of wire and simply bending the wire
back and forth until it breaks off.
6. When no more welding is to be done, turn off
the machine.
3. The Correct Electrical Stickout (ESO)
The electrical stickout (ESO) is the distance from
the end of the contact tip to the end of the wire.
See Figure B.12.
Once the arc has been established, maintaining
the correct ESO becomes extremely important.
The ESO should be approximately 3/8 to 1/2 inch
(10 to 12 mm) long.
WELD-PAK 100
Solidifying ridge
Molten puddle
LEARNING TO WELD
B-11
Helpful Hints
1. For general welding, it is not necessary to weave
the arc, neither forward or backward nor sideways.
Weld along at a steady pace. You will find it easier.
2. When welding on thin plate, you will find that you
will have to increase the welding speed, whereas
when welding on heavy plate, it is necessary to go
more slowly in order to get good penetration.
3. When welding sheet metal 16 gauge (1.5 mm) and
lighter, heat buildup may cause part warpage and
burn through. One way to eliminate these problems
is to use the back-stepping method illustrated in
Figure B.14.
FIGURE B.14
First weld from A to B; then from C to A; then
from D to C; then from E to D, and so on.
BACDE
Back-Stepping
For the WELD-PAK 100, use the following:
Mild Steel12 gauge or 1/8 inch
(3.0 mm)
Electrode0.035" (0.9 mm)
NR-211-MP
Innershield Wire
Voltage Setting “V”D
Wire Feed Speed “o|o”3
Refer to Figure B.15.
1. Learn to strike an arc by positioning the gun over
the joint and touching the wire to the work.
2. Position face shield to protect face and eyes.
3. Depress gun trigger, hold gun so contact tip to
work distance is about 3/8 to 1/2 inch (10 to 12
mm) and the gun is at proper angle.
4. After you strike the arc, practice the correct electrical stickout. Learn to distinguish it by its sound.
Practice
The best way of getting practice in the four skills that
enable you to maintain:
1. Correct welding position
2. Correct way to strike an arc
3. Correct electrical stickout
4. Correct welding speed
is to perform the following exercise.
FIGURE B.15
Contact
Tip
5. When you are sure that you can hold the correct
electrical stickout, with a smooth “crackling” arc
start moving. Look at the molten puddle constantly.
6. Run beads on a flat plate. Run them parallel to the
top edge (the edge farthest away from you). This
gives you practice in running straight welds, and
also gives you an easy way to check your
progress. The 10th weld will look considerably better than the first weld. By constantly checking on
your mistakes and your progress, welding will soon
be a matter of routine.
Gun Angle
WELD-PAK 100
B-12
LEARNING TO WELD
MACHINE SET UP FOR THE GMAW (MIG)
PROCESS
1. See PROCESS GUIDELINES in the OPERATION
section for selection of welding wire and shielding
gas, and for range of metal thicknesses that can
be welded.
2. See the Application Guide on the inside of wire
feed section door for information on setting the
controls.
3. Set the “Voltage” and “Wire Speed” controls to the
settings suggested on the Application Guide for the
welding wire and base metal thickness being used.
The voltage control is marked “V” and the wire
feed speed is marked ʻʼolo.ʼʼ
4. Check that the polarity is correct for the welding
wire being used. Set the polarity for DC(+) when
welding with the GMAW (MIG) process. See Work
Cable Installation in the INSTALLATION section
for instructions for changing polarity.
5. Check that the gas nozzle and proper size liner
and contact tip are being used and that the gas
supply is turned on. If adjustable, set for 15 to 20
cubic feet per hour (7 to 10 l/min.) under normal
conditions, increase to as high as 35 CFH (17
I/min.) under drafty (slightly windy) conditions.
FIGURE B.16
When using the GMAW process on light gauge material, weld from right to left (if you are right handed).
This results in a colder weld and has less tendency for
burn through.
2. The Correct Way To Strike An Arc
WARNING
ARC RAYS can burn eyes and skin.
When using an open arc process, it
Is necessary to use correct eye,
head and body protection.
Protect yourself and others, read
“ARC RAYS can burn” at the front
of this manual.
6. Connect work clamp to metal to be welded. Work
clamp must make good electrical contact to the
work piece. The work piece must also be grounded
as stated in the “Arc Welding Safety Precautions”
at the beginning of this manual.
WELDING TECHNIQUES FOR THE GMAW
(MIG) PROCESS
Four simple manipulations are of prime importance
when welding. With complete mastery of the four,
welding will be easy. They are as follows:
1. The Correct Welding Position
Figure B.16 illustrates the correct welding position
for right handed people. (For left handed people, it
is the opposite.)
When GMAW (MIG) welding on sheet metal, it is
important to use the “forehand” push technique.
Hold the gun (of the gun and cable assembly) in
your right hand and hold the shield with your left
hand. (Left handers simply do the opposite.)
1. Be sure the work clamp makes good electrical contact to the work.
2. Position gun over joint. End of wire may be lightly
touching the work.
3. Position face shield to protect face and eyes, close
gun trigger, and begin welding. Hold the gun so
that the contact tip to work distance is about 3/8 to
1/2 inch (10 – 12 mm).
4. To stop welding, release the gun trigger and pull
the gun away from the work after the arc goes out.
5. A ball may form at the tip end of the wire after
welding. For easier restrikes, the ball may be
removed by feeding out a few inches of wire and
cutting off the end of the wire with wire cutters.
6. When no more welding is to be done, close the
valve on the gas cylinder, momentarily operate the
gun trigger to release gas pressure, then turn off
the machine.
WELD-PAK 100
LEARNING TO WELD
B-13
FIGURE B.17
Contact Tip
Wire Electrode
ESO
3. The Correct Electrical Stickout (ESO)
The electrical stickout (ESO) is the distance from
the end of the contact tip to the end of the wire.
See Figure B.17.
Once the arc has been established, maintaining
the correct ESO becomes extremely important.
The ESO should be approximately 3/8 to 1/2 inch
(10 to 12 mm) long.
Helpful Hints
1. For general welding, it is not necessary to weave
the arc, neither forward or backward nor sideways.
Weld along at a steady pace. You will find it easier.
2. When welding on thin plate, you will find that you
will have to increase the welding speed, whereas
when welding on heavy plate, it is necessary to go
more slowly in order to get good penetration.
3. When welding sheet metal 16 gauge (1.5 mm) and
lighter, heat buildup may cause part warpage and
burn through. One way to eliminate these problems
is to use the back-stepping method illustrated in
Figure B.14.
Practice
The best way of getting practice in the four skills that
enable you to maintain:
1. Correct welding position
The easiest way to tell whether the ESO is the correct length is by listening to its sound. The correct
ESO has a distinctive “crackling” sound, very much
like eggs frying in a pan. A long ESO has a hollow,
blowing or hissing sound. If the ESO is too short,
you may stick the contact tip or nozzle to the weld
puddle and/or fuse the wire to the contact tip.
4. The Correct Welding Speed
The important thing to watch while welding is the
puddle of molten metal right behind the arc. See
Figure B.18. Do not watch the arc itself. It is the
appearance of the puddle and the ridge where the
molten Puddle solidifies that indicates correct welding speed. The ridge should be approximately 3/8”
(10 mm) behind the wire electrode.
Most beginners tend to weld too fast, resulting in a
thin, uneven, “wormy” looking bead. They are not
watching the molten metal.
FIGURE B.18
Molten puddle
Weld metal ridge
Base metal
2. Correct way to strike an arc
3. Correct electrical stickout
4. Correct welding speed
is to perform the following exercise.
For the WELD-PAK 100, use the following:
Mild Steel16 gauge or 1/16 inch
(1.6 mm)
ElectrodeLincolnweld 0.025 L-56
electrode
CO
2
Voltage Setting “V”C
Wire Feed Speed “o|o”4
Refer to Figure B.15.
1. Learn to strike an arc by positioning the gun over
the joint and touching the wire to the work.
2. Position face shield to protect face and eyes.
3. Depress gun trigger, hold gun so contact tip to
work distance Is about 3/8 to 1/2 inch (10 to 12
mm) and the gun is at proper angle.
WELD-PAK 100
B-14
LEARNING TO WELD
4. After you strike the arc, practice the correct electrical stickout. Learn to distinguish it by its sound.
5. When you are sure that you can hold the correct
electrical stickout, with a smooth “crackling” arc,
start moving. Look at the molten puddle constantly,
6. Run beads on a flat plate. Run them parallel to the
top edge (the edge farthest away from you). This
gives you practice in running straight welds, and
also gives you an easy way to check your
progress. The 10th weld will look considerably better than the first weld. By constantly checking on
your mistakes and your progress, welding will soon
be a matter of routine.
JOINT TYPES AND POSITIONS
Five types of welding joints are: Butt Welds, Fillet
Welds, Lap Welds, Edge Welds and Corner Welds.
See Figure B.19.
Of these, the Butt Weld and Fillet Weld are the two
most common welds.
Watch the molten metal to be sure it distributes itself
evenly on both edges and in between the plates.
FIGURE B.20
Penetration
Unless a weld penetrates close to 100% of the metal
thickness, a butt weld will be weaker than the material
welded together. In the example shown in Figure
B.21, the total weld is only half the thickness of the
material thus the weld is only approximately half as
strong as the metal.
FIGURE B.21
FIGURE B.19
Butt weldLap weld
Edge weldFillet weldCorner weld
Butt Welds
Place two plates side by side, leaving a space approximately one half the thickness of the metal between
them in order to get deeper penetration.
Securely clamp or tack weld the plates at both ends,
otherwise the heat will cause the plates to move apart.
See Figure B.20.
Now weld the two plates together. Weld from left to
right (if right handed). Point the wire electrode down in
the crack between the two plates, keeping the gun
slightly tilted in the direction of travel.
FIGURE B.22
In the example shown in Figure B.22, the joint has
been welded so that 100% penetration could be
achieved. The weld, if properly made, is as strong as
or stronger than the original metal.
Fillet Welds
When welding fillet welds, it is very important to hold
the wire electrode at a 45° angle between the two
sides or the metal will not distribute itself evenly. The
gun nozzle is generally formed at an angle to facilitate
this. See Figure B.23.
WELD-PAK 100
LEARNING TO WELD
B-15
FIGURE B.23
45°
Welding In The Vertical Position
Welding in the vertical position can be done either vertical-up or vertical-down. Vertical-up is used whenevera larger, stronger weld is desired. Vertical-down is
used primarily on sheet metal 5/32” (3.9 mm) and
under for fast, low penetrating welds.
WARNING
Use of this unit on thicker materials than recommended may result in poor welds. The welds may
“look” good, but may just be “sitting” on top, of
the plate. This is called “Cold Casting” and will
result in weld failure.
Vertical-up And Overhead Welding
The problem, when welding vertical-up, is to put the
molten metal where it is wanted and make it stay
there. If too much molten metal is deposited, gravity
will pull it downwards and make it “drip”. Therefore, a
certain technique has to be followed.
FIGURE B.24
PROPER GUN ANGLE
FOR GMAW PROCESS
WELDING IN THE VERTICAL UP POSITION
PROPER GUN ANGLE
FOR FCAW PROCESS
WELDING IN THE VERTICAL UP POSITION
Vertical-down Welding
Refer to Figure B.25 Vertical-down welds are applied
at a fast pace. These welds are therefore shallow and
narrow and, as such, are excellent for sheet metal.
Vertical-down welds may be applied to 5/32” (3.9 mm)
and lighter material.
Use stringer beads and tip the gun in the direction of
travel so the arc force helps hold the molten metal in
the joint. Move as fast as possible consistent with
desired bead shape.
The important thing is to continue lowering the entire
arm as the weld is made so the angle of the gun does
not change. Move the electrode wire fast enough that
the slag does not catch up with the arc. Vertical-down
welding gives thin, shallow welds. It should not be
used on heavy material where large welds are
required.
FIGURE B.25
When welding out-of-position, run stringer beads.
Donʼt whip, break the arc, move out of the puddle, or
move too fast in any direction. Use Wire Feed Speed
(WFS) in the low portion of the range. The general
technique and proper gun angle is illustrated in Figure
B.24.
Generally, keep the electrode nearly perpendicular to
the joint as illustrated. The maximum angle above perpendicular may be required if porosity becomes a
problem.
WELD-PAK 100
B-16
LEARNING TO WELD
TROUBLESHOOTING WELDS
Good welds have excellent appearance.
To Eliminate Porosity (in order of importance):
1. Turn on gas supply, if used
2. Decrease voltage.
3. Increase stickout.
4. Increase WFS (wire feed speed).
5. Decrease drag angle.
6. Decrease travel speed.
NOTE: Always be sure the joint is free from moisture,
oil, rust, paint or other contaminants.
To Eliminate a Ropy Convex Bead
(in order of importance):
To Reduce Spatter (in order of importance):
1. Increase voltage.
2. Increase drag angle.
3. Decrease stickout.
4. Increase WFS (wire feed speed).
5. Decrease travel speed.
6. Check for correct gas, if used.
To Correct Poor Penetration (in order of importance):
1. Decrease stickout.
2. Increase WFS (wire feed speed).
3. Decrease voltage.
4. Increase speed.
5. Decrease drag angle.
6. Check for correct gas, if used.
If Arc Blow Occurs (in order of importance):
NOTE: Try different ground connection locations
before adjusting procedures.
1. Decrease drag angle.
2. Increase stickout.
3. Decrease voltage.
4. Decrease WFS (wire feed speed.
5. Decrease travel speed.
1. Increase voltage.
2. Decrease stickout.
3. Decrease WFS (wire feed speed.
4. Decrease travel speed.
5. Decrease drag angle.
6. Check for correct gas, if used.
WELD-PAK 100
To Eliminate Stubbing* (in order of importance):
1. Increase voltage
2. Decrease WFS (wire feed speed)
3. Decrease stickout
4. Increase drag angle
* Stubbing occurs when the electrode drives through
the molten puddle and hits the bottom plate tending
to push the gun up.
LEARNING TO WELD
Proper Gun Handling
Most feeding problems are caused by improper handling of the gun cable or electrodes.
1. Do not kink or pull the gun around sharp corners
2. Keep the gun cable as straight as practical when
welding.
3. Do not allow dolly wheels or trucks to run over the
cables.
4. Keep the cable clean.
5. Innershield electrode has proper surface lubrication. Use only clean, rust-free electrode.
6. Replace contact tip when it becomes worn or the
end is fused or deformed.
B-17
WELD-PAK 100
B-18
APPLICATION CHART
WELD-PAK 100
ACCESSORIES
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.
C-1
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.
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 CO
.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 electrode, gas regulator, gas hose, regulator
adapter for CO
noid assembly, with all necessary hardware 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.
or Argon-mixed gas. Includes
2
cylinders and gas sole-
2
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.
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 necessary accessories for this conversion and
is provided for this purpose. The following
conversions should be made using the contents 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.
WELD-PAK 100
C-2
NOTES
WELD-PAK 100
MAINTENANCE
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Disconnect input power by removing
plug from receptacle before working
inside WELD-PAK 100. Use only grounded receptacle. Do not touch electrically
“hot” parts inside WELD-PAK 100.
• Have qualified personnel do the maintenance 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.
D-1
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
D-2
MAINTENANCE
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 procedure until no further dirt comes out.
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 perpendicular 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 nozzle.
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 contact tip for the electrode being used (wire
size is stenciled on the side of the contact tip) and screw it snugly into the gas
diffuser.
3. Remove spatter from inside of gas nozzle 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
the gasless nozzle should be screws
onto the diffuser.
®
process,
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
MAINTENANCE
D-3
CHANGING DRIVE ROLL
The drive roll has two grooves; one for .023"
– .025" (0.6 mm) solid steel electrode and a
larger knurled groove for .030" (0.8 mm)
solid and .035" (0.9 mm) flux-cored steel
electrode. As shipped, the drive roll is
installed in the .030"/.035" (0.8/0.9 mm)
position.
If .023" – .025" (0.6 mm) wire is to be used,
the drive roll must be reversed as follows:
1. Connect the machine to its rated input
power per instructions in Installation section.
2. Release the spring-loaded pressure arm
and lift the idle roll arm away from the
drive roll.
3. Turn the power switch to ON (marked
“I”).
4. Set the wire speed to minimum and jog
the drive unit with the trigger switch until
the drive roll set screw is facing up.
FIGURE D.1
3
2
1
Wire size is stenciled on
the ends of the drive roll.
CAUTION
When inching the welding wire, the drive
rolls, gun connector block, and gun contact tip are energized relative to work
and ground and remain energized for
several seconds after the gun trigger is
released.
5. Turn the power switch to OFF (marked
“O”).
6. Loosen the drive roll set screw with the
5/64" (2.0 mm) hex wrench supplied.
7. Remove the drive roll, flip over and reinstall with the .023 – .025" (0.6 mm)
groove (the smaller groove) closest to the
gearbox.
8. Push a length of straightened welding
wire through the wire feeder guide tubes
and adjust the position of the drive roll so
that the groove is centered on the wire.
Make certain the set screw is located on
the flat portion of the shaft and tighten.
WELD-PAK 100
D-4
MAINTENANCE
FIGURE D.2
Liner trim length
Set ScrewBrass Cable
Connector
Liner Assembly
(Liner bushing to be sealed tight
against brass cable connector)
Gas Diffuser
Gas Nozzle or
Gasless Nozzle
1-1/4 (31.8 mm)
Liner Trim Length
CHANGING LINER
NOTICE: The variation in cable lengths prevents the interchangeability of liners. Once
a liner has been cut for a particular gun, it
should not be installed in another gun
unless it can meet the liner cutoff length
requirement. Refer to Figure D.2.
1. 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. Remove the gas diffuser from the gun
tube by unscrewing counter-clockwise.
4. Lay the gun and cable out straight on a
flat surface. Loosen the set screw located
in the brass connector at the wire feeder
end of the cable. Pull the liner out of the
cable.
5. Insert a new untrimmed liner into the connector end of the cable. Be sure the liner
bushing is stenciled appropriately for the
wire size being used.
6. Fully seat the liner bushing into the connector. Tighten the set screw on the
brass cable connector. At this time, the
gas diffuser should not be installed onto
the end of the gun tube.
7. With the gas nozzle and diffuser removed
from the gun tube, be sure the cable is
straight, and then trim the liner to the
length shown in the Figure D.2. Remove
any burrs from the end of the liner.
8. Screw the gas diffuser onto the end of
the gun tube and securely tighten.
9. Replace the contact tip and nozzle.
WELD-PAK 100
GUN HANDLE PARTS
The gun handle consists of two halves that
are held together with a collar on each end.
To open up the handle, turn the collars
approximately 60 degrees counter-clockwise until the collar reaches a stop. Then
pull the collar off the gun handle. If the collars are difficult to turn, position the gun
handle against a corner, place a screwdriver against the tab on the collar and give the
screwdriver a sharp blow to turn the collar
past an internal locking rib. See Figure D-3.
FIGURE D.3
MAINTENANCE
D-5
➣
Counter-clockwise
WELD-PAK 100
D-6
NOTES
WELD-PAK 100
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.
This Troubleshooting Guide is provided to
help you locate and remedy possible problems with machine setup or operation.
Simply follow the three-step procedure
listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes possible symptoms that the machine may
exhibit. Find the listing that best describes
the symptom that the machine is exhibiting.
Symptoms are grouped into three main categories: output problems, function problems, welding problems.
E-1
WARNING
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may contribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted without removing the case wrap-around cover.
Step 3. PERFORM COMPONENT TESTS.
If you have exhausted all of the recommended tests in Step 2, Consult your Local
Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRICFIELD SERVICE FACILITY for assistance before you proceed.
NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the Lincoln
Electric Parts List.
WELD-PAK 100
NOTES
SQUARE WAVE TIG 255
NOTES
SQUARE WAVE TIG 255
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Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the readerʼs
to visualize mechanically drawn objects as they will appear
in their assembled form.
187 pages with more than 100 illustrations. Size 8-1/2” x
Durable, cloth-covered board binding.
$4.50 postage paid U.S.A.
ability
11”
Mainland
and ask for bulletin ED-80 or call 216-383-2259 and ask
Welding School Registrar.
Lincoln Welding School
BASIC COURSE$700.00
5 weeks of fundamentals
for the
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.
Prices include shipment by 4 th Class Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:
$5.00For order value up to $49.99
$10.00For order value between $50.00 & $99.99
$15.00For order value between $100.00 & $149.00
For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders)
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BOOKS OR FREE INFORMATIVE CATALOGSTelephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
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Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
Educational Video InformationIncentive Management$5.00IM
(ED-93)
James F. Lincoln Arc WeldingThe American Century of John C. Lincoln $5.00AC
Foundation Book InformationWelding Preheat Calculator$3.00WC-8
(JFLF-515)
New Lessons in Arc Welding$5.00L
How to Read Shop Drawings$4.50H
A New Approach to Industrial Economics $5.00NA
Pipe Welding Charts$4.50ED-89
SUB TOTAL
Additional Shipping Costs if any
TOTAL COST
WARNING
Spanish
AVISO DE
PRECAUCION
● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Keep flammable materials away.
● Mantenga el material combustible
fuera del área de trabajo.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-
dos.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
19
● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Turn power off before servicing.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
ouverts ou avec les dispositifs de
protection enlevés.
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
LIMITED WARRANTY
STATEMENT OF LIMITED WARRANTY
The Lincoln Electric Company (Lincoln) warrants to the
end user (purchaser) of all new welding and cutting equipment, electrode and flux (collectively called the “Goods”)
that it will be free of defects in workmanship and material.
This warranty is void if Lincoln or its Authorized Service
Facility finds that the equipment has been subjected to
improper installation, improper care or abnormal operations.
WARRANTY PERIOD
Lincoln will assume both the parts and labor expense of
correcting defects during the full warranty period. All warranty periods date from the date of purchase to the original
end user or from the date of manufacture if the original
invoice cannot be provided and are as follows:
7 Years
• Main power rectifiers on all non-inverter low frequency
(50 and 60 Hz) type welders.
3 Years
• All Lincoln welding machines, wirefeeders and plasma
cutting machines unless listed below.
The purchaser must contact Lincoln or Lincolnʼs Authorized
Service Facility about any defect claimed under Lincolnʼs
warranty.
Determination of warranty on welding and cutting equipment will be made by Lincoln or Lincolnʼs Authorized
Service Facility.
WARRANTY REPAIR:
If Lincoln or Lincolnʼs Authorized Service Facility confirms
the existence of a defect covered by this warranty, the
defect will be corrected by repair or replacement at
Lincolnʼs option.
At Lincolnʼs request, the purchaser must return, to Lincoln
or its Authorized Service Facility, any “Goods” claimed
defective under Lincolnʼs warranty.
FREIGHT COSTS:
The purchaser is responsible for shipment to and from the
Lincoln Authorized Service Facility.
WARRANTY LIMITATIONS
Lincoln will not accept responsibility or liability for repairs
made outside of a Lincoln Authorized Service Facility.
• All water coolers (internal or external models)
• All stick electrode, welding wire and flux.
• Arc welding and cutting robots and robotic controllers
• All Environmental Systems equipment, including portable
units, central units and accessories. (Does not include
consumable items listed under 30 day warranty.)
• All welding and cutting accessories including wire feed
modules, undercarriages, field installed options that are
sold separately, unattached options, welding supplies,
standard accessory sets, replacement parts, and
Magnum products. (Does not include expendable parts
and guns/torches listed under 90 and 30 day warranties)
90 Days
• All gun and cable assemblies, TIG and plasma torches
and spool guns.
30 Days
• All consumable items that may be used with the environmental systems described above. This includes hoses,
filters, belts and hose adapters.
• Expendable Parts - Lincoln is not responsible for the
replacement of any expendable part that is required due
to normal wear.
warranty superseded
see imws 1
Lincolnʼs liability under this warranty shall not exceed the
cost of correcting the defect of the Lincoln product.
Lincoln will not be liable for incidental or consequential
damages (such as loss of business, etc.) caused by the
defect or the time involved to correct the defect.
This written warranty is the only express warranty provided
by Lincoln with respect to its products. Warranties implied
by law such as the warranty of merchantability are limited
to the duration of this limited warranty for the equipment
involved.
This warranty gives the purchaser specific legal rights. The
purchaser may also have other rights which vary from state
to state.
(1)
Equipment manufactured for the Lincoln Electric Company is subject to
the warranty period of the original manufacturer.
(2)
All engines and engine accessories are warranted by the engine or
engine accessory manufacturer and are not covered by this warranty.
(3)
SAE400 WELD Nʼ AIR compressor is warranted by the compressor man-
ufacturer and not covered by this warranty.
May, ʻ99
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