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Lincoln Electric WELD-PACK 100 PLUS, Operator'S Manual

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Lincoln Electric WELD-PACK 100 PLUS Operator'S Manual Download Page 31

WELD-PAK 100

B-17

LEARNING TO WELD

Proper Gun Handling

Most feeding problems are caused by improper han-
dling 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 lubrica-

tion. Use only clean, rust-free electrode.

6. Replace contact tip when it becomes worn or the

end is fused or deformed.

Summary of Contents for WELD-PACK 100 PLUS

Page 1: ...ONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machine Code Numbers 10207 and above For use with machine Code Numbers 10023 For use with machine Code Nu...

Page 2: ...lding 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...

Page 3: ...prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydrau...

Page 4: ...t fumes outdoors ____________________________________________________ 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 r...

Page 5: ...propri s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse...

Page 6: ...mation must be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the...

Page 7: ...B 2 Limitations B 2 Controls and Settings B 2 Welding Operations B 3 Overload Protection B 6 Learning to Weld B 7 Application Chart B 18 Accessories Section C Accessories C 1 Replacement Parts C 1 Ma...

Page 8: ...WELD PAK 100 vii...

Page 9: ...0 TECHNICAL SPECIFICATIONS WELD PAK 100 INPUT SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT CABLE AND FUSE SIZES Height Width Depth Weight 12 0 in 9 75 in 16 5 in 47 Ibs 305 mm 248 mm 419 mm...

Page 10: ...7 Handshield with filter plate and lens 8 Instructional video 9 8 Spool Adapter 2 Spindle for mounting 10 lb Spools 10 Chipping hammer wire brush For available options and accessories refer to the Acc...

Page 11: ...output terminals Work Clamp Installation Attach the work clamp per the following Refer to Figure A 3 FIGURE A 3 WELD PAK 100 WELD PAK 100 4 5 8 3 6 7 1 2 1 Remove the screw pressure plate and backing...

Page 12: ...ted 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...

Page 13: ...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...

Page 14: ...talled 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...

Page 15: ...om work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can caus...

Page 16: ...measure of safety Overload protection incorporates both a thermo stat and a circuit breaker Quality wire drive with electronic overload protec tion Quick Release idle roll pressure arm is easily adjus...

Page 17: ...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 Make certain the start end of the wire which may pro trude through the s...

Page 18: ...ustment wing nut is nor mally 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 red...

Page 19: ...he 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...

Page 20: ...djustable 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 CO2 For...

Page 21: ...is helps pre vent 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...

Page 22: ...tective 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 finishe...

Page 23: ...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 ran...

Page 24: ...ckout 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 shoul...

Page 25: ...d 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 pr...

Page 26: ...f 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 opposit...

Page 27: ...e molten metal FIGURE B 18 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...

Page 28: ...y 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 w...

Page 29: ...tical Position Welding in the vertical position can be done either ver tical up or vertical down Vertical up is used whenev era larger stronger weld is desired Vertical down is used primarily on sheet...

Page 30: ...ase 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 impor tance 1 Decre...

Page 31: ...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 e...

Page 32: ...WELD PAK 100 B 18 APPLICATION CHART...

Page 33: ...en 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...

Page 34: ...C 2 NOTES WELD PAK 100...

Page 35: ...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 re...

Page 36: ...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 conta...

Page 37: ...unit with the trigger switch until the drive roll set screw is facing up When inching the welding wire the drive rolls gun connector block and gun con tact tip are energized relative to work and groun...

Page 38: ...ut of the cable 5 Insert a new untrimmed liner into the con nector end of the cable Be sure the liner bushing is stenciled appropriately for the wire size being used 6 Fully seat the liner bushing int...

Page 39: ...proximately 60 degrees counter clock wise until the collar reaches a stop Then pull the collar off the gun handle If the col lars are difficult to turn position the gun handle against a corner place a...

Page 40: ...D 6 NOTES WELD PAK 100...

Page 41: ...n be conducted with out removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS If you have exhausted all of the recom mended tests in Step 2 Consult your Local Authorized Field Service Fac...

Page 42: ...d to the machine 115vac 2 Make certain that power switch is in the ON position 3 Make sure circuit breaker inside wire drive compartment is reset 1 The thermostat may be tripped due to overheating Let...

Page 43: ...Field Service Facility FEEDING PROBLEMS 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 ELECTRIC FI...

Page 44: ...c is unstable Poor starting POSSIBLE AREAS OF MISADJUSTMENT S 1 Check for correct input voltage to machine 115vac 2 Check for proper electrode polarity for process 3 Check gun tip for wear or dam age...

Page 45: ...M P O U N D C R M 2 2 7 8 7 S 1 S W I T C H D 1 D 3 D 2 D 4 2 0 4 2 0 4 2 0 4 2 0 3 2 0 3 2 0 3 C 1 5 9 0 0 0 m f 4 0 V 2 0 3 2 0 4 G U N C A B L E C O N D U C T O R B L O C K T O W O R K E L E C T R...

Page 46: ...F 2 NOTES WELD PAK 100...

Page 47: ...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 WELD PAK 100 PARTS MANUAL PARTS...

Page 48: ...WELD PAK 100 NOTE This Parts Manual is provided as an informative guide only when ordering parts always refer to the Lincoln Electric Parts List 2 PARTS MAIN EXPLODED DIAGRAM...

Page 49: ...bly Contact 1 Factory 11a Slotted Hex Head Screw 10 3 8 S8025 70 4 long blunt point 12 Case Front Assembly See Case 1 Front Assby 12a Slotted Hex Head Screw 10 3 8 S8025 65 2 long blunt point 12b Slot...

Page 50: ...Motor Leads NSS 2 3 Idle Roll Arm L7562 1 4 Idle Roll Shaft S18436 1 5 Idle Roll M9300 55 1 6 Idle Roll Pressure Parts Includes S20156 3 1 6a 6f 6a Idle Roll Arm Clevis S18442 1 No Item Description Pa...

Page 51: ...Arc Volts Selector Switch Assembly M15750 1 Includes 7a 7e 7a Rotor S18873 1 7b Spring T6778 1 7c Moving Contact S18923 1 7d Indexing Cam S18872 1 No Item Description Part No Req d 7e 8 Hex Self Tappi...

Page 52: ...mplete Assembly Includes L7680 2 1 Items 1 5 below 1 Bracket for Fan Rectifier G1839 1 2 Rectifier Assembly both sides M15447 1 1 with leads 2a Rectifier Plate M15444 2 2b Rectifier Diode 70A 300V Ano...

Page 53: ...Thread Forming Screw 2h Ground 10 Shakeproof Lock T9695 1 1 Washer 2i Ground 10 24 Hex Nut CF000010 2 3 8 Spool Adapter M15445 1 4 Spindle Shaft Mountigns Includes S20156 2 1 4a 4g No Item Description...

Page 54: ...530 3 1 CABLE LINER M16291 1 035 045 0 9 1 2 mm For cables 15 4 5 m and less M16291 2 025 030 0 6 0 8 mm 2 CONTACT TIPS S19726 1 025 0 6 mm Standard Duty S19726 2 030 0 8 mm S19726 3 035 0 9 mm S19726...

Page 55: ...NOTES SQUARE WAVE TIG 255...

Page 56: ...NOTES SQUARE WAVE TIG 255...

Page 57: ...letin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for s...

Page 58: ...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 moja da Aislese del trabajo y...

Page 59: ...ute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali menta...

Page 60: ...to normal wear CONDITIONS OF WARRANTY TO OBTAIN WARRANTY COVERAGE The purchaser must contact Lincoln or Lincoln s Authorized Service Facility about any defect claimed under Lincoln s warranty Determin...

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