RETURN TO MAIN MENU IM822 MIG PAK HD February, 2003 For use with machine Code Number:11062 Safety Depends on You 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.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS The engine exhaust from this product contains Diesel engine exhaust and some of its constituents chemicals known to the State of California to cause are known to the State of California to cause cancancer, birth defects, or other reproductive harm. cer, birth defects, and other reproductive harm. The Above For Gasoline Engines The Above For Diesel Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.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. 3.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.
iii iii SAFETY WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to 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 hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv iv SAFETY 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 L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln 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.
vi MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components ...........................................................................A-2 Select Suitable Location ...................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – MIG PAK HD INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency 120V/60Hz Input Current 20 Amps @ Rated Output RATED OUTPUT Duty Cycle 20% Duty Cycle Amps 70 Volts at Rated Amperes 17 OUTPUT RANGE Welding Current Range DC OUTPUT: 35-88 Amps Maximum-Open Circuit Voltage 29V No Load 0 - 450 in/min (0 - 17.7 mm/min) While welding 0-300 in/min. (0-11.8 mm/min.
A-2 A-2 INSTALLATION Read entire installation section before starting installation. FIGURE A.1 SAFETY PRECAUTIONS 1 WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Only personnel that have read and understood the Machine 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.
A-3 A-3 INSTALLATION INPUT CONNECTIONS SELECT SUITABLE LOCATION (FIGURE A.4) Place the machine on a secure, level surface or recommended undercarriage. The machine may topple over if this procedure is not followed. To minimize over heating, locate the welder in a dry location where there is free circulation of clean air. Do not place on combustible surfaces. GAS INLET FITTING POWER INPUT CABLE STACKING Machines cannot be stacked. CHANGING POLARITY Refer to Figure A.4. 1.
A-4 A-4 INSTALLATION CODE REQUIREMENTS FOR ELECTRICAL INPUT CONNECTIONS SHIELDING GAS CONNECTION (FIGURE A.5) REGULATOR HOSE CYLINDER VALVE WARNING This welding machine must be connected to a power source in accordance with applicable electrical codes.
B-1 OPERATION Read entire operation section before operating the machine. 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. B-1 GENERAL DESCRIPTION The machine is a semiautomatic constant voltage DC arc welder.
B-2 B-2 OPERATION WELDING CAPABILITY TABLE B.1 – MIG WELDING MATERIAL/GAS COMBINATIONS The machine is rated at 70 amps, 17 volts, at 20% duty cycle on a ten minute basis. It is capable of higher output currents at lower duty cycles. LIMITATIONS The machine is recommended for welding on mild steel up to 1/8” thick. Material Carbon Steel Low Alloy Steel Gas CO2 or Argon/CO2 CO2 or Argon/CO2 FLUX-CORED (INNERSHIELD) WELDING The recommended electrode for the flux-cored, selfshielded process is 0.
B-3 B-3 OPERATION FIGURE B.4 – WIRE STICKOUT FIGURE B.3 – WIRE THREADING DETAILS SPRING LOADED THUMSCREW IDLER ROLL ARM WIRE WIRE FEED LOWER DRIVE ROLL CONTACT TIP INGOING GUIDE TUBE WIRE ELECTRODE Refer to Figure B.3. 4. Release the spring loaded thumbscrew and rotate the idle roll arm away from the wire feed drive roll. Ensure that the visible, stenciled size on the drive roll side facing you matches the wire size being used. 5.
B-4 OPERATION MAKING A WELD FIGURE B.5 – WELDING SETUP GUN CABLE WORKPIECE ARC WORK CLAMP READ the LEARNING TO WELD section of this manual prior to making your first weld. Also, refer to Table B.1 and the Procedure Decal located on the inside of the wire drive compartment door of your machine for process selection, consumables, and quick tips for welding. B-4 4. Check that the polarity is correct for the welding wire being used and that the gas supply, if required, is turned on. 5.
B-5 OPERATION CLEANING TIP AND GAS NOZZLE Keep the contact tip and nozzle clean to avoid arc bridging between them. Bridging can result in a shorted nozzle, poor welds and an overheated gun. Hint: Anti-stick spray or gel, available from a welding supplier, may reduce buildup and aid in spatter removal. CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES The machine is shipped from the factory ready to feed 0.035” (0.9 mm) diameter wire.
B-6 B-6 OPERATION LEARNING TO WELD WARNING No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the operator to understand welding and develop this skill. Fumes and slag generated from Innershield type electrodes recommended for use with this welding machine can be toxic. • Avoid contact with eyes and skin. THE ARC-WELDING CIRCUIT • Do not take internally. The operator’s knowledge of arc welding must go beyond the arc itself.
B-7 B-7 OPERATION 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.
B-8 B-8 OPERATION For GMAW (MIG) Process 1. Is most of my welding performed on 16 gauge and lighter materials? 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas supply? JOINT TYPES AND POSITIONS Five types of welding joints are: Butt Joint, Fillet Joint, Lap Joint, Edge Joint and Corner Joint. See Figure B.9. Of these, the Butt joint and Fillet joint are the two most common welds. 3.
B-9 B-9 OPERATION Penetration Unless a weld penetrates close to 100% of the metal thickness, a butt joint will be weaker than the material welded together. In the example shown in Figure B.11, the total weld is only half the thickness of the material thus the weld is only approximately half as strong as the metal. 45° FIGURE B.11 FIGURE B.13 Welding In The Vertical Position In the example shown in Figure B.12, the joint has been welded so that 100% penetration could be achieved.
B-10 OPERATION B-10 MACHINE SET UP FOR THE SELF-SHIELDED FCAW PROCESS 1. See the Application Guide on the inside of wire feed section door for information on setting the controls based on wire type and metal thickness being welded.. PROPER GUN ANGLE FOR GMAW PROCESS WELDING IN THE VERTICAL UP POSITION PROPER GUN ANGLE FOR FCAW PROCESS WELDING IN THE VERTICAL UP POSITION 2.
B-11 B-11 OPERATION Contact Tip Wire Electrode FIGURE B.16 3/8” (10mm) Electrical Stickout (ESO) WARNING FIGURE B.17 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.
B-12 B-12 OPERATION Helpful Hints For the MACHINE , use the following: 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.
B-13 B-13 OPERATION 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.
B-14 B-14 OPERATION 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. Contact Tip 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. Wire Electrode ESO FIGURE B.22 3.
B-15 OPERATION B-15 To Reduce Spatter: TROUBLESHOOTING WELDS Good welds have excellent appearance. (In order of priority): 1. Check or reset WFS & Volts on chart inside door. 2. Increase drag angle. 3. Decrease stickout. 4. Decrease travel speed. To Eliminate Porosity To Correct Poor Penetration (In order of priority): 1. Check or reset WFS & Volts on chart inside door. 2. Decrease stickout. 3. Decrease speed. 4. Decrease drag angle. (In order of priority): 1.
B-16 OPERATION 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.
C-1 ACCESSORIES ACCESSORIES INNERSHIELD WELDING WIRE NR-211-MP Innershield welding wire - .035” (0.9 mm) diameter flux-cored electrode. MIG WELDING WIRE Lincoln L56- .025” (0.6mm) diameter solid steel electrode) CONSUMABLE PARTS The following items are commonly consumed over the life of the welder and may need to be ordered. See the complete parts list at the end of this manual for machine replacement parts.
D-1 MAINTENANCE MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside machine. Use only grounded receptacle. Do not touch electrically “hot” parts inside machine • Have qualified personnel do the maintenance and trouble shooting work.
D-2 D-2 MAINTENANCE COMPONENT REPLACEMENT PROCEDURES CLEANING THE GUN LINER • Unplug the machine or turn the power switch to the OFF - “0” position. FIGURE D.1 – CONTACT TIP REPLACEMENT • Remove the gas nozzle and contact tip from the gun. CONTACT TIP AL .0-.040 • Clean the inside diameter with a short piece of wire. 1 • Clean the cable liner when rough and erratic wire feeding occur: NOZZLE Lay the cable out straight.
D-3 MAINTENANCE 3. Remove the Thumbscrew holding the drive roll. 4. Replace the drive roll so that the desired size, stenciled on the side of the drive roll, is toward the inside and visible. 5. Replace the Thumbscrew and tighten. GUN ASSEMBLY REMOVAL 1. Unplug machine. 2. Remove wire drive door and right case side. 3. Remove gas line connections. 4. Remove gun connections from output studs. 5. Remove trigger leads. The trigger leads are routed through the center panel and connected to the P.C.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING 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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is evident. None Contact your local Authorized Field Service Facility. No wire feed, weld output or gas flow when gun trigger is pulled. 1. Make sure correct voltage is applied to the machine (115vac). 2. Make certain that power switch is in the ON position. 3.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FEEDING PROBLEMS No wire feed when gun trigger is pulled. 1. The thermostat may be tripped due to overheating. Let machine cool. Weld within the duty cycle or remove any air obstruction to the machine. 2. Gun trigger may be faulty. 3. Drive Roll tension is set too high.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Bead is too thin (intermittently). 1. Travel speed is inconsistent. Decrease and maintain a constant travel speed. 2. Output heat range is too low. Set the Low – High Heat Range switch to High or the Fine Heat Adjustment to MAX. Bead is too thick (intermittently). 1. Travel speed is slow and/or inconsistent.
F-1 F-1 M20242 X2 X1 X1 X2 red black M2 NO GAS X2 X1 GAS A.01 DIAGRAMS X11 L X10 X9 X8 X7 X6 g 4 3 5 4 6 3 S1 2 G 1 B WELDER INPUT CABLE PLUG GREEN LEAD W 4 0I 5 M1 S2 2 1 1 2 T X2 X3 X1 X4 WIRING DIAGRAM g V X5 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el 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 your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. 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- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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