Lincoln-electric IM563 PRO 155 User Manual

PRO 155OPERATOR’S MANUALIM563-AApril, 2001Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. Howe

A-3A-3INSTALLATIONPRO 155SELECT SUITABLE LOCATIONLocate the welder in a dry location where there is freecirculation of clean air into the louvers in t

A-4A-4INSTALLATIONPRO 155Work Cable InstallationRefer to Figure A.2.1. Open the wire feed section door on the right side ofthe PRO 155.2. Pass the end

A-5A-5INSTALLATIONPRO 1552. With the cylinder securely installed, remove thecylinder cap. Stand to one side away from the out-let and open the cylinde

A-6PRO 155A-6INSTALLATIONELECTRICAL INPUT CONNECTIONSFIGURE A.6230 VOLT INPUT CONNECTIONSThe PRO 155 is shipped from the factory connectedfor 230 volt

B-1PRO 155B-1OPERATIONRead entire operation section beforeoperating the PRO 155.ELECTRIC SHOCK can kill.• Do not touch electrically liveparts or elect

B-2PRO 155B-2OPERATIONGENERAL DESCRIPTIONThe PRO 155 is a compact lightweight DC wire feed-er/power source. It has been designed for workshop,hobby, a

B-3B-3OPERATIONFIGURE B.1aFIGURE B.1bWELDING OPERATIONSSEQUENCE OF OPERATION Wire LoadingRefer to Figure B.2 and B.3.The machine power switch should b

B-4B-4OPERATIONFriction Brake AdjustmentWith wire spool installed on the spindle shaft and thewing nut loose, turn the spool by hand while slowlytight

B-5PRO 155B-5OPERATION1. See “Process Guidelines” in this section for selec-tion of welding wire and shielding gas and forrange of metal thicknesses t

B-6PRO 155B-6OPERATIONgauge [14 gauge (2.0 mm) for example] steel.The PRO 155 is suitable for .035" aluminum wire and.030" stainless wire w

PRO 155FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be r

B-7PRO 155B-7LEARNING TO WELDLEARNING TO WELDNo one can learn to weld simply by reading about it.Skill comes only with practice. The following pages w

B-8PRO 155B-8LEARNING TO WELDThe “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing thr

B-9B-9LEARNING TO WELD2. Can I afford the extra expense, space, and lack ofportability required for gas cylinders and gas sup-ply?3. Do I require clea

B-10B-10LEARNING TO WELDARC RAYS can burn eyes and skin.When using an open arc process, itIs necessary to use correct eye,head and body protection.Pro

B-11PRO 155B-11LEARNING TO WELDHelpful Hints1. For general welding, it is not necessary to weavethe arc, neither forward or backward nor sideways.Weld

B-12B-12LEARNING TO WELDMACHINE SET UP FOR THE GMAW (MIG)PROCESS1. See PROCESS GUIDELINES in the OPERATIONsection for selection of welding wire and sh

B-13PRO 155B-13LEARNING TO WELDFIGURE B.173. The Correct Electrical Stickout (ESO)The electrical stickout (ESO) is the distance fromthe end of the con

B-14PRO 155B-14LEARNING TO WELD4. After you strike the arc, practice the correct electri-cal stickout. Learn to distinguish it by its sound.5. When yo

B-15PRO 155B-15LEARNING TO WELDFIGURE B.23Welding In The Vertical PositionWelding in the vertical position can be done either ver-tical-up or vertical

B-16PRO 155B-16LEARNING TO WELDTROUBLESHOOTING WELDSGood welds have excellent appearance.To Eliminate Porosity (in order of importance):1. Turn on gas

PRO 155iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc wh

B-17PRO 155B-17LEARNING TO WELDPROPER GUN HANDLINGMost feeding problems are caused by improper han-dling of the gun cable or electrodes.1. Do not kink

B-18PRO 155B-18APPLICATION CHART

C-1C-1ACCESSORIESPRO 155MIG CONVERSIONSeveral changes are needed to convert the unit foroperation with the MIG (GMAW) process. TheKP665-035 drive roll

D-1D-1MAINTENANCEPRO 155MAINTENANCESAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Disconnect input power by removingplug from receptacle before workingin

D-2PRO 155D-2MAINTENANCE5. To remove the gun tube from the gun, remove thegas nozzle or gasless nozzle and remove the dif-fuser from the gun tube. Rem

D-3PRO 155D-3MAINTENANCECHANGING DRIVE ROLLThe drive roll has two knurled grooves; both for .035-.045 (0.9-1.2 mm) flux-cored steel electrode. If .023

D-4PRO 155D-4MAINTENANCE7. With the gas nozzle and diffuser removed from thegun tube, be sure the cable is straight, and then trimthe liner to the len

E-1E-1TROUBLESHOOTINGPRO 155If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact you

E-2E-2TROUBLESHOOTINGPRO 155PROBLEMS(SYMPTOMS)Major physical or electrical damageis evident.No wire feed, weld output or gasflow when gun trigger is p

E-3E-3TROUBLESHOOTINGPRO 155PROBLEMS(SYMPTOMS)No wire feed when gun trigger ispulled. Fan runs, gas flows andmachine has correct open circuitvoltage (

PRO 155FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Inst

E-4PRO 155E-4TROUBLESHOOTINGIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact you

F-1F-1WIRING DIAGRAMSPRO 155PRO 155 WIRING DIAGRAMELECTRICAL SYMBOLS PER E1537CAVITY NUMBERING SEQUENCE( COMPONENT SIDE OF BOARD )539541213GUN TRIGGER

NOTESPRO 155

Now Available...12th EditionThe Procedure Handbook of Arc WeldingWith over 500,000 copies of previous editions publishedsince 1933, the Procedure Hand

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB

ivivSAFETYPRO 155PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques

PRO 155Thank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as

viPRO 155viMASTER TABLE OF CONTENTS FOR ALL SECTIONSPageInstallation ...

A-1A-1INSTALLATIONPRO 155Type 75°C Wire Grounding WireFuse or in Conduit, Copper Copper Cond.Input Voltage Breaker Size Input Amps Power Cord Cond. AW

PRO 155A-2A-2INSTALLATIONRead entire installation section before startinginstallation.SAFETY PRECAUTIONSIDENTIFY AND LOCATE COMPONENTSIf you have not