Lincoln-electric MIG PAK HD IM822 User Manual

MIG PAK HDOPERATOR’S MANUALIM822February, 2003Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind.

INPUT CONNECTIONS (FIGURE A.4)Refer to Figure A.4.The machine has two input connections, the powerinput cable and the gas inlet fitting. The power inp

A-4INSTALLATION MIG PAK HDA-4SHIELDING GAS CONNECTION(FIGURE A.5)Refer to Figure A.5.1. Chain the cylinder to a wall or other stationary sup-port to

B-1OPERATIONB-1MIG PAK HDRead entire operation section beforeoperating the machine.ELECTRIC SHOCK can kill.• Do not touch electrically liveparts or el

B-2OPERATIONB-2TABLE B.1 – MIG WELDING MATERIAL/GAS COMBINATIONSMaterial GasCarbon Steel CO2 or Argon/CO2Low Alloy Steel CO2 or Argon/CO2FLUX-CORED (I

B-3OPERATIONB-3FIGURE B.3 – WIRE THREADING DETAILSRefer to Figure B.3.4. Release the spring loaded thumbscrew and rotatethe idle roll arm away from th

B-4OPERATIONB-4MAKING A WELDFIGURE B.5 – WELDING SETUPREAD the LEARNING TO WELD section of this man-ual prior to making your first weld. Also, refer

B-5OPERATIONB-5MIG PAK HDCLEANING TIP AND GAS NOZZLEKeep the contact tip and nozzle clean to avoid arcbridging between them. Bridging can result in a

B-6OPERATIONB-6MIG PAK HDLEARNING TO WELDNo one can learn to weld simply by reading aboutit. Skill comes only with practice. The followingpages will h

B-7OPERATIONB-7The “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing through the space

B-8OPERATIONB-8MIG PAK HDFor GMAW (MIG) Process1. Is most of my welding performed on 16 gauge andlighter materials?2. Can I afford the extra expense,

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

B-9OPERATIONB-9MIG PAK HDPenetrationUnless a weld penetrates close to 100% of the metalthickness, a butt joint will be weaker than the materialwelded

B-10OPERATIONB-10MIG PAK HDFIGURE B.14Vertical-down WeldingRefer to Figure B.15 Vertical-down welds are appliedat a fast pace. These welds are therefo

B-11OPERATIONB-11MIG PAK HDARC RAYS can burn eyes and skin.When using an open arc process, itIs necessary to use correct eye,head and body protection.

B-12OPERATIONB-12MIG PAK HDHelpful Hints1. For general welding, it is not necessary to weavethe arc, neither forward or backward nor sideways.Weld alo

B-13OPERATIONB-13MIG PAK HDMACHINE SET UP FOR THE GMAW (MIG)PROCESS1. See PROCESS GUIDELINES in the OPERATIONsection for selection of welding wire and

B-14OPERATIONB-14MIG PAK HDFIGURE B.223. The Correct Electrical Stickout (ESO)The electrical stickout (ESO) is the distance fromthe end of the contact

B-15OPERATIONB-15TROUBLESHOOTING WELDSGood welds have excellent appearance.To Eliminate Porosity (In order of priority):1. Check or reset WFS & V

B-16OPERATIONB-16Proper Gun HandlingMost feeding problems are caused by improper han-dling of the gun cable or electrodes.1. Do not kink or pull the g

C-1ACCESSORIESC-1ACCESSORIESINNERSHIELD WELDING WIRENR-211-MP Innershield welding wire - .035” (0.9 mm)diameter flux-cored electrode.MIG WELDING WIRE

MAINTENANCESAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Disconnect input power by removingplug from receptacle before workinginside machine. Use only g

iiSAFETYiiARC 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 when weld

D-2MAINTENANCED-2MID PAK HDCLEANING THE GUN LINER• Unplug the machine or turn the power switch to theOFF - “0” position.• Remove the gas nozzle and

D-3MAINTENANCED-3MIG PAK HD3. Remove the Thumbscrew holding the drive roll. 4. Replace the drive roll so that the desired size, sten-ciled on the sid

E-1TROUBLESHOOTINGE-1MIG PAK HDIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact

E-2TROUBLESHOOTINGE-2MIG PAK HDIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact

E-3TROUBLESHOOTINGE-3MIG PAK HDIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact

E-4TROUBLESHOOTINGE-4MIG PAK HDIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact

F-1DIAGRAMSF-1MIG PAK HDM20242A.01WIRING DIAGRAMWELDERINPUTCABLES11425M1WBG0IGREEN LEADPLUG361223T1S2544VggLM2redblackX1X2X3X5X4X8X11X10X9X2X1X2X1NO G

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

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

ivSAFETYivMar. ‘93PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques

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

viMASTER TABLE OF CONTENTS FOR ALL SECTIONSPageInstallation ...

A-1MIG PAK HDA-1Fuse orOutput Mode Input Voltage Breaker Size1Input Amps Power Cord Extension CordATRATED 120V/60Hz 20 Amp 20 15 Amp, 125V, Three Cond

A-2INSTALLATION MIG PAK HDA-2Read entire installation section before startinginstallation.SAFETY PRECAUTIONSIDENTIFY AND LOCATE COMPONENTSIf you hav