Lincoln-electric WELD-PAK 100 IMT460-D User Manual

WWEELLDD--PPAAKK 110000IMT460-DJanuary, 201022801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100 WEB SITE: www.lincolnelectri

10IDENTIFY AND LOCATE COMPONENTSIf you have not already done so, unpack the Weld-Pak fromits carton and remove all packing material around the WELD-PA

11LOCATIONLocate the welder on a secure level surface in a dry location.Locate where there is free circulation of clean air. Blockedair passages can

12GUN INSTALLATION1. Refer to Figure 1. Unplug the machine or turn powerswitch to the off “O” position.2. Pass the insulated terminals of

13INPUT POWER CONNECTIONS FOR RATEDOUTPUT• This welding machine must be connected to powersource in accordance with applicable electrical codes.• If

14CYLINDER may explode if damaged. Keepcylinder upright and chained to support.• Keep cylinder away from areas where it maybe damaged.• Never lift wel

15CONTROLS AND SETTINGSRefer to the case front t of the WELD-PAK.1. Power ON/OFF Switch — When the poweris on the fan motor will run and air

16WELDING SEQUENCE OF OPERATION WIRE LOADINGThe machine power switch should be turned to the OFF (“O”)position before working inside the wire feed enc

17Note: The brake should be adjusted with a spool of wireinstalled. When properly adjusted it should movefreely but not coast.FRICTION

185. Close the idle roll arm and latch the spring loaded pres-sure arm (2) in place . Rotate the spool counterclock-wise if required in order to

197. Remove gas nozzle and contact tip from end of gun.8. Turn the WELD-PAK ON (“I”).9. Straighten the gun cable assembly.10. Depress the gun trigger

2ARC WELDING CAN BE HAZARDOUS. PROTECT YOUR-SELF AND OTHERS FROM POSSIBLE SERIOUS INJURYOR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEAR-ERS SHO

204. Connect work clamp to metal to be welded. Work clampmust make good electrical contact to the workpiece. Theworkpiece must also be grounded a

21PROCESS GUIDELINESRefer to the Application chart on the inside of the wire feedcompartment door for information on setting the WELD-PAKfor mild stee

22LEARNING TO WELDNo one can learn to weld simply by reading about it. Skillcomes only with practice. The following pages will help theinexp

23Fumes and slag generated fromInnershield type electrodes recom-mended for use with this weldingmachine can be toxic.• Avoid contact with

24The “arc stream” is seen in the middle of the picture. This isthe electric arc created by the electric current flowing throughthe space between t

25When comparing the GMAW and FCAW processes, you cansee that the principal difference between the two lies in thetype of shielding used. GMAW uses ga

26For FCAW (Innershield) Process1. Do I want simplicity and portability?2. Will welding be performed outdoors or under windy con-ditions?3. Do I requi

27Butt WeldsPlace two plates side by side, leaving a space approximate-ly one half the thickness of the metal between them in orderto get deeper penet

28Fillet WeldsWhen welding fillet welds, it is very important to hold the wireelectrode at a 45° angle between the two sides or the metalwill not dis

29FIGURE 12Vertical-down WeldingRefer to Figure 13 Vertical-down welds are applied at a fastpace. These welds are therefore shallow and narrow and, as

3ELECTRIC AND MAGNETICFIELDS may be dangerous3.a. Electric current flowing through anyconductor causes localized Electricand Magnetic Field

30WELDING TECHNIQUES FOR THESELF-SHIELDED FCAW PROCESSFour simple manipulations are of prime importance whenwelding. With complete mastery of t

313. The Correct Contact Tip to Work Distance(CTWD)The Contact Tip to Work (CTWD) is the distance from theend of the contact tip to the end of the wir

32Helpful Hints1. For general welding, it is not necessary to weave the arc.Weld along at a steady pace. You will find it easier.2. When welding on

334. After you strike the arc, practice the correct contact tip towork distance. Learn to distinguish it by its sound.5. When you are sure that you ca

When using the GMAW process on light gauge material,weld from right to left (if you are right handed). This results ina colder weld and has le

354. The Correct Welding SpeedThe important thing to watch while welding is the puddleof molten metal right behind the arc. See Figure 21. Donot watch

36PracticeThe best way of getting practice is to perform the followingexercise.Refer to Figure 18.1. Learn to strike an arc by positioning the gun ove

37TROUBLESHOOTING WELDSGood welds have excellent appearance.To Eliminate Porosity (in order of importance):1. Turn on gas supply, if used2. Decrease v

38To Reduce Spatter (in order of importance):1. Increase voltage.2. Increase drag angle.3. Decrease stickout.4. Increase WFS (wire feed speed).5. Decr

39OPTIONAL ACCESSORIES1. K520 Utility Cart — Designed to transport the Lincolnfamily of small welders. Has provisions for mounting asingle

4SAFETY SEGURIDAD SÉCURITÉWELDING SPARKS cancause fire or explosion.4.a. Remove fire hazards from the weldingarea. If this is not possible, cover them

401. Install the gas solenoid. Complete instructions are includ-ed with the kit.2. Change the output polarity to DC(+). See “Work CableInstallatio

41SAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Disconnect input power by remov-ing plug from receptacle beforeworking inside WELD-PAK. Useonly grounded

42GUN AND CABLE MAINTENANCEGun Cable CleaningClean cable liner after using approximately 300 lbs (136 kg)of solid wire or 50 lbs (23 kg) of flux-cored

43CHANGING DRIVE ROLLThe drive roll has two grooves; one for .023" – .025" (0.6mm) solid steel electrode and a larger knur

44CHANGING LINERNOTICE: The variation in cable lengths prevents the inter-changeability of liners. Once a liner has been cut for a par-ticular gun,

45No wire feed, weld output or gas flow when gun trig-ger is pulled. Fan does NOT operate.1. Make sure correct voltage is applied to themachine.2. Mak

46Low or no gas flow when gun trigger is pulled. Wirefeed, weld output and fan operate normally.(Optional MIG Conversion Kit only.)1. Verify that gas

47 1NOTE: This diagram is for reference only. It may not beaccurate for all machines covered by this manual.The specific diagram for a

48PARTS PARTES PIÈCESPart Description Descripción de las partes Désignation des pièces Part NumberVoltage Control Switch Assembly Ensamble del Interr

49NOTES-NOTAS

5ELECTRIC SHOCK can kill.5.a. The electrode and work (or ground)circuits are electrically “hot” when thewelder is on. Do not touch these “hot”par

50WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabic● Do not touch electrically live parts orele

51WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabic● Turn power off before servicing.● Desconec

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6FUMES AND GASEScan be dangerous.6.a.Welding may produce fumes and gaseshazardous to health. Avoid breathing thesefumes and gases.When welding, keep y

CYLINDER may explode ifdamaged.7.a. Use only compressed gas cylinderscontaining the correct shielding gas forthe process used and properly operat-

8Read the entire manual before installing andoperating the WELD-PAKELECTRIC SHOCK can kill.• Only qualified personnel should installationor operate th

9TECHNICAL SPECIFICATIONS ESPECIFICACIONES TÉCNICASFuse Size Input Amps Power Cord20 Amp 20 15 Amp, 125VThree Prong Plug(NEMA Type 5-15P)15 Amp 12 15