Lincoln-electric WELD-PAK 3200HD User Manual

WELD-PAK 3200HDOPERATORS MANUALIM759May, 2002Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. H

A-3INSTALLATION WELD-PAK 3200HDA-345836712+-FIGURE A.2Work Clamp InstallationAttach the work clamp per the following:1. Unplug the machine or turn t

Work Cable InstallationRefer to Figure A.2.1. Open the wire feed section door on the right side ofthe WELD-PAK 3200HD.2. Pass the end of the work cabl

CYLINDER may explode if dam-aged. Keep cylinder upright andchained to support• Keep cylinder away from areaswhere it may be damaged.• Never lift welde

A-6INSTALLATION WELD-PAK 3200HDA-6INPUT CONNECTIONSRefer to Figure A.6.The WELD-PAK 3200HD has a power input cablelocated on the rear of the machine

A-7INSTALLATION WELD-PAK 3200HDA-7UNDERCARRIAGE ASSEMBLYCYLINDER may explodeif damaged.• Keep cylinder upright and securedto support.• Keep cylinder

B-1OPERATIONB-1WELD-PAK 3200HDRead entire operation section beforeoperating the WELD-PAK 3200HD.ELECTRIC SHOCK can kill.• Do not touch electrically li

B-2OPERATIONB-2Refer to Figure B.1b.4. Circuit Breaker – Protects machine from damage ifmaximum output is exceeded. Button will extendout when tripped

B-3OPERATIONB-3FIGURE B.1aFIGURE B.1bWELDING OPERATIONSSEQUENCE OF OPERATION Wire LoadingRefer to Figures B.2 and B.3.The machine power switch should

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

B-5OPERATIONB-5FIGURE B.6Making A Weld1. See “Process Guidelines” in this section for selec-tion of welding wire and shielding gas and forrange of met

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

B-6OPERATIONB-6The WELD-PAK 3200HD is suitable for .035" alu-minum wire and .030" stainless wire. Refer to TableB.1 for recommended procedu

B-7LEARNING TO WELDB-7LEARNING TO WELDNo one can learn to weld simply by reading about it.Skill comes only with practice. The following pageswill help

B-8LEARNING TO WELDB-8The “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing through th

B-9LEARNING TO WELDB-9WELD-PAK 3200HDFor GMAW (MIG) Process1. Is most of my welding performed on 16 gauge andlighter materials?2. Can I afford the ext

B-10LEARNING TO WELDB-10WELD-PAK 3200HDFIGURE B.12PenetrationUnless a weld penetrates close to 100% of the metalthickness, a butt weld will be weaker

B-11LEARNING TO WELDB-11WELD-PAK 3200HDFIGURE B.16Vertical-down WeldingRefer to Figure B.17 Vertical-down welds are appliedat a fast pace. These welds

B-12LEARNING TO WELDB-12WELD-PAK 3200HDARC RAYS can burn eyes and skin.When using an open arc process, itIs necessary to use correct eye,head and body

B-13LEARNING TO WELDB-13WELD-PAK 3200HDHelpful Hints1. For general welding, it is not necessary to weavethe arc, neither forward or backward nor sidew

B-14LEARNING TO WELDB-14WELD-PAK 3200HDMACHINE SET UP FOR THE GMAW (MIG)PROCESS1. See PROCESS GUIDELINES in the OPERATIONsection for selection of weld

B-15LEARNING TO WELDB-15WELD-PAK 3200HDFIGURE B.243. The Correct Electrical Stickout (ESO)The electrical stickout (ESO) is the distance fromthe end of

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

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

B-17LEARNING TO WELDB-17Proper Gun HandlingMost feeding problems are caused by improper han-dling of the gun cable or electrodes.1. Do not kink or pul

B-18APPLICATION CHARTB-18WELD-PAK 3200HD

C-1ACCESSORIESC-1OPTIONAL ACCESSORIES1. K664-2 Aluminum Feeding Kit — This kitrequired for welding with .035 Aluminum wire.Included with this kit are

C-2ACCESSORIESC-2REPLACEMENT PARTSComplete Gun and Cable AssemblyL8311-5 (K530-4)Contact Tip .025” (0.6 mm)S19726-1Contact Tip .030” (0.8 mm)S19726-2C

MAINTENANCESAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Disconnect input power by removingplug from receptacle before workinginside WELD-PAK 3200HD. Us

D-2MAINTENANCED-2WELD-PAK 3200HDGUN AND CABLE MAINTENANCEFOR MAGNUM™ 100L GUNGun Cable CleaningClean cable liner after using approximately 300 lbs(136

D-3MAINTENANCED-3WELD-PAK 3200HDCOMPONENTREPLACEMENTPROCEDURESCHANGING THE CONTACT TIP1. Refer to Figure D.2. Remove the gas nozzle fromthe gun by uns

GUN HANDLE PARTSThe gun handle consists of two halves that are heldtogether with a collar on each end. To open up thehandle, turn the collars approxim

E-1TROUBLESHOOTINGE-1WELD-PAK 3200HDIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con

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

E-2TROUBLESHOOTINGE-2WELD-PAK 3200HDIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con

E-3TROUBLESHOOTINGE-3WELD-PAK 3200HDIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con

E-4TROUBLESHOOTINGE-4WELD-PAK 3200HDIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con

F-1DIAGRAMSF-1WELD-PAK 3200HDS1SWITCHD1D3D2D4204204204203203203C159,000 f40V203204-+GUN CABLECONDUCTORBLOCKTOWORKELECTRICAL SYMBOLS PER E1537CAVITY N

NOTESWELD-PAK 3200HD

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

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ivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui par

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-1WELD PAK 3200HDA-1Fuse orOutput Mode Input Voltage Breaker Size1Input Amps Power Cord Extension CordThree Conductor#14 AWG(2.1 mm2) or LargerRATED

A-2INSTALLATION WELD-PAK 3200HDA-2Read entire installation section before startinginstallation.SAFETY PRECAUTIONSIDENTIFY AND LOCATE COMPONENTSIf yo