Lincoln Electric Pro 100 User Manual

PRO 100OPERATOR’S MANUALIM562-BMay, 2000Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. Howeve

A-3INSTALLATION PRO 100A-3SELECT SUITABLE LOCATIONLocate the welder in a dry location where there is freecirculation of clean air into the louvers i

A-4INSTALLATION PRO 100A-4and installation details.Connecting Gun Cable to the PRO 1001. Refer to Figure A.2. Unplug the machine or turnpower switch

2. With the cylinder securely installed, remove thecylinder cap. Stand to one side away from the out-let and open the cylinder valve very slightly for

A-6INSTALLATION PRO 100A-6INPUT CONNECTIONSFIGURE A.6Refer to Figure A.6.The PRO 100 has a power input cable located on therear of the machine.CODE

B-1OPERATIONB-1PRO 100Read entire operation section beforeoperating the PRO 100.ELECTRIC SHOCK can kill.• Do not touch electrically liveparts or elect

B-2OPERATIONB-2● No external shielding gas is required when usedwith Lincoln Innershield .035” (0,9 mm) NR®-211-MP electrode.● Accommodates 4” (100 mm

B-3OPERATIONB-3FIGURE B.1aFIGURE B.1bWELDING OPERATIONSSEQUENCE OF OPERATION Wire LoadingRefer to Figure B.2 AND B3.The machine power switch should be

Gun HandleGas Diffuser/Contact TipGas NozzleFIGURE B.5B-4OPERATIONB-4Note: The brake should be adjusted with a spool ofwire installed. When properly a

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

B-6OPERATIONB-6lower cost. A mixed gas consisting of 75 to 80%Argon and 20 to 25% CO2is recommended for weld-ing on heavier gauge [12 gauge (2,5 mm) f

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

B-7LEARNING TO WELDB-7PRO 100LEARNING TO WELDNo one can learn to weld simply by reading about it.Skill comes only with practice. The following pageswi

B-8LEARNING TO WELDB-8PRO 100The “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing thr

B-9LEARNING TO WELDB-9PRO 1002. Can I afford the extra expense, space, and lack ofportability required for gas cylinders and gas sup-ply?3. Do I requi

B-10LEARNING TO WELDB-10PRO 100FIGURE B.12PenetrationUnless a weld penetrates close to 100% of the metalthickness, a butt weld will be weaker than the

B-11LEARNING TO WELDB-11PRO 100FIGURE B.16Vertical-down WeldingRefer to Figure B.17 Vertical-down welds are appliedat a fast pace. These welds are the

B-12LEARNING TO WELDB-12PRO 100ARC RAYS can burn eyes and skin.When using an open arc process, itIs necessary to use correct eye,head and body protect

B-13LEARNING TO WELDB-13PRO 100Helpful Hints1. For general welding, it is not necessary to weavethe arc, neither forward or backward nor sideways.Weld

B-14LEARNING TO WELDB-14PRO 100MACHINE SET UP FOR THE GMAW (MIG)PROCESS1. See PROCESS GUIDELINES in the OPERATIONsection for selection of welding wire

B-15LEARNING TO WELDB-15PRO 100FIGURE B.243. The Correct Electrical Stickout (ESO)The electrical stickout (ESO) is the distance fromthe end of the con

4. After you strike the arc, practice the correct electri-cal stickout. Learn to distinguish it by its sound.5. When you are sure that you can hold th

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-17LEARNING TO WELDB-17PRO 100Proper Gun HandlingMost feeding problems are caused by improper han-dling of the gun cable or electrodes.1. Do not kink

B-18APPLICATION CHARTB-18PRO 100

C-1ACCESSORIESC-1OPTIONAL ACCESSORIES1. K520 Utility Cart — Designed to transport the Lin-coln family of small welders. Has provisions formounting a s

D-1MAINTENANCED-1PRO 100MAINTENANCESAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Disconnect input power by removingplug from receptacle before workingin

D-2MAINTENANCED-2GUN AND CABLE MAINTENANCEFOR MAGNUM™ 100L GUNGun Cable CleaningClean cable liner after using approximately 300 lbs(136 kg) of solid w

D-3MAINTENANCED-3COMPONENTREPLACEMENT PROCEDURESCHANGING THE CONTACT TIP1. Refer to Figure D.2. Remove the gas nozzle fromthe gun by unscrewing counte

D-4MAINTENANCED-4PRO 100CHANGING LINERNOTICE: The variation in cable lengths pre-vents the interchangeability of liners. Oncea liner has been cut for

D-5MAINTENANCED-5PRO 100GUN HANDLE PARTSThe gun handle consists of two halves that are heldtogether with a collar on each end. To open up thehandle, t

E-1TROUBLESHOOTINGE-1PRO 100This Troubleshooting Guide is provided tohelp you locate and remedy possible prob-lems with machine setup or operation. Si

E-2TROUBLESHOOTINGE-2PRO 100Observe Safety Guidelinesdetailed in the beginning of this manual.TROUBLESHOOTING GUIDEPROBLEMS(SYMPTOMS)Major physical or

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-3TROUBLESHOOTINGE-3PRO 100TROUBLESHOOTING GUIDEObserve Safety Guidelinesdetailed in the beginning of this manual.PROBLEMS(SYMPTOMS)No wire feed when

E-4TROUBLESHOOTINGE-4PRO 100Observe Safety Guidelinesdetailed in the beginning of this manual.TROUBLESHOOTING GUIDEIf for any reason you do not unders

F-1DIAGRAMSF-1PRO 100S1SWITCHD1D3D2D4204204204203203203C159,000 mf40V203204-+GUN CABLECONDUCTORBLOCKTOWORKELECTRICAL SYMBOLS PER E1537CAVITY NUMBERING

NOTES PRO 100

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 instructionset les précautions de sûreté specifiques qui parra

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

viTABLE OF CONTENTSPageInstallation ...Section ATe

A-1PRO 100A-1INSTALLATIONFuse orOutput Mode Input Voltage Breaker Size Input Amps Power Cord Extension CordRATED 115V/60Hz 20 Amp 20 15 Amp, 125V,Thre

A-2INSTALLATION PRO 100A-2Read entire installation section before startinginstallation.SAFETY PRECAUTIONSIDENTIFY AND LOCATE COMPONENTSIf you have n