Lincoln Electric Welding System IM822 User Manual
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IM822  
February, 2003  
MIG PAK HD  
For use with machine Code Number:11062  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However, your  
overall safety can be increased by  
proper installation ... and thought-  
ful operation on your part. DO  
NOT INSTALL, OPERATE OR  
REPAIR THIS EQUIPMENT  
WITHOUT READING THIS  
MANUAL AND THE SAFETY  
PRECAUTIONS CONTAINED  
THROUGHOUT. And, most  
importantly, think before you act  
and be careful.  
Date of Purchase:  
Serial Number:  
Code Number:  
Model:  
Where Purchased:  
OPERATOR’S MANUAL  
Copyright © 2003 Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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ii  
ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5.b. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
5.d. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
Mar ‘95  
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SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
the welding sparks from starting a fire.  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
process used and properly operating  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact  
can cause overheating and create a fire hazard.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
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SAFETY  
5. Toujours porter des lunettes de sécurité dans la zone de  
PRÉCAUTIONS DE SÛRETÉ  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
Pour votre propre protection lire et observer toutes les instruc-  
tions et les précautions de sûreté specifiques qui parraissent  
dans ce manuel aussi bien que les précautions de sûreté  
générales suivantes:  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
8. S’assurer que la masse est connectée le plus prés possible  
de la zone de travail qu’il est pratique de le faire. Si on place  
la masse sur la charpente de la construction ou d’autres  
endroits éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher  
metallique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une  
grande partie du corps peut être en contact avec la  
masse.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les  
vapeurs du solvant pour produire du phosgéne (gas forte-  
ment toxique) ou autres produits irritants.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à soud-  
er parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
2. Dans le cas de travail au dessus du niveau du sol, se pro-  
téger contre les chutes dans le cas ou on recoit un choc. Ne  
jamais enrouler le câble-électrode autour de n’importe quelle  
partie du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du  
rayonnement de l’arc et des projections quand on soude  
ou quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code  
de l’électricité et aux recommendations du fabricant. Le dis-  
positif de montage ou la piece à souder doit être branché à  
une bonne mise à la terre.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflamma-  
bles.  
2. Autant que possible, I’installation et l’entretien du poste  
seront effectués par un électricien qualifié.  
3. Avant de faires des travaux à l’interieur de poste, la  
debrancher à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection  
libres de l’huile, tels que les gants en cuir, chemise épaisse,  
pantalons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
Mar. ‘93  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
Please Examine Carton and Equipment For Damage Immediately  
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims  
for material damaged in shipment must be made by the purchaser against the transportation company at the  
time the shipment is received.  
Please record your equipment identification information below for future reference. This information can be  
found on your machine nameplate.  
Model Name & Number _____________________________________  
Code & Serial Number _____________________________________  
Date of Purchase _____________________________________  
Whenever you request replacement parts for product registration on-line or information on this equipment  
always supply the information you have recorded above.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or  
loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to  
this equipment.  
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vi  
MASTER TABLE OF CONTENTS FOR ALL SECTIONS  
Page  
Installation .......................................................................................................Section A  
Technical Specifications ........................................................................................A-1  
Identify and Locate Components...........................................................................A-2  
Select Suitable Location ........................................................................................A-3  
Stacking.................................................................................................................A-3  
Changing Polarity ..................................................................................................A-3  
Gun Installation......................................................................................................A-3  
Input Connections..................................................................................................A-3  
Gas Connections ...................................................................................................A-3  
Shielding Gas Connections ...................................................................................A-4  
Code Requirements ..............................................................................................A-4  
________________________________________________________________________  
Operation .........................................................................................................Section B  
Safety Precautions ................................................................................................B-1  
General Description...............................................................................................B-1  
Recommended Processes.....................................................................................B-1  
Operation Features and Controls .........................................................................B-1  
Design Features ....................................................................................................B-1  
Welding Capability.................................................................................................B-2  
Limitations..............................................................................................................B-2  
Controls and Settings ............................................................................................B-2  
Welding Operations ...............................................................................................B-2  
Shielding Gas ........................................................................................................B-3  
Making a Weld and Process Table........................................................................B-4  
Cleaning Tip and Gas Nozzle................................................................................B-5  
Changing Machine over to Feed Other Wire Sizes,Overload Protection...............B-5  
Learning to Weld....................................................................................B-6 thru B-16  
________________________________________________________________________  
Accessories.....................................................................................................Section C  
Accessories ...........................................................................................................C-1  
Replacement Parts................................................................................................C-1  
________________________________________________________________________  
Maintenance ....................................................................................................Section D  
Safety Precautions ................................................................................................D-1  
Items Requiring No Maintenance ..........................................................................D-1  
Routine Maintenance.............................................................................................D-1  
Cleaning the Gun Liner..........................................................................................D-2  
Cleaning Components as Required.......................................................................D-2  
Component Replacement Procedures ..................................................................D-2  
Changing Contact Tip............................................................................................D-2  
Changing the Drive Roll.........................................................................................D-2  
Gun Assembly Removal........................................................................................D-3  
Work Cable Installation..........................................................................................D-3  
________________________________________________________________________  
Troubleshooting..............................................................................................Section E  
Safety Precautions.................................................................................................E-1  
How to Use Troubleshooting Guide.......................................................................E-1  
Troubleshooting Guide.........................................................................E-2 THRU E-4  
________________________________________________________________________  
Wiring Diagrams..............................................................................................Section F  
Wiring Diagram .....................................................................................................F-1  
________________________________________________________________________  
Parts Lists ....................................................................................................P437 Series  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS – MIG PAK HD  
INPUT – SINGLE PHASE ONLY  
Standard Voltage/Frequency  
Input Current  
20 Amps @ Rated Output  
120V/60Hz  
RATED OUTPUT  
Duty Cycle  
Amps  
Volts at Rated Amperes  
20% Duty Cycle  
70  
17  
OUTPUT RANGE  
Maximum-Open Circuit Voltage  
29V  
Welding Current Range  
DC OUTPUT: 35-88 Amps  
No Load 0 - 450 in/min  
(0 - 17.7 mm/min)  
While welding 0-300 in/min.  
(0-11.8 mm/min.)  
RECOMMENDED INPUT CABLE AND FUSE SIZES  
Fuse or  
Output Mode Input Voltage Breaker Size1 Input Amps  
Power Cord  
Extension Cord  
AT  
RATED  
OUTPUT  
120V/60Hz  
20 Amp  
20  
15 Amp, 125V,  
Three Prong Plug  
(NEMA Type 5-15P)  
Three Conductor  
#12 AWG  
(3.3 mm ) or Larger  
2
Up to 50 Ft. (15.2 mm)  
PHYSICAL DIMENSIONS  
Height  
12.8 in  
Width  
8.8 in  
Depth  
18 in  
Weight  
46 Ibs  
325 mm  
224 mm  
457 mm  
20.9 kg  
1If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.  
MIG PAK HD  
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A-2  
A-2  
INSTALLATION  
Read entire installation section before starting  
installation.  
FIGURE A.1  
SAFETY PRECAUTIONS  
1
WARNING  
ELECTRIC SHOCK can kill.  
• Only qualified personnel should perform  
this installation.  
• Only personnel that have read and under-  
stood the Machine Operating Manual  
should install and operate this equipment.  
• Machine must be plugged into a receptacle  
which is grounded per any national, local  
or other applicable electrical codes.  
IM000  
October 1998  
OPERATOR'S MANUAL  
2
For use with machines having Code Numbers: 00000  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However, your  
overall safety can be increased by  
proper installation...and thoughtful  
operation on your part. DO NOT  
INSTALL, OPERATE OR REPAIR  
THIS EQUIPMENT WITHOUT  
READING THIS MANUALAND THE  
3
S
A
F
E
T
T
P
R
E
C
A
U
T
I
O
N
S
CONTAINED THROUGHOUT And,  
.
most importantly, think before you  
act and be careful.  
• The Machine power switch is to be in the  
OFF (“O”) position when installing work  
cable and gun and when connecting power  
cord to input power.  
World's Leader in Welding and Cutting Products  
Premier Manufacturer of Industrial Motors  
Sales and Service through Subsidiaries and Distributors Worldwide  
22801 St. Clair Ave. Cleveland, ohio 44117-1199 U.S.A. el. (216) 481-8100  
T
4
IDENTIFY AND LOCATE  
COMPONENTS  
5
If you have not already done so, unpack the machine  
from its carton and remove all packing material  
around the machine. The following items are shipped  
loose. (see Figure A.1):  
6
1. MIG PAK HD with work clamp, Gun and cable  
assembly attached.  
8
7
2. This operator’s manual  
10  
3. Two contact tips for .035(0.9mm) diameter wire.  
9
4. Three contact tips for .025(0.6mm) diameter wire.  
5. Gas Nozzle.  
6. Chipping hammer and brush.  
7. Starter spool of .035” (0.9mm) NR211-MP flux  
cored wire.  
8. Starter spool of .025” (0.6mm) solid mig wire.  
9. Gas regulator and hose with hose clamps.  
10. Handshield with filter plate and lens.  
For available options and accessories refer to the  
Accessories Section of this manual.  
MIG PAK HD  
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A-3  
A-3  
INSTALLATION  
INPUT CONNECTIONS  
SELECT SUITABLE LOCATION  
(FIGURE A.4)  
Place the machine on a secure, level surface or rec-  
ommended undercarriage. The machine may topple  
over if this procedure is not followed. To minimize over  
heating, locate the welder in a dry location where there  
is free circulation of clean air. Do not place on com-  
bustible surfaces.  
GAS INLET FITTING  
POWER INPUT CABLE  
STACKING  
Machines cannot be stacked.  
CHANGING POLARITY  
Refer to Figure A.4.  
1. For Negative Polarity Welding (DC-): Refer to  
Figure A.2. As delivered, the machine is wired for  
Negative polarity with the gun cable connected to  
the Negative (-) output terminal and the work cable  
to the Positive (+) output terminal. Make sure that  
both thumbscrews are tight. This is the typical con-  
figuration for Flux Cored Welding (FCAW).  
The machine has two input connections, the power  
input cable and the gas inlet fitting. The power input  
cable and gas inlet fitting are located on the rear.  
GAS CONNECTION  
When using the MIG process, a cylinder of shielding  
gas (appropriate for the metal being welded) must be  
obtained.  
WORK CABLE  
FIGURE A.2  
GUN CABLE  
GUN CABLE  
WORK CABLE  
WARNING  
CYLINDER may explode if damaged.  
Keep cylinder upright and chained to  
support.  
• Keep cylinder away from areas where it  
may be damaged.  
• Never lift welder with cylinder attached.  
• Never allow welding electrode to touch cylinder.  
• Keep cylinder away from welding or other live  
electrical circuits.  
2.For Positive Polarity Welding (DC+): Refer to  
Figure A.3. To wire for Positive polarity, connect  
the gun cable to the Positive (+) output terminal and  
the work cable to the Negative (-) terminal. This is  
the typical configuration for the Metal Inert Gas  
(MIG) process. Make sure that both thumbscrews  
are tight.  
BUILDUP OF SHIELDING GAS may harm  
health or kill.  
• Shut off shielding gas supply when not  
in use.  
(FIGURE A.3)  
GUN CABLE  
WORK CABLE  
• SEE AMERICAN NATIONAL STANDARD Z-49.1,  
“SAFETY IN WELDING AND CUTTING” PUB-  
LISHED BY THE AMERICAN WELDING SOCIETY.  
------------------------------------------------------------------------  
GUN CABLE  
WORK CABLE  
MIG PAK HD  
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A-4  
A-4  
INSTALLATION  
SHIELDING GAS CONNECTION  
CODE REQUIREMENTS FOR ELECTRI-  
CAL INPUT CONNECTIONS  
(FIGURE A.5)  
REGULATOR  
CYLINDER VALVE  
WARNING  
This welding machine must be connected to a  
power source in accordance with applicable elec-  
trical codes.  
HOSE  
GAS CYLINDER  
------------------------------------------------------------------------  
The United States National Electrical Code (Article  
630-B, 1990 Edition) provides standards for amperage  
handling capability of supply conductors based on  
duty cycle of the welding source.  
If there is any question about the installation meeting  
applicable electrical code requirements, consult a  
qualified electrician.  
Refer to Figure A.5.  
1. Chain the cylinder to a wall or other stationary sup-  
port to prevent the cylinder from falling over.  
Insulate the cylinder from the work circuit work  
ground.  
2. With the cylinder securely installed, remove the  
cylinder cap. Stand to one side away from the out-  
let and open the cylinder valve very slightly for an  
instant. This blows away any dust or dirt which may  
have accumulated in the valve outlet.  
CAUTION  
Do not connect the machine to an input power  
supply with a rated voltage that is greater than 125  
volts.  
Do not remove the power cord ground prong.  
REQUIREMENTS FOR MAXIMUM OUTPUT  
A line cord with a 15 amp, 125 volt, three-prong plug  
(NEMA Type 5-15P) is factory installed on the  
machine Connect this plug to a mating grounded  
receptacle which is connected to a 20 amp branch cir-  
cuit with a nominal voltage rating of 115 volts to 125  
volts, 60 hertz, AC only. If connected to a circuit pro-  
tected by fuses, use a time delay fuse marked “D”.  
With this installation, the machine can be used at an  
output of 70 amps, 17 volts, 20% duty cycle (2 min-  
utes of every 10 minutes used for welding).  
WARNING  
BE SURE TO KEEP YOUR FACE AWAY FROM  
THE VALVE OUTLET WHEN “CRACKING” THE  
VALVE. Never stand directly in front of or behind  
the flow regulator when opening the cylinder  
valve. Always stand to one side.  
------------------------------------------------------------------------  
3. Attach one end of the inlet gas hose to the outlet fit-  
ting of the gas cylinder secure with hose clamp.  
Connect the other end to the Gas Inlet Fitting on  
the machine and secure with hose clamp. Make  
certain the gas inlet hose is not kinked or twisted.  
EXTENSION CORD USAGE  
If an extension cord is required, use one that is rated  
for the application and is 3 conductor #14 AWG (2.1  
mm2) or larger. The recommended maximum lengths  
are 25 ft (7.5 m) if #14 AWG (2.1 mm2) is used and 50  
ft (15 m) if #12 AWG (3.3 mm2) is used.  
4. The machine is supplied with a regulator suitable  
for a mixed shielding gas CO2 / Argon. For welding  
with 100% CO2 a suitable regulator or adapter must  
be purchased separately from a welding gas suppli-  
er. To prevent leakage, if welding with 100% CO2  
shielding gas the regulator for carbon dioxide must  
have a plastic adapter washer seated in the fitting  
that attaches to the cylinder. This adapter is avail-  
able from your local gas supplier.  
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B-1  
B-1  
OPERATION  
Read entire operation section before  
GENERAL DESCRIPTION  
operating the machine.  
The machine is a semiautomatic constant voltage DC  
arc welder. The machine uses a single phase con-  
stant voltage transformer, solid state rectifier and a  
DC permanent magnet motor for feeding and welding  
solid steel electrode and flux-cored electrode.  
The machine is ideally suited for individuals having  
access to 115 volt AC input power and wanting the  
ease of use, quality and dependability of both metal  
inert gas (MIG) welding and the Innershield electrode  
process (self-shielded flux-cored welding). The  
machine will handle reels of wire up to 2 lbs(1 kg).  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live  
parts or electrode with skin or  
wet clothing. Insulate yourself  
from work and ground.  
• Always wear dry insulating  
gloves.  
RECOMMENDED PROCESSES  
The machine can be used for welding carbon and low-  
alloy steel with CO or argon/CO mixture shielding  
FUMES AND GASES can be  
dangerous.  
2
2
gas. The welder can also be used without gas for the  
self-shielded, Innershield electrode process. The  
machine is configured for the Flux Cored Arc Welding  
process as delivered from the factory.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to  
remove fumes from breathing  
zone.  
OPERATIONAL FEATURES AND CONTROLS  
WELDING SPARKS can  
cause fire or explosion.  
The machine has the following controls as standard:  
• Power ON/OFF Switch  
• Heat Range Switch  
• Keep flammable material away.  
• 1 – 2 Fine Heat Adjustment Switch  
• Wire Speed Control  
• Do not weld on closed contain-  
ers.  
DESIGN FEATURES AND ADVANTAGES  
• Operates on 115 volt input.  
• Solid state output control.  
ARC RAYS can burn eyes  
and skin.  
• Overload protection - incorporates a thermostat to  
protect the welder from overheating caused by mal-  
functions or overly heavy use.  
• Wear eye, ear and body protec-  
• Permanent magnet wire drive motor.  
• Easy-to-set controls for arc voltage and wire speed.  
• Thumbscrew release idle roll pressure arm is easily  
adjusted.  
tion.  
• Reversible, dual groove drive roll will feed .023-  
.035” (0.6- 0.9 mm) diameter wire.  
• Accommodates spools of wire up to 4”(102mm)  
diameter.  
• No external shielding gas is required when used  
with Lincoln Innershield .035” (0.9 mm) NR®-211-  
MP electrode.  
Observe all safety information throughout  
this manual.  
• Easy to change polarity.  
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B-2  
B-2  
OPERATION  
TABLE B.1 – MIG WELDING MATERIAL/GAS COMBINATIONS  
WELDING CAPABILITY  
The machine is rated at 70 amps, 17 volts, at 20%  
duty cycle on a ten minute basis. It is capable of high-  
er output currents at lower duty cycles.  
Material  
Carbon Steel  
Low Alloy Steel  
Gas  
CO2 or Argon/CO2  
CO2 or Argon/CO2  
LIMITATIONS  
FLUX-CORED (INNERSHIELD) WELDING  
The recommended electrode for the flux-cored, self-  
shielded process is 0.035” (0.9 mm) diameter Lincoln  
Innershield NR-211-MP on 1 lbs. (.5 kg) spools.  
The machine is recommended for welding on mild  
steel up to 1/8” thick.  
SEQUENCE OF OPERATIONS  
WIRE LOADING AND THREADING  
CONTROLS AND SETTINGS  
FIGURE B.1  
Refer to Figure B.2.  
4
Turn machine power switch to the OFF (“0”) position  
before working inside the wire feed enclosure.  
Make sure that the wire feed drive roll and the contact  
tip of the gun match the diameter and type of wire  
used.  
1. Push the spool onto the spindle so that the wire  
feeds off the bottom of the spool, toward the drive  
roll.  
3
1
2. Push the spool spacer onto the spindle, against the  
spool.  
3. Slide the spring onto the spool, then press on the  
spool lock, turning it clockwise to lock the spool  
assembly onto the spindle.  
2
Refer to Figure B.1.  
1. Power ON/OFF Switch -When the power is ON  
the welding output and wire feeder are ON (“hot”)  
when the gun trigger is pressed.  
FIGURE B.2  
2. Low / High Heat Range Switch. -A rocker switch  
control that gives low or high coarse range adjust-  
ment of the power source output voltage.  
SPOOL  
SPACER  
3. 1 – 2 Fine Heat Adjustment Switch. -Allows fine  
adjustment of the voltage within the selected Low  
or High output range.  
SPINDLE  
SPOOL  
LOCK  
SPOOL  
4. Wire Speed Control. -Controls the wire feed  
speed. Wire speed is not affected when changes  
are made in the voltage control.  
SPRING  
WELDING OPERATIONS  
PROCESS GUIDELINES  
MIG WELDING  
Table B.1 shows the recommended material/gas  
combinations for MIG welding with solid electrodes.  
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B-3  
B-3  
OPERATION  
FIGURE B.4 – WIRE STICKOUT  
FIGURE B.3 – WIRE THREADING DETAILS  
SPRING LOADED  
THUMSCREW  
IDLER ROLL ARM  
WIRE  
CONTACT  
TIP  
INGOING GUIDE TUBE  
WIRE FEED  
LOWER DRIVE ROLL  
3/8"  
ELECTRICAL  
STICKOUT  
WIRE  
ELECTRODE  
Refer to Figure B.3.  
10. Remove the gas nozzle and contact tip from the  
gun.  
11. Turn the machine ON (“I”).  
12. Straighten the gun cable assembly.  
13.Depress the gun trigger switch and feed welding  
wire through the gun and cable. (Point the gun  
away from yourself and others while feeding wire.)  
Release the gun trigger after wire appears at the  
end of the gun.  
4. Release the spring loaded thumbscrew and rotate  
the idle roll arm away from the wire feed drive roll.  
Ensure that the visible, stenciled size on the drive  
roll side facing you matches the wire size being  
used.  
5. Carefully detach the end of the wire from the spool  
maintain tension on the wire. To prevent the spool  
from unwinding and do not release the wire until  
after step 5.  
14.Turn off the machine.  
6. Cut the bent portion of wire off and straighten the  
first 4” (102 mm).  
15.Replace the contact tip and nozzle. Refer to Figure  
B-4. Cut the wire off so that 3/8”(10mm) protrudes  
from the end of the tip.  
16.Turn on the machine. The machine is now ready to  
weld.  
7. Thread the wire through the incoming guide tube,  
over the drive roll, and into the gun liner.  
8. Close the idle roll arm and turn down the thumb-  
screw until the idle roller presses down firmly on the  
wire. (Now you may release the welding wire).  
Make sure the wire is positioned in the groove of  
the lower drive roll.  
9. The spring loaded thumbscrew on the idle roll arm  
adjusts the pressure on the wire. Adjust pressure  
by turning the thumbscrew to prevent spool over-  
run, but still allow smooth and easy wire feeding.  
Start with the pressure set to an intermediate value.  
Readjust, if necessary. Slightly less pressure may  
be required when using 0.023 - 0.025” (0.6 mm)  
wire. If the drive roll slips while feeding wire, the  
pressure should be increased until the wire feeds  
properly.  
SHIELDING GAS  
When using the MIG process, you will need a cylinder  
of carbon dioxide (CO2) or argon-carbon dioxide  
mixed shielding gas  
The preset regulator supplied with the machine is  
designed for use with argon blend gas. An adapter  
and plastic washer are needed for using 100% CO2  
gas. This adapter is available from your local gas sup-  
plier.  
1. Open the cylinder valve slowly a fraction of a turn.  
When the cylinder pressure gauge pointer stops  
moving, open the valve fully.  
2. Keep the cylinder valve closed, except when weld-  
ing. When finished welding:  
WARNING  
• Close the cylinder valve to stop gas flow.  
• Depress the gun trigger briefly to release the  
pressure in the gas hose.  
• When feeding the welding wire  
through the gun, the drive roll, the  
gun connector block and the gun  
contact tip are always energized rela-  
tive to work and ground.  
• Turn off the machine.  
-----------------------------------------------------------------------  
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B-4  
B-4  
OPERATION  
MAKING A WELD  
4. Check that the polarity is correct for the welding wire  
being used and that the gas supply, if required, is  
turned on.  
FIGURE B.5 – WELDING SETUP  
5. Refer to Figure B.5. Connect the work clamp to the  
metal to be welded. The work clamp must make  
good electrical contact to the work piece. The work  
piece must also be grounded as stated in Arc  
Welding Safety Precautions in the beginning of this  
manual.  
GUN CABLE  
6. Based on the welding process type and material  
thickness of the work piece, use the chart below (or  
on the procedure decal located on the wire drive  
door) to set the correct wire feed speed and heat  
range setting.  
WORKPIECE  
ARC  
WORK CLAMP  
7. Based on the weld joint type and orientation of the  
weld joint, position the gun into the joint at the cor-  
rect angle. Refer to the LEARNING TO WELD sec-  
tion of this manual.  
8. To begin welding, raise your hand shield to protect  
your eyes and pull the trigger.  
9. While welding, travel at a constant speed and main-  
tain an electrode stickout of 3/8". Follow the correct  
direction of travel for the process and joint type and  
orientation as detailed in the LEARNING TO WELD  
section of this manual.  
10. To stop welding, release the gun trigger.  
11. When no more welding is to be done, close the  
valve on the gas cylinder (if used), momentarily  
operate the gun trigger to release gas pressure,  
and turn off the machine.  
READ the LEARNING TO WELD section of this man-  
ual prior to making your first weld. Also, refer to Table  
B.1 and the Procedure Decal located on the inside of  
the wire drive compartment door of your machine for  
process selection, consumables, and quick tips for  
welding.  
1. Select the right welding process based on the type  
and condition of the pieces to be welded; the envi-  
ronment in which welding is to be done; and the  
desired finished appearance of the weld.  
2. Select and install the welding wire to match the  
process. Use Genuine Lincoln Electric Brand wire.  
Wire quality is essential for successful welding.  
3. Install the drive roll, contact tip, and nozzle appro-  
priate for the weld process.  
TABLE B.1  
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B-5  
B-5  
OPERATION  
CLEANING TIP AND GAS NOZZLE  
Keep the contact tip and nozzle clean to avoid arc  
bridging between them. Bridging can result in a short-  
ed nozzle, poor welds and an overheated gun. Hint:  
Anti-stick spray or gel, available from a welding suppli-  
er, may reduce buildup and aid in spatter removal.  
CHANGING MACHINE OVER TO FEED  
OTHER WIRE SIZES  
The machine is shipped from the factory ready to feed  
0.035” (0.9 mm) diameter wire. To operate the  
machine with other sizes of wire, it is necessary to  
change the contact tip and change the drive roll to  
other sizes. Refer to Changing the Contact Tip and  
Changing the Drive Roll in the MAINTENANCE sec-  
tion for specific information on these procedures.  
OVERLOAD PROTECTION  
THERMAL PROTECTION  
The machine has a maximum output duty cycle of  
20%. If the duty cycle is exceeded, a thermal protector  
will shut off the output until the machine cools to a  
normal operating temperature. This is an automatic  
function of the machine and does not require user  
intervention.  
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B-6  
B-6  
OPERATION  
LEARNING TO WELD  
WARNING  
No one can learn to weld simply by reading about  
it. Skill comes only with practice. The following  
pages will help the operator to understand welding  
and develop this skill.  
Fumes and slag generated from  
Innershield type electrodes recom-  
mended for use with this welding  
machine can be toxic.  
• Avoid contact with eyes and skin.  
• Do not take internally.  
THE ARC-WELDING CIRCUIT  
The operator’s knowledge of arc welding must go  
beyond the arc itself. The operator must know how to  
control the arc, and this requires a knowledge of the  
welding circuit and the equipment that provides the  
electric current used in the arc. Figure B.5 illustrates  
the welding circuit for a typical welding machine. The  
circuit begins where the gun cable is attached to the  
welding machine. Current flows through the gun  
cable, gun, and contact tip, to the wire and across the  
arc. On the work side of the arc, current flows through  
the base metal to the work cable and back to the  
welding machine. This circuit must be complete for the  
current to flow.  
• Keep out of reach of children.  
• Follow all safety precautions  
found in this operating manual.  
The gun and cable assembly is held by the operator  
who guides the automatically fed wire along the joint,  
maintaining a contact tip to work distance of about 3/8  
to 1/2 inch (10 – 12 mm) This is called electrical stick-  
out. This electrical stickout (ESO) must be properly  
maintained by the operator. The electric arc is made  
in the gap between the work and the tip end of a small  
diameter wire. When the power source is properly set,  
the arc gap is maintained automatically.  
This machine’s welding circuit has a voltage output of  
29 volts DC maximum. This voltage is quite low and is  
only present when the gun trigger is depressed.  
Arc welding is a manual skill requiring a steady hand,  
good physical condition, and good eyesight. The oper-  
ator controls the welding arc, and, therefore, the quali-  
ty of the weld made.  
To weld, the work clamp must be tightly connected to  
clean base metal. Remove paint, rust, dirt or oil as  
necessary and connect the work clamp as close as  
possible to the area you wish to weld. This helps pre-  
vent current from going through an unwanted path.  
Avoid allowing the welding circuit to pass through  
hinges, bearings, electronic components, or similar  
devices that can be damaged. See Figure B.6. Always  
disconnect electrical devices before welding upon  
them.  
THE SELF-SHIELDED FCAW (FLUX  
CORE) WELDING ARC  
Figure B.7 illustrates the action taking place in the self  
shielded FCAW (Innershield) welding arc. It closely  
resembles what is actually seen while welding.  
FIGURE B.6  
Bearings  
Hinges  
Electrical Components  
Burning of core materials  
inside wire electrode  
results in shield of gas.  
WRONG  
CURRENT  
PATH  
Cored Wire  
Protective Slag  
Arc Stream  
Weld Metal  
CORRECTT CURRENT  
PATH  
*
FIGURE B.7  
* For best results position work clamp approximantely  
12 inches(294mm) from the welded area.  
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B-7  
B-7  
OPERATION  
The “arc stream” is seen in the middle of the picture.  
This is the electric arc created by the electric current  
flowing through the space between the end of the wire  
electrode and the base metal. The temperature of this  
arc is about 6000°F, which is more than enough to  
melt metal. The arc is very bright, as well as hot, and  
cannot be looked at with the naked eye without risking  
painful injury. The very dark lens, specifically  
designed for arc welding must be used with the hand  
or face shield whenever viewing the arc.  
THE GMAW (MIG) WELDING ARC  
Figure B.8 illustrates the GMAW (MIG) welding arc.  
Solid wire does not contain fluxes or ingredients to  
form its own shielding and no slag forms to protect the  
molten weld metal. For this reason, a continuous even  
flow of shielding gas is needed to protect the molten  
weld metal from atmospheric contaminant’s such as  
oxygen and nitrogen. Shielding gas is supplied  
through the gun and cable assembly, through the gas  
nozzle and into the welding zone.  
The arc melts the base metal and actually digs into it  
much as water through a nozzle on a garden hose  
digs into the earth. The molten metal forms a molten  
pool or crater and tends to flow away from the arc. As  
it moves away from the arc, it cools and solidifies.  
Gas nozzle  
The function of the Innershield cored wire electrode is  
much more than simply to carry current to the arc. The  
wire core is composed of fluxes and/or alloying ingre-  
dients around which a steel sheath has been formed.  
It is simply a stick electrode turned inside out in a con-  
tinuous wire form.  
Solid wire  
electrode  
Shielding gas  
Weld metal  
Base metal  
FIGURE B.8  
The cored wire melts in the arc and tiny droplets of  
molten metal shoot across the arc into the molten  
pool. The wire sheath provides additional filler metal  
for the joint to fill the groove or gap between the two  
pieces of base metal.  
When comparing the GMAW and FCAW processes,  
you can see that the principal difference between the  
two lies in the type of shielding used. GMAW uses gas  
for shielding, thus we have Gas Metal Arc Welding.  
FCAW uses the melting or burning of the core ingredi-  
ents for shielding, and is thus termed Self-Shielded  
Flux Cored Arc Welding.  
The core materials also melt or burn in the arc and  
perform several functions. They make the arc stead-  
ier, provide a shield of smoke-like gas around the arc  
to keep oxygen and nitrogen in the air away from the  
molten metal, and provide a flux for the molten pool.  
The flux picks up impurities and forms the protective  
slag on top of the weld during cooling.  
The recommended wire for Gas Metal Arc Welding  
(MIG) is Lincolnweld 0.025” (0.6 mm) L-56 electrode.  
Lincolnweld” L-56 is capable of welding a wide range  
of mild steels in all positions, however, more skill IS  
required for out-of-position welding with the GMAW  
process.  
After running a weld bead, the slag may be removed  
with a chipping hammer and wire brush. This  
improves appearance and allows for inspection of the  
finished weld.  
Since machine size and output characteristics limit the  
size and type of wire electrode which can be used,  
Lincoln 0.035’ (0.9 mm) NR-211-MP Innershield elec-  
trode is recommended for Self-Shielded Flux Cored  
Arc Welding.  
PROCESS SELECTION  
By gaining knowledge of the differences between the  
two processes, you will be able to select the best  
process for the job you have at hand. In selecting a  
process, you should consider:  
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B-8  
B-8  
OPERATION  
JOINT TYPES AND POSITIONS  
For GMAW (MIG) Process  
1. Is most of my welding performed on 16 gauge and  
lighter materials?  
Five types of welding joints are: Butt Joint, Fillet Joint,  
Lap Joint, Edge Joint and Corner Joint. See Figure  
B.9.  
2. Can I afford the extra expense, space, and lack of  
portability required for gas cylinders and gas sup-  
ply?  
Of these, the Butt joint and Fillet joint are the two most  
common welds.  
3. Do I require clean, finished-looking welds?  
If you have answered yes to all the above questions  
GMAW may be the process for you. If you have  
answered no to any of the above questions, then you  
should consider using the FCAW process.  
Butt joint  
Lap joint  
For FCAW (Innershield) Process  
1. Do I want simplicity and portability?  
2. Will welding be performed outdoors or under windy  
conditions?  
Edge joint  
Fillet joint  
Corner joint  
3. Do I require good all position welding capability?  
4. Will most welding be performed on 16 gauge and  
heavier, somewhat rusty or dirty materials?  
FIGURE B.9  
Butt Joint  
5. Weld must be cleaned prior to painting.  
Place two plates side by side, leaving a space approx-  
imately one half the thickness of the metal between  
them in order to get deeper penetration.  
COMMON METALS  
Securely clamp or tack weld the plates at both ends,  
otherwise the heat will cause the plates to move apart.  
See Figure B.10.  
Most metals found around the farm, small shop or  
home are low carbon steel, sometimes referred to as  
mild steel. Typical items made with this type of steel  
include most sheet metal, plate, pipe and rolled  
shapes such as channels and angle irons. This type of  
steel can usually be easily welded without special pre-  
cautions. Some steels, however, contain higher car-  
bon levels or other alloys and are more difficult to  
weld. Basically, if a magnet sticks to the metal and  
you can easily cut the metal with a file, chances are  
good that the metal is mild steel and that you will be  
able to weld the material.  
Now weld the two plates together. Weld from left to  
right (if right handed). Point the wire electrode down in  
the crack between the two plates, keeping the gun  
slightly tilted in the direction of travel. Watch the  
molten metal to be sure it distributes itself evenly on  
both edges and in between the plates. This is referred  
to as the “pull technique”. On thin gauge sheet metal,  
use the “push technique”. See “Welding Techniques  
for GMAW (MIG) Process”.  
Regardless of the type of metal being welded, in order  
to get a quality weld, it is important that the metal is  
free of oil, paint, rust or other contaminant’s.  
FIGURE B.10  
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B-9  
B-9  
OPERATION  
Penetration  
Unless a weld penetrates close to 100% of the metal  
thickness, a butt joint will be weaker than the material  
welded together. In the example shown in Figure  
B.11, the total weld is only half the thickness of the  
material thus the weld is only approximately half as  
strong as the metal.  
45°  
FIGURE B.11  
FIGURE B.13  
Welding In The Vertical Position  
Welding in the vertical position can be done either ver-  
tical-up or vertical-down. Vertical-up is used whenever  
a larger, stronger weld is desired. Vertical-down is  
used primarily on sheet metal  
.
In the example shown in Figure B.12, the joint has  
been welded so that 100% penetration could be  
achieved. The weld, if properly made, is as strong as  
or stronger than the original metal.  
WARNING  
Use of this unit on thicker materials than recom-  
mended may result in welds of poor quality. The  
welds may appear to be fine, but may lack the  
fusion or bonding necessary to give a strong  
weld. This is called "Cold Casting" or "cold lap-  
ping" and is some what similar to a cold solder  
joint. Weld failure may result.  
FIGURE B.12  
------------------------------------------------------------------------  
Fillet Welds  
Vertical-up And Overhead Welding  
When welding fillet welds, it is very important to hold  
the wire electrode at a 45° angle between the two  
sides or the metal will not distribute itself evenly. The  
gun nozzle is generally formed at an angle to facilitate  
this. See Figure B.13.  
The problem, when welding vertical-up, is to put the  
molten metal where it is wanted and make it stay  
there. If too much molten metal is deposited, gravity  
will pull it downwards and make it “drip”. Therefore, a  
certain technique has to be followed.  
When welding out-of-position, run stringer beads.  
Don’t whip, break the arc, move out of the puddle, or  
move too fast in any direction. Use Wire Feed Speed  
(WFS) in the low portion of the range. The general  
technique and proper gun angle is illustrated in Figure  
B.14.  
Generally, keep the electrode nearly perpendicular to  
the joint as illustrated. The maximum angle above per-  
pendicular may be required if porosity becomes a  
problem.  
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B-10  
B-10  
OPERATION  
MACHINE SET UP FOR THE  
SELF-SHIELDED FCAW PROCESS  
1. See the Application Guide on the inside of wire  
feed section door for information on setting the  
controls based on wire type and metal thickness  
being welded..  
2. Set the “Voltage” and “Wire Speed” controls to the  
settings suggested on the Application Guide for the  
welding wire and base metal thickness being used.  
The voltage control is marked “V” and the wire feed  
speed is marked ‘’olo.’’  
PROPER GUN ANGLE  
FOR GMAW PROCESS  
WELDING IN THE VERTICAL UP POSITION  
PROPER GUN ANGLE  
FOR FCAW PROCESS  
WELDING IN THE VERTICAL UP POSITION  
FIGURE B.14  
3. Check that the polarity is correct for the welding  
wire being used. Set the polarity for DC(–) when  
welding with NR-211-MP Innershield electrode.  
See Work Cable Installation in the INSTALLATION  
section for instructions on changing polarity.  
Vertical-down Welding  
Refer to Figure B.15 Vertical-down welds are applied  
at a fast pace. These welds are therefore shallow and  
narrow and, as such, are excellent for sheet metal.  
Suggested settings for welding Vertical-down welds  
are found in table b.1.  
4. When using Innershield electrode, use the gasless  
nozzle instead of a gas nozzle to improve visibility  
of the arc.  
Use stringer beads and tip the gun in the direction of  
travel so the arc force helps hold the molten metal in  
the joint. Move as fast as possible consistent with  
desired bead shape.  
5. Connect work clamp to metal to be welded. Work  
clamp must make good electrical contact to the  
work piece. The work piece must also be grounded  
as stated in the “Arc Welding Safety Precautions”  
at the beginning of this manual.  
The important thing is to continue lowering the entire  
arm as the weld is made so the angle of the gun does  
not change. Move the electrode wire fast enough that  
the slag does not catch up with the arc. Vertical-down  
welding gives thin, shallow welds. It should not be  
used on heavy material where large welds are  
required.  
WELDING TECHNIQUES FOR THE SELF-  
SHIELDED FCAW PROCESS  
Four simple manipulations are of prime importance  
when welding. With complete mastery of the four,  
welding will be easy. They are as follows:  
1. The Correct Welding Position  
Figure B.16 illustrates the correct welding position  
for right handed people. (For left handed people, it  
is the opposite.)  
Hold the gun (of the gun and cable assembly) in  
your right hand and hold the shield with your left  
hand. (Left handers simply do the opposite.)  
When using the FCAW Process, weld from left to  
right (if you are right handed). This enables you to  
clearly see what you are doing. (Left handers do  
the opposite.) Tilt the gun toward the direction of  
travel holding the electrode at an angle as shown  
in Figure B.18.  
FIGURE B.15  
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B-11  
B-11  
OPERATION  
Contact Tip  
Wire Electrode  
FIGURE B.16  
3/8” (10mm)  
Electrical Stickout (ESO)  
WARNING  
FIGURE B.17  
ARC RAYS can burn eyes and skin.  
The easiest way to tell whether the ESO is the cor-  
rect length is by listening to its sound. The correct  
ESO has a distinctive “crackling” sound, very much  
like eggs frying in a pan. A long ESO has a hollow,  
blowing or hissing sound. If the ESO is too short,  
you may stick the contact tip or nozzle to the weld  
puddle and/or fuse the wire to the contact tip.  
When using an open arc process, it  
Is necessary to use correct eye,  
head and body protection.  
Protect yourself and others, read  
“ARC RAYS can burn” at the front  
of this manual.  
4. The Correct Welding Speed  
2. The Correct Way To Strike An Arc  
1. Be sure the work clamp makes good electrical  
contact to the work.  
The important thing to watch while welding is the  
puddle of molten metal right behind the arc. See  
Figure B.18. Do not watch the arc itself. It is the  
appearance of the puddle and the ridge where the  
molten puddle solidifies that indicates correct weld-  
ing speed. The ridge should be approximately 3/8”  
(10 mm) behind the wire electrode.  
2. Position gun over joint. End of wire may be  
lightly touching the work.  
3. Position face shield to protect face and eyes,  
close gun trigger, and begin welding. Hold the  
gun so that the contact tip to work distance is  
about 3/8 to 1/2 inch (10 – 12 mm).  
Most beginners tend to weld too fast, resulting in a  
thin uneven, “wormy” looking bead. They are not  
watching the molten metal.  
4. To stop welding, release the gun trigger and  
the pull the gun away from the work after the  
arc goes out.  
5. A ball may form at the tip end of the wire after  
welding. For easier restrikes (with Innershield  
wire) the ball may be removed by feeding out a  
few inches of wire and simply bending the wire  
back and forth until it breaks off.  
Solidifying ridge  
Molten puddle  
6. When no more welding is to be done, turn off  
the machine.  
3. The Correct Electrical Stickout (ESO)  
The electrical stickout (ESO) is the distance from  
the end of the contact tip to the end of the wire.  
FIGURE B.18  
See Figure B.17  
Once the arc has been established, maintaining  
the correct ESO becomes extremely important.  
The ESO should be approximately 3/8”(10mm)  
long.  
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B-12  
B-12  
OPERATION  
Helpful Hints  
For the MACHINE , use the following:  
Mild Steel  
Electrode  
12 gauge or 1/8 inch  
(3.0 mm)  
1. For general welding, it is not necessary to weave  
the arc, neither forward or backward nor sideways.  
Weld along at a steady pace. You will find it easier.  
0.035" (0.9 mm)  
NR-211-MP  
2. When welding on thin plate, you will find that you  
will have to increase the welding speed, whereas  
when welding on heavy plate, it is necessary to go  
more slowly in order to get good penetration.  
Innershield Wire  
Coarse Voltage Setting  
Fine Voltage Setting  
“Hi”  
“2”  
“4”  
3. When welding sheet metal 16 gauge (1.5 mm) and  
lighter, heat buildup may cause part warpage and  
burn through. One way to eliminate these problems  
is to use the back-stepping method illustrated in  
Figure B.19.  
Wire Speed Feed Setting  
Refer to Figure B.20.  
1. Learn to strike an arc by positioning the gun over  
the joint and touching the wire to the work.  
2. Position face shield to protect face and eyes.  
First weld from A to B; then from C to A; then  
from D to C; then from E to D, and so on.  
3. Depress gun trigger, hold gun so contact tip to  
work distance is about 3/8 to 1/2 inch (10 to 12  
mm) and the gun is at proper angle.  
B
A
C
D
E
4. After you strike the arc, practice the correct electri-  
cal stickout. Learn to distinguish it by its sound.  
Back-Stepping  
FIGURE B.19  
5. When you are sure that you can hold the correct  
electrical stickout, with a smooth “crackling” arc  
start moving. Look at the molten puddle constantly,  
and look at the “ridge” where the metal solidifies.  
Practice  
The best way of getting practice in the four skills that  
enable you to maintain:  
6. Run beads on a flat plate. Run them parallel to the  
top edge (the edge farthest away from you). This  
gives you practice in running straight welds, and  
also gives you an easy way to check your  
progress. The 10th weld will look considerably bet-  
ter than the first weld. By constantly checking on  
your mistakes and your progress, welding will soon  
be a matter of routine.  
1. Correct welding position  
2. Correct way to strike an arc  
3. Correct electrical stickout  
4. Correct welding speed  
is to perform the following exercise.  
Contact  
Tip  
ESO  
Gun Angle  
FIGURE B.20  
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B-13  
B-13  
OPERATION  
MACHINE SET UP FOR THE GMAW (MIG)  
PROCESS  
1. See PROCESS GUIDELINES in the OPERATION  
section for selection of welding wire and shielding  
gas, and for range of metal thicknesses that can be  
welded.  
2. See the Application Guide on the inside of wire  
feed section door for information on setting the  
controls.  
FIGURE B.21  
When using the GMAW process on light gauge mater-  
ial, weld from right to left (if you are right handed).  
This results in a colder weld and has less tendency for  
burn through.  
3. Set the “Voltage” and “Wire Speed” controls to the  
settings suggested on the Application Guide for the  
welding wire and base metal thickness being used.  
The voltage control is marked “V” and the wire feed  
speed is marked ‘’olo.’’  
2. The Correct Way To Strike An Arc  
WARNING  
4. Check that the polarity is correct for the welding  
wire being used. Set the polarity for DC(+) when  
welding with the GMAW (MIG) process. See Work  
Cable Installation in the INSTALLATION section for  
instructions for changing polarity.  
ARC RAYS can burn eyes and skin.  
When using an open arc process, it  
Is necessary to use correct eye,  
head and body protection.  
5. Check that the gas nozzle and proper size liner  
and contact tip are being used and that the gas  
supply is turned on. If adjustable, set for 15 to 20  
cubic feet per hour (7 to 10 l/min.) under normal  
conditions, increase to as high as 35 CFH (17  
I/min.) under drafty (slightly windy) conditions.  
Protect yourself and others, read  
“ARC RAYS can burn” at the front  
of this manual.  
1. Be sure the work clamp makes good electrical con-  
tact to the work.  
6. Connect work clamp to metal to be welded. Work  
clamp must make good electrical contact to the  
work piece. The work piece must also be grounded  
as stated in the “Arc Welding Safety Precautions”  
at the beginning of this manual.  
2. Position gun over joint. End of wire may be lightly  
touching the work.  
3. Position face shield to protect face and eyes, close  
gun trigger, and begin welding. Hold the gun so  
that the contact tip to work distance is about 3/8 to  
1/2 inch (10 – 12 mm).  
WELDING TECHNIQUES FOR THE GMAW  
(MIG) PROCESS  
Four simple manipulations are of prime importance  
when welding. With complete mastery of the four,  
welding will be easy. They are as follows:  
4. To stop welding, release the gun trigger and pull  
the gun away from the work after the arc goes out.  
5. A ball may form at the tip end of the wire after  
welding. For easier restrikes, the ball may be  
removed by feeding out a few inches of wire and  
cutting off the end of the wire with wire cutters.  
1. The Correct Welding Position  
Figure B.21 illustrates the correct welding position  
for right handed people. (For left handed people, it  
is the opposite.)  
6. When no more welding is to be done, close the  
valve on the gas cylinder, momentarily operate the  
gun trigger to release gas pressure, then turn off  
the machine.  
When GMAW (MIG) welding on sheet metal, it is  
important to use the “forehand” push technique.  
Hold the gun (of the gun and cable assembly) in  
your right hand and hold the shield with your left  
hand. (Left handers simply do the opposite.)  
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B-14  
B-14  
OPERATION  
Helpful Hints  
1. For general welding, it is not necessary to weave  
the arc, neither forward or backward nor sideways.  
Weld along at a steady pace. You will find it easier.  
Contact Tip  
2. When welding on thin plate, you will find that you  
will have to increase the welding speed, whereas  
when welding on heavy plate, it is necessary to go  
more slowly in order to get good penetration.  
Wire Electrode  
ESO  
3. When welding sheet metal 16 gauge (1.5 mm) and  
lighter, heat buildup may cause part warpage and  
burn through. One way to eliminate these problems  
is to use the back-stepping method illustrated in  
Figure B.21.  
FIGURE B.22  
3. The Correct Electrical Stickout (ESO)  
The electrical stickout (ESO) is the distance from  
the end of the contact tip to the end of the wire.  
See Figure B.22.  
Practice  
Once the arc has been established, maintaining  
the correct ESO becomes extremely important.  
The ESO should be approximately 3/8 to 1/2 inch  
(10 to 12 mm) long.  
The best way of getting practice in the four skills that  
enable you to maintain:  
1. Correct welding position  
The easiest way to tell whether the ESO is the cor-  
rect length is by listening to its sound. The correct  
ESO has a distinctive “crackling” sound, very much  
like eggs frying in a pan. A long ESO has a hollow,  
blowing or hissing sound. If the ESO is too short,  
you may stick the contact tip or nozzle to the weld  
puddle and/or fuse the wire to the contact tip.  
2. Correct way to strike an arc  
3. Correct electrical stickout  
4. Correct welding speed  
is to perform the following exercise.  
For the MACHINE , use the following:  
4. The Correct Welding Speed  
The important thing to watch while welding is the  
puddle of molten metal right behind the arc. See  
Figure B.23. Do not watch the arc itself. It is the  
appearance of the puddle and the ridge where the  
molten Puddle solidifies that indicates correct weld-  
ing speed. The ridge should be approximately 3/8”  
(10 mm) behind the wire electrode.  
Mild Steel  
16 gauge or 1/16 inch  
(1.6 mm)  
Electrode  
Lincolnweld 0.025 L-56  
electrode  
GAS TYPE  
75Ar / 25 CO  
100% CO  
2
2
Most beginners tend to weld too fast, resulting in a  
thin, uneven, “wormy” looking bead. They are not  
watching the molten metal.  
Coarse Voltage Setting  
“Hi”  
“Hi”  
Fine Voltage Setting  
“2”  
“1”  
Wire Speed Feed Setting  
“7”  
“5”  
Refer to Figure B.20.  
Molten puddle  
Weld metal ridge  
1. Learn to strike an arc by positioning the gun over  
the joint and touching the wire to the work.  
Base metal  
2. Position face shield to protect face and eyes.  
FIGURE B.23  
3. Depress gun trigger, hold gun so contact tip to  
work distance Is about 3/8 to 1/2 inch (10 to 12  
mm) and the gun is at proper angle.  
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B-15  
B-15  
OPERATION  
To Reduce Spatter:  
TROUBLESHOOTING WELDS  
Good welds have excellent appearance.  
(In order of priority):  
1. Check or reset WFS & Volts on chart inside door.  
2. Increase drag angle.  
3. Decrease stickout.  
4. Decrease travel speed.  
To Eliminate Porosity  
To Correct Poor Penetration (In order of priority):  
1. Check or reset WFS & Volts on chart inside door.  
2. Decrease stickout.  
3. Decrease speed.  
4. Decrease drag angle.  
If Arc Blow Occurs* (In order of priority):  
NOTE: Try different work connection locations before  
adjusting procedures.  
(In order of priority):  
1. Check or reset WFS & Volts on chart inside door.  
1. Check or reset WFS & Volts on chart inside door.  
2. Decrease drag angle.  
3. Increase stickout.  
2. Clean joints from moisture, paint, rust etc.  
3. Increase stickout.  
4. Decrease travel speed.  
4. Decrease drag angle.  
*Arc blow is the effect of a magnetic field which forces  
the arc from its normal path visual results are concave  
face uneven leg lengths heavy spatter and porosity.  
5. Decrease travel speed.  
NOTE: Always be sure the joint is free from moisture,  
oil, rust, paint or other contaminant’s.  
To Eliminate Stubbing** (In order of priority):  
1. Check or reset WFS & Volts on chart inside door.  
2. Decrease stickout  
To Eliminate a Ropy Convex Bead  
3. Increase drag angle  
** Stubbing occurs when the electrode drives through  
the molten puddle and hits the bottom plate tending  
to push the gun up.  
Proper Gun Handling  
Most feeding problems are caused by improper han-  
dling of the gun cable or electrodes.  
1. Do not kink or pull the gun around sharp corners  
2. Keep the gun cable as straight as practical when  
welding.  
(In order of priority):  
1. Check or reset WFS & Volts on chart inside door.  
2. Decrease stickout.  
3. Do not allow dolly wheels or trucks to run over the  
cables.  
4. Keep the cable clean.  
3. Decrease travel speed.  
4. Decrease drag angle.  
5. Innershield electrode has proper surface lubrica-  
tion. Use only clean, rust-free electrode.  
6. Replace contact tip when it becomes worn or the  
end is fused or deformed.  
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B-16  
B-16  
OPERATION  
Proper Gun Handling  
Most feeding problems are caused by improper han-  
dling of the gun cable or electrodes.  
1. Do not kink or pull the gun around sharp corners  
2. Keep the gun cable as straight as practical when  
welding.  
3. Do not allow dolly wheels or trucks to run over the  
cables.  
4. Keep the cable clean.  
5. Innershield electrode has proper surface lubrica-  
tion. Use only clean, rust-free electrode.  
6. Replace contact tip when it becomes worn or the  
end is fused or deformed.  
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C-1  
C-1  
ACCESSORIES  
ACCESSORIES  
INNERSHIELD WELDING WIRE  
NR-211-MP Innershield welding wire - .035” (0.9 mm)  
diameter flux-cored electrode.  
MIG WELDING WIRE  
Lincoln L56- .025” (0.6mm) diameter solid steel elec-  
trode)  
CONSUMABLE PARTS  
The following items are commonly consumed over the  
life of the welder and may need to be ordered. See  
the complete parts list at the end of this manual for  
machine replacement parts.  
ITEM DESCRIPTION  
PART NO.  
S24355-12  
G3364  
1
2
3
4
Chipping Hammer/Brush  
Face Shield  
Filter Lens/Clear Cover Lens G3364-C & -D  
Drive Roll - “.023-.035”  
(0.6-0.9 mm)  
Contact Tip “.023-.025”  
(0.6 mm)  
KP2315-1  
KH710  
5
6
7
8
Contact Tip “.035”(0.9 mm) KH712  
Flux Nozzle (Gasless)  
Gas Nozzle  
KH726  
KH725  
9
10  
Gas Hose  
Gas Diffuser  
T10642-120  
S25351-1  
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D-1  
D-1  
MAINTENANCE  
MAINTENANCE  
SAFETY PRECAUTIONS  
WARNING  
ELECTRIC SHOCK can kill.  
• Disconnect input power by removing  
plug from receptacle before working  
inside machine. Use only grounded  
receptacle. Do not touch electrically  
“hot” parts inside machine  
• Have qualified personnel do the mainte-  
nance and trouble shooting work.  
ITEMS REQUIRING  
NO MAINTENANCE  
• Drive Motor and Gearbox – Lifetime lubrication  
• Wire Reel Spindle – Do NOT lubricate shaft  
ROUTINE AND PERIODIC  
MAINTENANCE  
BEFORE EACH USE  
• Check over machine and accessories for any obvious condi-  
tion that may prevent safe performance or operation. Repair  
or replace items as necessary to correct any abnormal con-  
dition.  
AFTER 5 MINUTES OF WELDING  
or when spatter accumulates in the gas nozzle:  
• Clean the contact tip and gas nozzle to avoid bridging  
between the nozzle and contact tip. Bridging results in a  
shorted nozzle, poor welds and overheated gun. Hint: Anti-  
stick spray or gel available from a welding supplier may  
reduce buildup and aid in spatter removal.  
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D-2  
D-2  
MAINTENANCE  
CLEANING THE GUN LINER  
COMPONENT REPLACEMENT  
PROCEDURES  
• Unplug the machine or turn the power switch to the  
OFF - “0” position.  
FIGURE D.1 – CONTACT TIP REPLACEMENT  
• Remove the gas nozzle and contact tip from the  
gun.  
CONTACT  
TIP  
• Clean the inside diameter with a short piece of wire.  
0
4
0
L
.
-
A
0
. 1  
• Clean the cable liner when rough and erratic wire  
feeding occur:  
NOZZLE  
Lay the cable out straight. Blow out gently with dry  
compressed air through the wire guide tube and check  
the condition of the tube. Bend the cable back and  
forth, then blow the tube out again. Repeat until  
clean.  
CHANGING THE CONTACT TIP  
CAUTION  
1. Refer to Figure D.1. Remove the gas nozzle from  
the gun by unscrewing it counter-clockwise.  
Excessive pressure at start may cause the dirt to  
form a plug.  
------------------------------------------------------------------------  
2. Remove the existing contact tip from the gun by  
unscrewing it counter-clockwise.  
CLEANING COMPONENTS AS REQUIRED  
3. Insert and tighten the desired contact tip. Do not  
overtighten.  
• Unplug the machine or turn the power switch to the  
OFF - “0” position.  
4. Replace the gas nozzle.  
• Blow dirt out of the welder with low pressure air to  
eliminate excessive dirt and dust buildup that could  
cause the welder to run hot.  
CHANGING THE DRIVE ROLL  
FIGURE D.2 – DRIVE ROLL REPLACEMENT  
• Vacuum accumulated dirt from the gear-box and  
wire feed section.  
SPRING LOADED  
HANDLE SCREW  
• Inspect the incoming guide tube and clean the  
inside diameter if necessary. Replace when exces-  
sively worn.  
WIRE  
UPPER  
IDLER ROLL ARM  
INGOING GUIDE TUBE  
WIRE FEED  
LOWER DRIVE ROLL  
• Replace Contact Tip - when the hole is enlarged or  
elongated. (Refer to Changing The Contact Tip, in  
this section.)  
• Check the condition of the wire feed rollers.  
Remove any metallic dust deposited in the feed  
area (rollers and entrance and outlet wire guide).  
The machine Wire Feed Drive Roll has two grooves;  
one for 0.023” - 0.025” (0.6 mm) solid steel electrode  
and the other for 0.030” (0.8 mm) solid and 0.035”  
(0.9 mm) flux-cored steel electrode. See Figure D.2.  
Use the appropriate sized groove for the wire used (as  
indicated by the stenciling on the side of the drive roll).  
Reverse the drive roll as follows.  
• Check the gas hose and fittings for tightness.  
Refer to Figure D.2.  
1. Make certain the machine power switch is OFF -  
“0”.  
2. Open the spring loaded pressure arm. Lift up the  
idle roll arm.  
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D-3  
D-3  
MAINTENANCE  
3. Remove the Thumbscrew holding the drive roll.  
4. Replace the drive roll so that the desired size, sten-  
ciled on the side of the drive roll, is toward the  
inside and visible.  
5. Replace the Thumbscrew and tighten.  
GUN ASSEMBLY REMOVAL  
1. Unplug machine.  
2. Remove wire drive door and right case side.  
3. Remove gas line connections.  
4. Remove gun connections from output studs.  
5. Remove trigger leads. The trigger leads are routed  
through the center panel and connected to the P.C.  
board (X8, X9). Use care in removal as not to  
damage the P.C. board or adjoining connections.  
6. Unfasten the 2 retaining bolts and 1 screw securing  
the gun strain relief. (note the alignment of the gun  
in the wire drive.)  
7. Installation is the reverse of removal. (7 thru 1)  
WORK CABLE INSTALLATION  
The work cable and clamp comes already installed. If  
you should ever need to replace or reinstall the cable,  
do the following. Refer to Figure D.3.  
FIGURE D.3  
WORK CABLE AND GROMMET  
1. Remove the case sides.  
2. Pass the end of the work cable with the terminal lug  
through the Work Cable Access Hole in the case  
front.  
3. Route the cable through the rubber grommet in the  
metal divider under and around the back of the  
Wire Feed Gearbox.  
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E-1  
E-1  
TROUBLESHOOTING  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and  
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical  
Shock, please observe all safety notes and precautions detailed throughout this manual.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
Step 3. RECOMMENDED COURSE OF ACTION  
This column provides a course of action for the  
Possible Cause, generally it states to contact your  
local Lincoln Authorized Field Service Facility.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that  
best describes the symptom that the machine is  
exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled “POSSIBLE CAUSE” lists  
the obvious external possibilities that may contribute  
to the machine symptom.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
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E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major physical or electrical damage None  
is evident.  
Contact your local Authorized Field  
Service Facility.  
No wire feed, weld output or gas  
flow when gun trigger is pulled.  
1. Make sure correct voltage is  
applied to the machine (115vac).  
2. Make certain that power switch  
is in the ON position.  
3. The thermostat may be tripped  
due to overheating. Let machine  
cool. Weld within the duty cycle  
or remove any air obstruction to  
the machine.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service  
Facility.  
No weld output when gun trigger is 1. Gun tip may be worn. Replace.  
pulled.  
2. Gun trigger may be faulty.  
3. The gun or work cable may be  
faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FEEDING PROBLEMS  
No wire feed when gun trigger is  
pulled.  
1. The thermostat may be tripped  
due to overheating. Let machine  
cool. Weld within the duty cycle  
or remove any air obstruction to  
the machine.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service  
2. Gun trigger may be faulty.  
3. Drive Roll tension is set too high. Facility.  
4. Wire may be kinked or jammed.  
Inspect Drive Roll and Guide  
Tubes.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
MIG PAK HD  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
WELDING PROBLEMS  
Bead is too thin (intermittently).  
1. Travel speed is inconsistent.  
Decrease and maintain a con-  
stant travel speed.  
2. Output heat range is too low.  
Set the Low – High Heat Range  
switch to High or the Fine Heat  
Adjustment to MAX.  
If all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service  
Facility.  
Bead is too thick (intermittently).  
1. Travel speed is slow and/or  
inconsistent. Increase and main-  
tain a constant travel speed.  
2. Output heat range is too high.  
Set the Low – High Heat Range  
switch to Low or the Fine Heat  
Adjustment to MIN.  
Bead does not penetrate base 1. Travel speed is inconsistent.  
metal.  
Decrease and maintain a con-  
stant travel speed.  
2. Output heat range is too low.  
Set the Low – High Heat Range  
switch to High or the Fine Heat  
Adjustment to MAX.  
Wire sputters and sticks to work- 1. The wire is damp. Change to dry  
piece.  
wire. Be sure wire is stored in a  
dry location.  
2. Wire feed speed (WFS) is too  
fast. Reduce WFS.  
Edge of weld has ragged depres- 1. Travel speed is too fast. Reduce  
sions.  
travel speed.  
2. WFS is too fast. Reduce WFS.  
3. Output heat range is too high.  
Set the Low – High Heat Range  
switch to Low or the Fine Heat  
Adjustment to MIN  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
MIG PAK HD  
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F-1  
F-1  
DIAGRAMS  
1
0
X 1  
X 1  
X 9  
X 8  
X 7  
X 6  
X 5  
X 4  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The  
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.  
MIG PAK HD  
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● Do not touch electrically live parts or  
electrode with skin or wet clothing.  
● Insulate yourself from work and  
ground.  
● Keep flammable materials away.  
● Wear eye, ear and body protection.  
WARNING  
Spanish  
● No toque las partes o los electrodos ● Mantenga el material combustible  
● Protéjase los ojos, los oídos y el  
cuerpo.  
bajo carga con la piel o ropa moja-  
da.  
● Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
AVISO DE  
PRECAUCION  
French  
● Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
● Gardez à l’écart de tout matériel  
inflammable.  
● Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
● Isolez-vous du travail et de la terre.  
German  
● Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
● Isolieren Sie sich von den  
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
● Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
● Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE  
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS  
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A  
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-  
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
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● Keep your head out of fumes.  
● Use ventilation or exhaust to  
remove fumes from breathing zone.  
● Turn power off before servicing.  
● Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
● Los humos fuera de la zona de res-  
piración.  
● Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
● Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
● No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
● Débranchez le courant avant  
l’entretien.  
● N’opérez pas avec les panneaux  
ouverts ou avec les dispositifs de  
protection enlevés.  
● Gardez la tête à l’écart des fumées.  
● Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ATTENTION  
German  
● Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
● Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
● Vermeiden Sie das Einatmen von  
Schweibrauch!  
● Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
● Não opere com as tampas removidas.  
● Desligue a corrente antes de fazer  
serviço.  
● Mantenha-se afastado das partes  
moventes.  
● Não opere com os paineis abertos  
ou guardas removidas.  
● Mantenha seu rosto da fumaça.  
● Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
● Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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