Lincoln Electric MIG-PAK 10 manual

M M I I G G - - P P A A K K 1 1 0 0 IM551-C May , 2002 22801 St. Clair Ave. Cleveland, Ohio 441 17-1 199 U.S.A. T el. 216.481.8100 WEB SITE: www .lincolnelectric.com Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by proper installation ... an[...]

2 ARC WELDING CAN BE HAZARDOUS. PROTECT YOUR- SELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEA TH. KEEP CHILDREN A W A Y . P ACEMAKER WEAR- ERS SHOULD CONSUL T WITH THEIR DOCTOR BEFORE OPERA TING. Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safe[...]

3 ELECTRIC AND MAGNETIC FIELDS may be dangerous 3.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and weldingmachines 3.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before[...]

4 SAFETY SEGURIDAD SÉCURITÉ WELDING SP ARKS can cause fire or explosion. 4.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent 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 weldin[...]

5 ELECTRIC SHOCK can kill. 5.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 cloth- ing. Wear dry , hole-free gloves to insulate hands. 5.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large [...]

6 FUMES AND GASES can be dangerous. 6.a.Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventila- tion and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with elec- trodes which require special ventilation[...]

CYLINDER may explode if damaged. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operat- ing 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 posi[...]

8 Read the entire manual before installing and operating the MIG-P AK ELECTRIC SHOCK can kill. • Only qualified personnel should installation or operate this equipment. • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes. • The MIG-P AK power switch is to be in the OFF (?[...]

9 TECHNICAL SPECIFICA TIONS ESPECIFICACIONES TÉCNICAS Fuse Size Input Amps Power Cord 20 Amp 20 15 Amp, 125V Three Prong Plug (NEMA T ype 5-15P) 15 Amp 12 15 Amp, 125V Three Prong Plug (NEMA T ype 5-15P) Extension Cord Up to 25 Ft. (7.6 mm): Three Conductor #14 AWG (2.1 mm 2 ) or Larger Up to 50 Ft. (15.2 mm): Three Conductor #12 AWG (3.3 mm 2 ) o[...]

10 IDENTIFY AND LOCA TE COMPONENTS If you have not already done so, unpack the MIG-P AK from its carton and remove all packing material around the MIG- P AK. Remove the following loose items from the carton): INST ALLA TION IDENTIFIQUE Y LOCALICE LOS COMPONENTES Si aún no lo ha hecho, desempaque la MIG-P AK y retire todo el material de empaque. Sa[...]

INST ALLA TION INST ALACIÓN INST ALLA TION SELECT SUIT ABLE LOCA TION Locate the welder in a dry location wherethere is free circu- lation of clean air into the louvers in the back and out the front of the unit. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block[...]

12 INST ALLA TION INST ALACIÓN INST ALLA TION WORK CLAMP INST ALLA TION Attach the work clamp per the following: 1. Unplug the machine or turn the power switch to the OFF position. 2. Insert the work cable terminal lug with the larger hole through the strain relief hole in the work clamp as shown in Figure 2. 3. Fasten securely with the bolt and n[...]

13 FIGURE 3 GUN INST ALLA TION As shipped from the factory , the MIG P AK 10 is ready to feed .023" – .025" (0.6 mm) solid wire. If .030" (0.8 mm) solid wire is to be used, change the contact tip to the appropriate size. Connecting Gun Cable to the MIG P AK 1. Refer to Figure 1 Unplug the machine or turn power switch to the OFF “[...]

14 4. Conecte las terminales del cable de control del gatillo de la antorcha a los dos conectores aislados de 6.4 mm (1/4 ” ), que se localizan arriba de la etiqueta “ Gun T rigger Connection ” (Conexi ó n del Gatillo de la Antorcha) en la secci ó n de alimentaci ó n de alambre (4). Cualquier cable puede ir en cualquier conector . Acomode [...]

15 BUILDUP OF SHIELDING GAS may harm health or kill. • Shut off shielding gas supply when not in use. • SEE AMERICAN NA TIONAL ST ANDARD Z- 49.1, “SAFETY IN WELDING AND CUT- TING” PUBLISHED BY THE AMERICAN WELDING SOCIETY . ------------------------------------------------------------------------------- 1. Chain the cylinder to a wall or oth[...]

16 INST ALLA TION CONNEXIONS D'ALIMENT A TION D'ENTRÉE V oir la figure 5. La MIG P AK est munie d'un c â ble d'alimentation qui se trouve à l'arri è re de la machine. EXIGENCES DU CODE RELA TIVES AUX CONNEX- IONS D'ENTRÉ •Cette machine de soudage doit être connectée à une source d'al- imentation conform?[...]

17 Lea todo el manual antes de instalar u operar la MIG P AK 10. PRECAUCIONES DE SEGURIDAD LA DESCARGA ELÉCTRICA puede causar la muerte • No toque las partes eléctricas activas ni el electrodo con ropa mojada o húmeda. Aíslese del trabajo y tierra. • Siempre utilice guantes aislantes secos. LOS HUMOS Y LOS GASES pueden ser peligrosos. • M[...]

18 The MIG P AK 10 is ideally suited for individuals having access to 1 15 volt AC input power , and wanting the ease of use, quality and dependability of both gas metal arc welding or GMA W (also known as MIG welding) and the Innershield electrode process (self shielded flux cored or FCA W). The MIG P AK 10 is a rugged and reliable machine that ha[...]

19 WELDING CAP ABILITY The MIG P AK 10 is rated at 88 amps, 18 volts, at 20% duty cycle on a ten minute basis. CSA rated output at 62 amps at 20 volts at 20% duty cycle. It is capable of higher output cur- rents at lower duty cycles. LIMIT A TIONS Arc Gouging cannot be performed with the MIG P AK 10. The MIG P AK 10 is not recommended for pipe thaw[...]

20 OPERA TION OPERACIÓN FONCTIONNEMENT FIGURE 6b FIGURE 6a[...]

21 WELDING SEQUENCE OF OPERA TION WIRE LOADING Refer to Figures 7 and 8. The machine power switch should be turned to the OFF ( “ O ” ) position before working inside the wire feed enclosure. The welder is shipped from the factory ready to feed 8" (200 mm) diameter spools with 2.2" (56 mm) maximum width. These spools fit on a 2" [...]

22 FRICTION BRAKE ADJUSTMENT With wire spool installed on the spindle shaft and the wing nut loose, turn the spool by hand while slowly tightening the wing nut until a light drag is felt. T ighten the wing nut an additional 1/4 turn. Note: When properly adjusted, the brake should provide only enough drag to prevent overrun of the spool and excess s[...]

23 5. Close the idle roll arm (2) and latch the spring loaded pres- sure arm (1) in place. Rotate the spool counterclockwise if required in order to take up extra slack in the wire. 6. The idle roll pressure adjustment wing nut is factory set to approximately five full turns from where the wing nut first engages the threads of the pressure arm (1).[...]

24 7. Remove gas nozzle and contact tip from end of gun. 8. T urn the MIG-P AK ON ( “ I ” ). 9. Straighten the gun cable assembly . 10. Depress the gun trigger switch and feed welding wire through the gun and cable. (Point gun away from your- self and others while feeding wire.) Release gun trigger after wire appears at end of gun. Note: If the[...]

25 MAKING A WELD 1. See "Process Guidelines" in this section for selection of welding wire and shielding gas and for range of metal thicknesses that can be welded.. 2. See Aplication chart on the inside of the wire feed com- partment door for information on setting the MIG P AK 10 controls. Refer to T able B.1 for aluminium and stainless [...]

26 7. Position gun over joint. End of wire may be lightly touch- ing the work. 8. Lower welding helmet, close gun trigger , and begin welding. Hold the gun so the contact tip to work distance is about 3/8 inch (10 mm). 9. T o stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out. 10. When no more weld[...]

27 T ABLE 1 CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES The MIG P AK 10 is shipped from the factory ready to feed 0.023 ” -.025" (0.6 mm) diameter wire. T o operate the MIG P AK 10 with other sizes of wire, it is necessary to change the contact tip and change the drive roll over to other sizes. Refer to Changing the Contact T ip and Chang[...]

28 WELDING WITH FCA W (Innershield) When using the FCA W process, the correct drive roll and electrode polarity must be used. See Work Cable Installation in INST ALLA TION section for changing the polarity . Innershield welding kit K549-1 (for .035" / 0.9mm) is also available. OVERLOAD PROTECTION Output Overload The MIG P AK 10 is equipped wit[...]

29 LEARNING T O WELD No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced operator to understand welding and develop this skill. For more detailed information, order a copy of “ New Lessons in Arc Welding ” listed at the end of this manual. THE ARC-WELDING CIRCUIT T[...]

30 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 . • Keep out of reach of children. • Follow all safety precautions found in this operating manual. -----------------------------------------------------------[...]

31 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 lo[...]

32 When comparing the GMA W and FCAW processes, you can see that the principal difference between the two lies in the type of shielding used. GMA W uses gas for shielding, thus we have Gas Metal Arc Welding. FCA W uses the melting or burning of the core ingredients for shielding, and is thus termed Self-Shielded Flux Cored Arc Welding. The recommen[...]

33 For FCA W (Innershield) Process 1. Do I want simplicity and portability? 2. Will welding be performed outdoors or under windy con- ditions? 3. Do I require good all position welding capability? 4. Will most welding be performed on 16 gauge and heav- ier , somewhat rusty or dirty materials? 5. Weld must be cleaned prior to painting. COMMON MET AL[...]

34 Butt Welds Place two plates side by side, leaving a space approximate- ly one half the thickness of the metal between them in order to get deeper penetration. Securely clamp or tack weld the plates at both ends, other- wise the heat will cause the plates to move apart. See Figure 17. Now weld the two plates together . Weld from left to right (if[...]

35 Fillet Welds 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 20. FIGURE 20 Welding In The V ertical Position Welding in the vertical position can be done [...]

36 FIGURE 21 V ertical-down Welding Refer to Figure 22 V ertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow and, as such, are excellent for sheet metal. V ertical-down welds may be applied to 5/32 ” (3.9 mm) and lighter material. Use stringer beads and tip the gun in the direction of travel so the arc forc[...]

37 WELDING TECHNIQUES FOR THE SELF-SHIELDED FCA W 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 23 illustrates the correct welding position for right handed people. (For left handed people, it is the oppo-[...]

38 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 24.) Once the arc has been established, maintaining the cor- rect ESO becomes extremely important. The ESO should be approximately 3/8 to 1/2 inch (10 to 12 mm) long. FIGURE 24 The easiest way[...]

39 Helpful Hints 1. For general welding, it is not necessary to weave the arc. Weld along at a steady pace. Y ou will find it easier . 2. When welding on thin plate, you will find that you will have to increase the welding speed, whereas when weld- ing on heavy plate, it is necessary to go more slowly in order to get good penetration. 3. When weldi[...]

40 4. After you strike the arc, practice the correct electrical stickout. Learn to distinguish it by its sound. 5. When you are sure that you can hold the correct electri- cal stickout, with a smooth “ crackling ” arc start moving. Look at the molten puddle constantly , and look at the “ ridge ” where the metal solidifies. 6. Run beads on a[...]

When using the GMA W process on light gauge material, weld from right to left (if you are right handed). This results in a colder weld and has less tendency for burn through. 2. The Correct Way T o Strike An Arc 1. Be sure the work clamp makes good electrical con- tact to the work. 2. Position gun over joint. End of wire may be lightly touching the[...]

42 4. The Correct Welding Speed The important thing to watch while welding is the puddle of molten metal right behind the arc. See Figure 30. Do not watch the arc itself. It is the appearance of the pud- dle and the ridge where the molten Puddle solidifies that indicates correct welding speed. The ridge should be approximately 3/8 ” (10 mm) behin[...]

43 Practice The best way of getting practice is to perform the following exercise. Refer to Figure 27. 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. 3. Depress gun trigger, hold gun so contact tip to work dis- tance Is about 3/8 to 1/2 inch (10 to[...]

44 TROUBLESHOOTING WELDS Good welds have excellent appearance. T o Eliminate Porosity (in order of importance): 1. Turn on gas supply , if used 2. Decrease voltage. 3. Increase stickout. 4. Increase WFS (wire feed speed). 5. Decrease drag angle. 6. Decrease travel speed. NOTE: Always be sure the joint is free from moisture, oil, rust, paint or othe[...]

45 T o Reduce Spatter (in order of importance): 1. Increase voltage. 2. Increase drag angle. 3. Decrease stickout. 4. Increase WFS (wire feed speed). 5. Decrease travel speed. 6. Check for correct gas, if used. T o Correct Poor Penetration (in order of importance): 1. Decrease stickout. 2. Increase WFS (wire feed speed). 3. Increase voltage. 4. Dec[...]

46 OPTIONAL ACCESSORIES 1. K549-1 .035" (0.9 mm) Innershield ® Welding Kit — Includes a contact tip, a gasless nozzle and a .035/.045" (.9/1.2 mm) cable liner . The fitting on the end of the liner is stenciled with the maximum rated wire size (.045"/1.2 mm). Also included is a 10 lb. (4.5 kg.) spool of .035" (0.9 mm) Innershi[...]

47 6. K697-1 Power Cord Extension — Extension 1 15V power cord (20 ’ /6.1m) allows extra convenience when work is located some distance away from power receptacle. INNERSHIELD (FCA W) CONVERSION Several changes are needed to convert the unit for operation with the Innershield (FCA W) process. The K549-1 or K549-2 Innershield Kits include all th[...]

48 REPLACEMENT P ARTS Complete Gun and Cable Assembly L831 1-6 (K530-5) Contact Tip .025 ” (0.6 mm) S19726-1 Contact Tip .030 ” (0.8 mm) S19726-2 Contact Tip .035 ” (0.9 mm) S19726-3 Contact Tip-T apered .025 ” (0.6 mm) S20278-1 Contact Tip-T apered .030 ” (0.8 mm) S20278-2 Contact Tip-T apered .035 ” (0.9 mm) S20278-3 Liner .030 - .035[...]

49 SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by remov- ing plug from receptacle before working inside MIG-P AK. Use only grounded receptacle. Do not touch electrically “ hot ” parts inside MIG- P AK. • Have qualified personnel do the maintenance and trouble shooting work. ------------------------------------------[...]

ENTRETIEN DU PISTOLET ET DU C Â BLE PISTOLET MAGNUM MC 100L Nettoyage du c â ble du pistolet Nettoyer le conduit int é rieur apr è s avoir utilis é approxima- tivement 300 lb (136 kg) de fil plein ou 50 lb (23 kg) de fil fourr é . S é parer le c â ble du d é vidoir et l' é tendre sur le sol. Enlever le tube contact du pistolet. Insuf[...]

51 MAINTENANCE MANTENIMIENTO ENTRETIEN Contact Tip Cable Liner Drive Roll Punta de Contacto Gu í a de Alambre Rodillo Impulsor Components shipped with S19726-1 M16291-6 KP665-035 MIG-P AK 10 • .025 ” (0.6mm) .030 ” - .035 ” 2 Smooth grooves/ranuras Lisas Componentes enviados (0.8 - 0.9 mm) Small/Peque ñ o .023-.025 ” (Side/Lado Bisel) c[...]

52 CHANGING DRIVE ROLL The drive roll has two grooves; one for .023" – .025" (0.6 mm) solid steel electrode and a larger knurled groove for .030" (0.8 mm) solid and .035" (0.9 mm) flux-cored steel electrode. As shipped, the drive roll is installed in the .030"/.035" (0.8/0.9 mm) position. If .023" – .025"[...]

53 CHANGING LINER NOTICE: The variation in cable lengths prevents the inter- changeability of liners. Once a liner has been cut for a par- ticular gun, it should not be installed in another gun unless it can meet the liner cutoff length requirement. Refer to Figure below . 1. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 2. Re[...]

54 No wire feed, weld output or gas flow when gun trig- ger is pulled. Fan does NOT operate. 1. Make sure correct voltage is applied to the machine. 2. Make certain that power switch is in the ON position. 3. Make sure circuit breaker inside wire drive com- partment is reset. No wire feed, weld output or gas flow when gun trig- ger is pulled Fan op[...]

55 Low or no gas flow when gun trigger is pulled. Wire feed, weld output and fan operate normally . 1. Verify that gas solenoid is properly installed. 2. Check gas supply , flow regulator and gas hoses. 3. Check gun connection to machine for obstruc- tion or leaky seals. Arc is unstable – Poor starting 1. Check for correct input voltage to machin[...]

56 S1 SWITCH D1 D3 D2 D4 204 204 204 203 203 203 C1 59,000 f 40V 203 204 - + GUN CABLE CONDUCTOR BLOCK TO WORK ELECTRICAL SYMBOLS PER E1537 CAVITY NUMBERING SEQUENCE ( COMPONENT SIDE OF BOARD ) 539 541 T1 GUN TRIGGER THERMOSTAT 208 5K WIRE SPEED R2 (W) (B) N.C. N.C. COMPONENT VIEWED FROM REAR. ON-OFF N.C. 209 WINDING 24V AUXILIARY FAN MOTOR X1 202 [...]

57 P ARTS P ARTES PI È CES Part Description Descripci ó n de las partes D é signation des pi è ces Part Number V oltage Control Switch Assembly Ensamble del Interruptor de Control de V oltaje S é lecteur de tension M15750 Knob (V oltage Switch) Perilla (Interruptor de V oltaje) Bouton (s é lecteur de tension) M15796 Line Switch Interruptor de[...]

MIG-P AK 10 NOTES[...]

MIG-P AK 10 NOTES[...]

NOTES MIG-P AK 10[...]

61 Now A vailable...12th Edition The Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry . This printing will go fast so don ’ t delay . Place your order now using the coupon below . The hardbound book[...]

62 W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic ● Do not touch electrically live parts or electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa moja- da. ● Aislese de[...]

63 W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic ● T urn power off before ser vicing. ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio. ● Débranchez le courant avant l’entre- tien. ● Strom vor Wartungsarbe[...]

World's Leader in W elding and Cutting Products[...]