Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent d a n s c e m a n u e l a u s s i b i e n q u e l e s p r é c a u t i o n s d e s û r e t é générales suivantes: Sûreté Pour So...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and ...
Page 7 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
vi MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1Identify...
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS – MIG PAK HD; INPUT – SINGLE PHASE ONLY
A-1 MIG PAK HD A-1 Fuse or Output Mode Input Voltage Breaker Size 1 Input Amps Power Cord Extension Cord AT RATED 120V/60Hz 20 Amp 20 15 Amp, 125V, Three Conductor OUTPUT Three Prong Plug #12 AWG (NEMA Type 5-15P) (3.3 mm2) or Larger Up to 50 Ft. (15.2 mm) INSTALLATION TECHNICAL SPECIFICATIONS – MIG...
Page 9 - MIG PAK HD; SAFETY PRECAUTIONS; MIG PAK HD with work clamp, Gun and cable; ELECTRIC SHOCK can kill.
A-2 INSTALLATION MIG PAK HD A-2 Read entire installation section before startinginstallation. SAFETY PRECAUTIONS IDENTIFY AND LOCATE COMPONENTS If you have not already done so, unpack the machinef r o m i t s c a r t o n a n d r e m o v e a l l p a c k i n g m a t e r i a laround the machine. The fo...
Page 10 - SELECT SUITABLE LOCATION; STACKING; Machines cannot be stacked.; CHANGING POLARITY
INPUT CONNECTIONS (FIGURE A.4) Refer to Figure A.4. The machine has two input connections, the powerinput cable and the gas inlet fitting. The power inputcable and gas inlet fitting are located on the rear. GAS CONNECTION When using the MIG process, a cylinder of shieldinggas (appropriate for the me...
Page 11 - SHIELDING GAS CONNECTION; REQUIREMENTS FOR MAXIMUM OUTPUT
A-4 INSTALLATION MIG PAK HD A-4 SHIELDING GAS CONNECTION (FIGURE A.5) Refer to Figure A.5. 1. Chain the cylinder to a wall or other stationary sup- p o r t t o p r e v e n t t h e c y l i n d e r f r o m f a l l i n g o v e r .Insulate the cylinder from the work circuit workground. 2. With the cylin...
Page 12 - OPERATION; GENERAL DESCRIPTION; • Accommodates spools of wire up to 4”(102mm)
B-1 OPERATION B-1 MIG PAK HD R e a d e n t i r e o p e r a t i o n s e c t i o n b e f o r eoperating the machine. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin orwet clothing. Insulate yourselffrom work and ground. • Always wear dry insulating gloves. FUMES ...
Page 13 - TABLE B.1 – MIG WELDING MATERIAL/GAS COMBINATIONS; WELDING CAPABILITY; W i r e S p e e d C o n t r o l . - C o n t r o l s t h e w i r e f e e d; WELDING OPERATIONS; PROCESS GUIDELINES
B-2 OPERATION B-2 TABLE B.1 – MIG WELDING MATERIAL/GAS COMBINATIONS Material Gas Carbon Steel CO2 or Argon/CO2 Low Alloy Steel CO2 or Argon/CO2 FLUX-CORED (INNERSHIELD) WELDINGThe recommended electrode for the flux-cored, self-shielded process is 0.035” (0.9 mm) diameter LincolnInnershield NR-211-MP...
Page 14 - FIGURE B.3 – WIRE THREADING DETAILS; SHIELDING GAS
B-3 OPERATION B-3 FIGURE B.3 – WIRE THREADING DETAILS Refer to Figure B.3.4. 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 driveroll side facing you matches the wire size beingused. 5. Carefully det...
Page 15 - MAKING A WELD; FIGURE B.5 – WELDING SETUP
B-4 OPERATION B-4 MAKING A WELD FIGURE B.5 – WELDING SETUP READ the LEARNING TO WELD section of this man-ual prior to making your first weld. Also, refer to TableB.1 and the Procedure Decal located on the inside ofthe wire drive compartment door of your machine forprocess selection, consumables, and...
Page 16 - OVERLOAD PROTECTION; THERMAL PROTECTION
B-5 OPERATION B-5 MIG PAK HD CLEANING TIP AND GAS NOZZLE Keep the contact tip and nozzle clean to avoid arcbridging 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 i...
Page 17 - LEARNING TO WELD; THE ARC-WELDING CIRCUIT
B-6 OPERATION B-6 MIG PAK HD LEARNING TO WELD No one can learn to weld simply by reading aboutit. Skill comes only with practice. The followingpages will help the operator to understand weldingand develop this skill. THE ARC-WELDING CIRCUIT The operator’s knowledge of arc welding must gobeyond the a...
Page 18 - PROCESS SELECTION
B-7 OPERATION B-7 The “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing through the space between the end of the wireelectrode and the base metal. The temperature of thisarc is about 6000°F, which is more than enough tomelt metal. The a...
Page 19 - COMMON METALS
B-8 OPERATION B-8 MIG PAK HD For GMAW (MIG) Process1. Is most of my welding performed on 16 gauge and lighter materials? 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas sup-ply? 3. Do I require clean, finished-looking welds? If you have answered y...
Page 20 - Welding In The Vertical Position
B-9 OPERATION B-9 MIG PAK HD PenetrationUnless a weld penetrates close to 100% of the metalthickness, a butt joint will be weaker than the materialwelded together. In the example shown in FigureB.11, the total weld is only half the thickness of thematerial thus the weld is only approximately half as...
Page 21 - See the Application Guide on the inside of wire; The Correct Welding Position
B-10 OPERATION B-10 MIG PAK HD FIGURE B.14 Vertical-down WeldingRefer to Figure B.15 Vertical-down welds are appliedat a fast pace. These welds are therefore shallow andnarrow and, as such, are excellent for sheet metal.Suggested settings for welding Vertical-down weldsare found in table b.1. Use st...
Page 23 - Helpful Hints
B-12 OPERATION B-12 MIG PAK HD 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. 2. When welding on thin plate, you will find that you will have to increase the welding speed, whe...
Page 26 - TROUBLESHOOTING WELDS; Good welds have excellent appearance.; To Eliminate Porosity; Do not allow dolly wheels or trucks to run over the
B-15 OPERATION B-15 TROUBLESHOOTING WELDS Good welds have excellent appearance. To Eliminate Porosity (In order of priority):1. Check or reset WFS & Volts on chart inside door. 2. Clean joints from moisture, paint, rust etc. 3. Increase stickout. 4. Decrease drag angle. 5. Decrease travel speed....
Page 27 - Proper Gun Handling
B-16 OPERATION B-16 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 cable...
Page 28 - ACCESSORIES; INNERSHIELD WELDING WIRE
C-1 ACCESSORIES C-1 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 thelife of the welde...
Page 29 - • Drive Motor and Gearbox – Lifetime lubrication; MAINTENANCE
MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before workinginside machine. Use only groundedreceptacle. Do not touch electrically“hot” parts inside machine • Have qualified personnel do the mainte- nance and trouble shooting work. ...
Page 30 - CLEANING THE GUN LINER; CAUTION
D-2 MAINTENANCE D-2 MID PAK HD CLEANING THE GUN LINER • Unplug the machine or turn the power switch to the OFF - “0” position. • Remove the gas nozzle and contact tip from the gun. • Clean the inside diameter with a short piece of wire. • Clean the cable liner when rough and erratic wire feeding occ...
Page 31 - GUN ASSEMBLY REMOVAL; Unfasten the 2 retaining bolts and 1 screw securing; WORK CABLE INSTALLATION; Pass the end of the work cable with the terminal lug
D-3 MAINTENANCE D-3 MIG PAK HD 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 theinside and visible. 5. Replace the Thumbscrew and tighten. GUN ASSEMBLY REMOVAL 1. Unplug machine.2. Remove wire...
Page 32 - TROUBLESHOOTING; Step 3. RECOMMENDED COURSE OF ACTION
E-1 TROUBLESHOOTING E-1 MIG PAK HD If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guid...
Page 33 - OUTPUT PROBLEMS; Observe all Safety Guidelines detailed throughout this manual
E-2 TROUBLESHOOTING E-2 MIG PAK HD 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. CAUTION PROBLEMS(SYMPTOMS) Major...
Page 34 - for technical troubleshooting assistance before you proceed.; The thermostat may be tripped; FEEDING PROBLEMS
E-3 TROUBLESHOOTING E-3 MIG PAK HD 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. CAUTION PROBLEMS(SYMPTOMS) No wi...
Page 35 - WELDING PROBLEMS
E-4 TROUBLESHOOTING E-4 MIG PAK HD 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. CAUTION PROBLEMS(SYMPTOMS) Bead ...
Page 36 - DIAGRAMS; IRI
F-1 DIAGRAMS F-1 MIG PAK HD M 2024 2 A. 01 W IRI NG DI AGRAM W E LDER IN PUT CABLE S1 1 4 2 5 M1 W B G 0I GR EEN LEAD PLUG 3 6 1 2 2 3 T 1 S2 5 4 4 V g g L M2 re d bl a c k X1 X2 X3 X5 X4 X8 X11 X10 X9 X2 X1 X2 X1 NO G AS GA S X2 X1 X7 X6 NOTE: This diagram is for reference only. It may not be accur...