Page 2 - SAFETY; WARNING; Mar; 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 ’ s recommendations. 8.c. Ground the equipment in...
Page 5 - iv
iv SAFETY iv PR É CAUTIONS DE S Û RET É Pour votre propre protection lire et observer toutes les instructions et les pr é cautions de s û ret é specifiques qui parraissent dans ce manuel aussi bien que les pr é cautions de s û ret é g é n é rales suiv- antes: S û ret é Pour Soudage A L ’ Arc 1. Prot...
Page 6 - Thank You; as much pride as we have in bringing this product to 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 - TABLE OF CONTENTS; Page
vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1Identify and Locate Components ....
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS
A-1 PRO 100 A-1 INSTALLATION Fuse or Output Mode Input Voltage Breaker Size Input Amps Power Cord Extension Cord RATED 115V/60Hz 20 Amp 20 15 Amp, 125V, Three Conductor Three Prong Plug #14 AWG (NEMA Type 5-15P) (2.1 mm 2 ) or Larger Up to 25 Ft. (7.6 mm) CSA 115V/60Hz 15 Amp 12 15 Amp, 125V, Three ...
Page 9 - SAFETY PRECAUTIONS; Gun and cable assembly; ELECTRIC SHOCK can kill.
A-2 INSTALLATION PRO 100 A-2 Read entire installation section before startinginstallation. SAFETY PRECAUTIONS IDENTIFY AND LOCATE COMPONENTS If you have not already done so, unpack the PRO 100f 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 PRO 100. Remove th...
Page 10 - SELECT SUITABLE LOCATION; STACKING; OUTPUT CONNECTIONS; Work Clamp Installation
A-3 INSTALLATION PRO 100 A-3 SELECT SUITABLE LOCATION Locate the welder in a dry location where there is freecirculation of clean air into the louvers in the back andout the front of the unit. A location that minimizes theamount of smoke and dirt drawn into the rear louversreduces the chance of dirt...
Page 11 - Connecting Gun Cable to the PRO 100; GUN INSTALLATION
A-4 INSTALLATION PRO 100 A-4 and installation details. Connecting Gun Cable to the PRO 100 1. Refer to Figure A.2. Unplug the machine or turn power switch to the OFF “ O ” position. 2. Pass the insulated terminals of the gun trigger con- trol leads, one at a time, through the Gun Cableand Control Le...
Page 12 - Chain the cylinder to a wall or other stationary sup-
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 aninstant. This blows away any dust or dirt which mayhave accumulated in the valve outlet. BE SURE TO KEEP YOUR FACE AWAY FROM THEVALVE OUTLET WHEN ...
Page 13 - INPUT CONNECTIONS; Requirements For Rated Output; Do not remove the power cord ground prong.; Requirements For CSA Rated Output
A-6 INSTALLATION PRO 100 A-6 INPUT CONNECTIONS FIGURE A.6 Refer to Figure A.6. The PRO 100 has a power input cable located on therear of the machine. CODE REQUIREMENTS FOR INPUT CONNECTIONS This welding machine must be connected topower source in accordance with applicable elec-trical codes. The Uni...
Page 14 - OPERATION
B-1 OPERATION B-1 PRO 100 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 PRO 100. 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 AND...
Page 15 - WELDING CAPABILITY; RECOMMENDED PROCESSES; OFF
B-2 OPERATION B-2 ● No external shielding gas is required when usedwith Lincoln Innershield .035 ” (0,9 mm) NR ® -211- MP electrode. ● Accommodates 4 ” (100 mm) diameter spool of wire. Will accommodate 8 ” (200 mm) diameter with optional spindle. WELDING CAPABILITY The PRO 100 is rated at 88 amps, 1...
Page 16 - WELDING OPERATIONS; SEQUENCE OF OPERATION; ) position before working inside the wire feed; Note:When loading and removing the 8; Spools make
B-3 OPERATION B-3 FIGURE B.1a FIGURE B.1b WELDING OPERATIONS SEQUENCE OF OPERATION Wire LoadingRefer to Figure B.2 AND B3. The machine power switch should be turned to theOFF ( “ O ” ) position before working inside the wire feed enclosure. The machine is shipped from the factory ready to feed4 ” (1...
Page 17 - Note: The brake should be adjusted with a spool of
Gun Handle Gas Diffuser/ Contact Tip Gas Nozzle FIGURE B.5 B-4 OPERATION B-4 Note: The brake should be adjusted with a spool of wire installed. When properly adjusted it shouldmove freely but not coast. Friction Brake Adjustments 1. With wire spool installed, check free movement and coast of the spo...
Page 18 - Making A Weld; PROCESS GUIDELINES
B-5 OPERATION B-5 Making A Weld 1. See “ Process Guidelines ” in this section for selec- tion of welding wire and shielding gas and forrange of metal thicknesses that can be welded. 2. See the Application chart on the inside of the wire feed compartment door for information on settingthe PRO 100 con...
Page 19 - OVERLOAD PROTECTION
B-6 OPERATION B-6 lower cost. A mixed gas consisting of 75 to 80%Argon and 20 to 25% CO2 is recommended for weld- ing on heavier gauge [12 gauge (2,5 mm) for exam-ple] steel. The PRO 100 is suitable for .035" aluminum wire and.030" stainless wire. Refer to Table B.1 for recom-mended procedur...
Page 20 - LEARNING TO WELD; THE ARC-WELDING CIRCUIT; Avoid contact with eyes and skin.
B-7 LEARNING TO WELD B-7 PRO 100 LEARNING TO WELD No one can learn to weld simply by reading about it.Skill comes only with practice. The following pageswill help the inexperienced operator to understandwelding and develop this skill. For more detailed infor-mation, order a copy of “ New Lessons in ...
Page 21 - PROCESS SELECTION
B-8 LEARNING TO WELD B-8 PRO 100 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...
Page 22 - COMMON METALS
B-9 LEARNING TO WELD B-9 PRO 100 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 yes to all the above questionsG M A W m a y b e t h e p r o c e s s f o r y o u . I f y o...
Page 23 - angle between the two; Welding In The Vertical Position; drip
B-10 LEARNING TO WELD B-10 PRO 100 FIGURE B.12 PenetrationUnless a weld penetrates close to 100% of the metalthickness, a butt weld will be weaker than the materialwelded together. In the example shown in FigureB.13, the total weld is only half the thickness of thematerial thus the weld is only appr...
Page 24 - The Correct Welding Position
B-11 LEARNING TO WELD B-11 PRO 100 FIGURE B.16 Vertical-down WeldingRefer to Figure B.17 Vertical-down welds are appliedat a fast pace. These welds are therefore shallow andnarrow and, as such, are excellent for sheet metal.Vertical-down welds may be applied to 5/32 ” (3.9 mm) and lighter material. ...
Page 25 - ARC RAYS can burn eyes and skin.
B-12 LEARNING TO WELD B-12 PRO 100 ARC RAYS can burn eyes and skin. When using an open arc process, itIs necessary to use correct eye,head and body protection. Protect yourself and others, read “ ARC RAYS can burn ” at the front of this manual. 2. The Correct Way To Strike An Arc 1. Be sure the work...
Page 26 - Helpful Hints; For general welding, it is not necessary to weave; Practice; Mild Steel
B-13 LEARNING TO WELD B-13 PRO 100 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,...
Page 28 - The Correct Welding Speed
B-15 LEARNING TO WELD B-15 PRO 100 FIGURE B.24 3. The Correct Electrical Stickout (ESO) The electrical stickout (ESO) is the distance fromthe end of the contact tip to the end of the wire.See Figure B.24. Once the arc has been established, maintainingthe correct ESO becomes extremely important.The E...
Page 29 - TROUBLESHOOTING WELDS; To Eliminate Porosity
4. After you strike the arc, practice the correct electri- cal stickout. Learn to distinguish it by its sound. 5. When you are sure that you can hold the correct electrical stickout, with a smooth “ crackling ” arc, start moving. Look at the molten puddle constantly, 6. Run beads on a flat plate. Ru...
Page 30 - Proper Gun Handling
B-17 LEARNING TO WELD B-17 PRO 100 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...
Page 31 - APPLICATION CHART
Page 32 - ACCESSORIES; OPTIONAL ACCESSORIES; K 6 6 4 - 2 A l u m i n u m F e e d i n g K i t; MIG CONVERSION
C-1 ACCESSORIES C-1 OPTIONAL ACCESSORIES 1. K520 Utility Cart — Designed to transport the Lin- coln family of small welders. Has provisions formounting a single gas cylinder. Has front castersand large rear wheels. Handle height is easilyadjustable. Bottom tray provided for tools andaccessories. Eas...
Page 33 - MAINTENANCE; POWER SOURCE COMPARTMENT
D-1 MAINTENANCE D-1 PRO 100 MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before workinginside PRO 100. Use only groundedreceptacle. Do not touch electrically “ hot ” parts inside PRO 100. • Have qualified personnel do the mainte- n...
Page 34 - FOR MAGNUM; Gun Cable Cleaning; CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM
D-2 MAINTENANCE D-2 GUN AND CABLE MAINTENANCE FOR MAGNUM ™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs(136 kg) of solid wire or 50 lbs (23 kg) of flux-coredwire. Remove the cable from the wire feeder and lay itout straight on the floor. Remove the contact tip from...
Page 35 - CHANGING THE CONTACT TIP; CAUTION
D-3 MAINTENANCE D-3 COMPONENTREPLACEMENT PROCEDURES CHANGING THE CONTACT TIP 1. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 2. Remove the existing contact tip from the gun by unscrewing counter-clockwise. 3. Insert and hand tighten desired contact tip. 4....
Page 36 - CHANGING LINER; Liner trim length
D-4 MAINTENANCE D-4 PRO 100 CHANGING LINER NOTICE: The variation in cable lengths pre-vents the interchangeability of liners. Oncea liner has been cut for a particular gun, its h o u l d n o t b e i n s t a l l e d i n a n o t h e r g u nunless it can meet the liner cutoff lengthrequirement. Refer t...
Page 37 - GUN HANDLE PARTS
D-5 MAINTENANCE D-5 PRO 100 GUN HANDLE PARTS The gun handle consists of two halves that are heldtogether with a collar on each end. To open up thehandle, turn the collars approximately 60 degreescounter-clockwise until the collar reaches a stop. Thenpull the collar off the gun handle. If the collars...
Page 38 - TROUBLESHOOTING; HOW TO USE TROUBLESHOOTING GUIDE; LOCAL AUTHORIZED LINCOLN ELECTRIC
E-1 TROUBLESHOOTING E-1 PRO 100 This Troubleshooting Guide is provided tohelp you locate and remedy possible prob-lems with machine setup or operation. Sim-p l y f o l l o w t h e t h r e e - s t e p p r o c e d u r e listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “ PR...
Page 39 - TROUBLESHOOTING GUIDE; OUTPUT PROBLEMS
E-2 TROUBLESHOOTING E-2 PRO 100 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS(SYMPTOMS) Major physical or electrical damageis evident. No wire feed, weld output or gasflow when gun trigger is pulled. Fandoes NOT operate. No wire feed, weld output ...
Page 40 - weld; FEEDING PROBLEMS; Check gun connection to; GAS FLOW PROBLEMS
E-3 TROUBLESHOOTING E-3 PRO 100 TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual. PROBLEMS(SYMPTOMS) No wire feed when gun trigger ispulled. Fan runs, gas flows andmachine has correct open circuitvoltage (32vcd maximum) – weld output. POSSIBLE AREAS OFMISADJUST...
Page 41 - WELDING PROBLEMS
E-4 TROUBLESHOOTING E-4 PRO 100 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILI...
Page 42 - DIAGRAMS; PRO100 WIRING DIAGRAM
F-1 DIAGRAMS F-1 PRO 100 S1 SWITCH D1 D3 D2 D4 204 204 204 203 203 203 C1 59,000 mf 40V 203 204 - + GUN CABLE CONDUCTOR BLOCK TO WORK ELECTRICAL SYMBOLS PER E1537 CAVITY NUMBERING SEQUENCE ( COMPONENT SIDE OF BOARD ) 539 541 T1 213 GUN TRIGGER THERMOSTAT 208 5K WIRE SPEED R2 (W) (B) N.C. N.C. COMPON...
Page 43 - NOTES
Page 44 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
Now Available...12th EditionThe 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. T h i s p r i n t i n g w i l l g o f a s t s o d o n ’ t d e l a y . P ...
Page 45 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...
