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WELD-PAK 3200HD
For use with machine Code Number:10932

May, 2002

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 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:

OPERATORS MANUAL

ISO 9001

ANSI RAB

Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations, Inc. to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
Copyright 2002 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

SAFETY

WARNING
CALIFORNIA PROPOSITION 65 WARNINGS The engine exhaust from this product contains Diesel engine exhaust and some of its constituents chemicals known to the State of California to cause are known to the State of California to cause cancancer, birth defects, or other reproductive harm. cer, birth defects, and other reproductive harm. The Above For Gasoline Engines The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of Safety in Welding & Cutting - ANSI Standard Z49.1 from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE powered 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.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
____________________________________________________ 1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated. ____________________________________________________ 1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment. ____________________________________________________ 1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts. ___________________________________________________ 1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

FUMES AND GASES can be dangerous.
5.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 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. 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 products. 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 manufacturers instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employers safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 5.e. Also see item 1.b.
WELDING SPARKS can cause fire or explosion.
6.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 welding near hydraulic lines. Have a fire extinguisher readily available.
CYLINDER may explode if damaged.
7.a. Use only compressed gas cylinders containing the correct shielding gas for the 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. 7.c. Cylinders should be located: Away from areas where they may be struck or subjected to physical damage. 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. 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.

120V/60Hz

20 Amp
15 Amp, 125V, Three Prong Plug (NEMA Type 5-15P)

PHYSICAL DIMENSIONS

Height 12.0 in 305 mm

Width 9.75 in 248 mm

Depth 16.5 in 419 mm
connected to a circuit protected by fuses use Time Delay Fuse marked D.

WELD PAK 3200HD

11. Undercarriage: a) Base b) Gas bottle support base c) (2) Gas bottle support brackets
Read entire installation section before starting installation.
SAFETY PRECAUTIONS WARNING
Only qualified personnel should perform this installation. Only personnel that have read and understood the WELD-PAK 3200 HD 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. The WELD-PAK 3200 HD power switch is to be in the OFF (O) position when installing work cable and gun and when connecting power cord to input power.
For available options and accessories refer to the Accessories Section of this manual.
As shipped from the factory, the WELD-PAK 3200HD gun liner is ready to feed.023 (0.6 mm).035 (0.9 mm) wire. The contact tip is sized for.023.025 (0.6 mm) wire feeding. FIGURE A.1
IDENTIFY AND LOCATE COMPONENTS
If you have not already done so, unpack the WELDPAK 3200HD from its carton and remove all packing material around the WELD-PAK 3200HD. Remove the following loose items from the carton (see Figure A.1): 1. WELD-PAK 3200HD
2. Gun and cable assembly(1) 3. Literature and miscellaneous including: a) This operating manual b) 3 extra.023"-.025 (0.6 mm) contact tips c) 3 extra.035 (.09mm)contact tips d) Hex key wrench for removal of drive roll.
4. 10 ft (3.0 m) work cable.
5. Work clamp. 6. Sample spool of.025 (0.6 mm) L-56 MIG wire. 7. Sample spool of.035 (.09mm) NR-211 MP Innershield Flux Cored Wire 8. Handshield with filter plate and lens. 9. Adjustable mixed-Gas Regulator & Hose. 10. Mig Nozzle Assembly

Work Clamp Installation

Attach the work clamp per the following:

SELECT SUITABLE LOCATION

Locate the welder in a dry location where there is free circulation 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 air passages and cause overheating.

Cleaning Tip And Nozzle Clean the contact tip and nozzle to avoid arc bridging between the nozzle and contact tip which can result in a shorted nozzle, poor welds and an overheated gun. Hint: Anti-stick spray or gel, available from a welding supply distributor, may reduce buildup and aid in spatter removal.

PROCESS GUIDELINES

The WELD-PAK 3200HD can be used for welding mild steel using the GMAW, single pass, process which requires a supply of shielding gas or it can be used for the self-shielded, Innershield process (FCAW). The recommended gases and electrodes for GMAW are welding grade CO2 gas or an argon-CO2 blended gas (75 to 80% argon and 25 to 20% CO2) and.025" (0.6 mm) diameter Lincoln L-56 mild-steel welding wire, supplied on 12-1/2 lb (5.7 kg) spools. The blended gas is recommended for welding on heavier steel, 14 gauge (2.0 mm), for example. The recommended electrode for the self-shielded process is.035 (0.9 mm) diameter Lincoln Innershield NR-211-MP on 10 lb (4.5 kg) spools. This electrode can be used for all position welding of 20 gauge (1.0 mm) through 5/16" (8 mm) steel. Thickness of 1/4" (6 mm) and 5/16" (8 mm) require multiple passes. This wire can also be used for the welding of galvanized coated sheet metal.

GUN CABLE

WORKPIECE ARC

WORK CLAMP

FIGURE B.7
The WELD-PAK 3200HD is suitable for.035" aluminum wire and.030" stainless wire. Refer to Table B.1 for recommended procedure settings (requires K499 Argon Regulator Kit). TABLE B.1
Process Welding Wire Shielding Gas 100% Argon Voltage/Wire Speed 16 ga 14 ga 12 ga 10 ga B-5 D-7 D-9 D-9
2. If using a regulator with an adjustable flow meter, close the gun trigger and adjust the flow to give cubic ft per hour (CFH) (I/min) [use CFH (I/min) when welding out of position or in a drafty location for CO2]. For argon mixed gas, trigger to release gas pressure, and adjust the flow to give CFH (I/min). 3. Keep the cylinder valve closed, except when using the WELD-PAK 3200HD. When finished welding: a) Close the cylinder valve to stop gas flow.

THE SELF-SHIELDED FCAW WELDING ARC
Figure B.9 illustrates the action taking place in the self shielded FCAW (Innershield) welding arc. It closely resembles what is actually seen while welding.
Cored Wire Protective Slag
Burning of core materials inside wire electrode results in shield of gas. Arc Stream

Weld Metal

Hinges

Bearings

FIGURE B.9
FIGURE B.8 WELD-PAK 3200HD
THE GMAW (MIG) WELDING ARC
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 6000F, 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 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. 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 ingredients around which a steel sheath has been formed. It is simply a stick electrode turned inside out in a continuous wire form. 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. The core materials also melt or burn in the arc and perform several functions. They make the arc steadier, 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. 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 electrode is recommended for Self-Shielded Flux Cored Arc Welding.
Figure B.10 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.

Gas nozzle Solid wire electrode Shielding gas

Weld metal Base metal

FIGURE B.10
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 ingredients for shielding, and is thus termed Self-Shielded Flux Cored Arc Welding. 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.

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:
JOINT TYPES AND POSITIONS
For GMAW (MIG) Process 1. 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 supply? 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. For FCAW (Innershield) Process 1. Do I want simplicity and portability? 2. Will welding be performed outdoors or under windy conditions? 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? 5. Weld must be cleaned prior to painting.
Five types of welding joints are: Butt Welds, Fillet Welds, Lap Welds, Edge Welds and Corner Welds. See Figure B.11. Of these, the Butt Weld and Fillet Weld are the two most common welds.

Butt weld

Lap weld

Edge weld

Fillet weld

Corner weld

FIGURE B.11 Butt Welds Place two plates side by side, leaving a space approximately 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, otherwise the heat will cause the plates to move apart. See Figure B.12. 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.

COMMON METALS

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 precautions. Some steels, however, contain higher carbon 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. In addition, aluminum and stainless steel can be welded using the K664-1 Aluminum Welding Kit. For further information on identifying various types of steels and other metals, and for proper procedures for welding them, we again suggest you purchase a copy of New Lessons in Arc Welding. 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.

MACHINE SET UP FOR THE SELF-SHIELDED FCAW 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.
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.16 Vertical-down Welding Refer to Figure B.17 Vertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow and, as such, are excellent for sheet metal. Vertical-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 force helps hold the molten metal in the joint. Move as fast as possible consistent with desired bead shape. 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.
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. 4. 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. 5. When using Innershield electrode, the gasless nozzle may be used instead of a gas nozzle to improve visibility of the arc. 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.
WELDING TECHNIQUES FOR THE SELFSHIELDED 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.18 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. WELD-PAK 3200HD

FIGURE B.17

FIGURE B.18
3/8 1/2 (mm) Electrical Stickout (ESO)
ARC RAYS can burn eyes and skin. 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. 2. The Correct Way To Strike An Arc 1. Be sure the work clamp makes good electrical contact to the work. 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 (mm). 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

FIGURE B.19 The easiest way to tell whether the ESO is the correct 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. 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.20. Do not watch the arc itself. It is the appearance of the puddle and the ridge where the molten puddle solidifies that indicates correct welding speed. The ridge should be approximately 3/8 (10 mm) behind the wire electrode. Most beginners tend to weld too fast, resulting in a thin uneven, wormy looking bead. They are not watching the molten metal.
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. See Figure B.19. 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. WELD-PAK 3200HD

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: 1. The Correct Welding Position Figure B.23 illustrates the correct welding position for right handed people. (For left handed people, it is the opposite.) 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.)

Helpful Hints

Wire Electrode ESO
FIGURE B.24 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.24. 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 easiest way to tell whether the ESO is the correct 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. 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.25. Do not watch the arc itself. It is the appearance of the puddle and the ridge where the molten Puddle solidifies that indicates correct welding speed. The ridge should be approximately 3/8 (10 mm) behind the wire electrode. Most beginners tend to weld too fast, resulting in a thin, uneven, wormy looking bead. They are not watching the molten metal.
For the WELD-PAK 3200HD, use the following:
Mild Steel Electrode 16 gauge or 1/16 inch (1.6 mm) Lincolnweld 0.025 L-56 electrode CO2 C 4
Voltage Setting V Wire Feed Speed o|o Refer to Figure B.22.

3. K520 Utility Cart Designed to transport the Lincoln family of small welders. Has provisions for mounting a single gas cylinder. Has front casters and large rear wheels. Handle height is easily adjustable. Bottom tray provided for tools and accessories. Easy assembly required; takes less than 15 minutes. 4. K586-1 Deluxe Adjustable Gas Regulator & Hose Kit Accommodates CO2 or mixed Gas Cylinders.

C-2 REPLACEMENT PARTS

Complete Gun and Cable Assembly L8311-5 (K530-4) 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-Tapered.025 (0.6 mm) S20278-1 Contact Tip-Tapered.030 (0.8 mm) S20278-2 Contact Tip-Tapered.035 (0.9 mm) S20278-3 Liner.023 -.030 (0.6 - 0.8 mm) M16291-2 Liner.030 -.035 (0.8 - 0.9 mm) M16291-6
Liner.035/.045 (0.9/1.2 mm) M16291-1 Gas Diffuser S19728 Gas Nozzle M16294 Gas Nozzle-Tip Recessed 3/8 (9.5 mm) Opening I.D. M16684 Gas Nozzle-Tip Recessed 1/2 (12.7 mm) Opening I.D. M16684-1 Gas Nozzle-Tip Recessed 5/8 (15.9 mm) Opening I.D. M16684-2 Spot Welding Nozzle M17846 Gasless Nozzle (Innershield Only) M16418

MAINTENANCE

MAINTENANCE SAFETY PRECAUTIONS WARNING
ELECTRIC SHOCK can kill. Disconnect input power by removing plug from receptacle before working inside WELD-PAK 3200HD. Use only grounded receptacle. Do not touch electrically hot parts inside WELD-PAK 3200HD. Have qualified personnel do the maintenance and trouble shooting work.

ROUTINE MAINTENANCE

POWER SOURCE COMPARTMENT
No user serviceable parts inside! Do not attempt to perform service in the power source (fixed) side of the WELD-PAK 3200HD. Take the unit to an authorized Lincoln Service Center if you experience problems. NO maintenance is required. In extremely dusty locations, dirt may clog the air passages causing the welder to run hot with premature tripping of thermal protection. If so, blow dirt out of the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build-up on internal parts.

WIRE FEED COMPARTMENT

1. When necessary, vacuum accumulated dirt from gearbox and wire feed section. 2. Occasionally inspect the incoming guide tube and clean inside diameter if necessary. 3. Motor and gearbox have lifetime lubrication and require no maintenance.

Do not touch electrically live parts Only qualified persons should install, use or service this machine.
H2 LS1 H2 H2 N.O. SPOT/STITCH TIMER OPTIONAL 539 J2 5K RJUMPERED PLUG STANDARD

CONTROL P.C. BOARD

S1 ON-OFF SWITCH CR1 115V/60HZ GAS SOLENOID H1 H1 WIRE SPEED
THERMOSTAT (MOUNTED TO SEC. COIL) N.C. GUN TRIGGER

115V/60HZ FAN MOTOR

AUXILIARY WINDING

213A (W) 539

+ (B) OUTPUT CHOKE

WIRE FEED MOTOR

CIRCUIT BREAKER 204 DN.B. N.D. D2 N.D.

DIAGRAMS

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.

X3 X4 X5

S2 SELECTOR SWITCH X2
GUN CABLE CONDUCTOR 59,000 f 40V 203 N.A. D4 D203 BLOCK

H2 T1 X1

CASE LATCH JJ10 LATCH CAVITY NUMBERING SEQUENCE ( COMPONENT SIDE OF BOARD ) 1

GROUNDING

N.A. DIODES D2 & D4 ARE MOUNTED ON THE OUTSIDE HEATSINK. N.B. DIODES D1 & D3 ARE MOUNTED ON THE INSIDE HEATSINK, WHICH IS CLOSEST TO THE CENTER PANEL. N.C. COMPONENT VIEWED FROM REAR. N.D. BOLTED ALUMINUM CONNECTIONS REQUIRE T12837 JOINT COMPOUND (DOW CORNING 340) WHEN REATTACHING.
TO WORK ELECTRICAL SYMBOLS PER E1537 LEAD COLOR CODE: B-BLACK W-WHITE
TO EARTH GROUND PER NATIONAL, LOCAL OR OTHER APPLICABLE

ELECTRICAL CODES.

M19924
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The book contains the latest information and application data on the American Welding Society Standard Welding Symbols. Detailed discussion tells how engineers and draftsmen use the short-cut language of symbols to pass on assembly and welding information to shop personnel. Practical exercises and examples develop the readers ability to visualize mechanically drawn objects as they will appear in their assembled form. 187 pages with more than 100 illustrations. Size 8-1/2 x 11 Durable, cloth-covered board binding. $4.50 postage paid U.S.A. Mainland The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland, Ohio. Over 100,000 students have graduated. Tuition is low and the training is hands on For details write: Lincoln Welding School 22801 St. Clair Ave. Cleveland, Ohio 44117-1199.
and ask for bulletin ED-80 or call 216-383-2259 and ask for the Welding School Registrar.
Lincoln Welding School BASIC COURSE 5 weeks of fundamentals

$700.00

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USE THIS FORM TO ORDER: BOOKS OR FREE INFORMATIVE CATALOGS Lincoln Welding School (ED-80) Seminar Information (ED-45) Educational Video Information (ED-93) James F. Lincoln Arc Welding Foundation Book Information (JFLF-515)

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BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901. Code L PH H IM NA AC WC-8 ED-89 Quantity Cost