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Lincoln Electric IM822 - page 1
MIG P AK HD OPERA TOR’S MANUAL IM822 February, 2003 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 MANUA ...
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Lincoln Electric IM822 - page 2
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. ________________________________________________ ...
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Lincoln Electric IM822 - page 3
ii SAFETY ii ARC RA YS can burn. 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. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin ...
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Lincoln Electric IM822 - page 4
FOR ELECTRICALL Y powered equipment. 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. 8.c. Ground the equipment in accordance with the U.S. National Electrical C ...
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Lincoln Electric IM822 - page 5
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 dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les ...
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Lincoln Electric IM822 - page 6
Thank You 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay par ...
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Lincoln Electric IM822 - page 7
vi MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components ......................... ...
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Lincoln Electric IM822 - page 8
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 mm 2 ) or Larger Up to 50 Ft. (15.2 mm) INST ALLA TION TECHNICAL SPECIFICA TIONS – MIG P AK HD INPUT – SINGLE PHASE ONL Y RA TE ...
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Lincoln Electric IM822 - page 9
A-2 INST ALLA TION MIG PAK HD A-2 Read entire installation section before starting installation. SAFETY PRECAUTIONS IDENTIFY AND LOCA TE COMPONENTS 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): 1. MIG PAK HD with work c ...
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Lincoln Electric IM822 - page 10
INPUT CONNECTIONS (FIGURE A.4) Refer to Figure A.4. 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. CYLINDER ma ...
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Lincoln Electric IM822 - page 11
A-4 INST ALLA TION 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- 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 ...
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Lincoln Electric IM822 - page 12
B-1 OPERA TION B-1 MIG PAK HD Read entire operation section before operating the machine. 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. FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ...
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Lincoln Electric IM822 - page 13
B-2 OPERA TION 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) 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. SEQUENCE OF OP ...
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Lincoln Electric IM822 - page 14
B-3 OPERA TION 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 drive roll side facing you matches the wire size being used. 5. Carefully detach the end of the wire from the spool mai ...
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Lincoln Electric IM822 - page 15
B-4 OPERA TION 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 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 righ ...
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Lincoln Electric IM822 - page 16
B-5 OPERA TION B-5 MIG PAK HD 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 F ...
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Lincoln Electric IM822 - page 17
B-6 OPERA TION B-6 MIG PAK HD 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 operator to understand welding and develop this skill. THE ARC-WELDING CIRCUIT The operator ’ s knowledge of arc welding must go beyond the arc itself. The operator must know how to ...
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Lincoln Electric IM822 - page 18
B-7 OPERA TION B-7 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, ...
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Lincoln Electric IM822 - page 19
B-8 OPERA TION B-8 MIG PAK HD 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 sup- ply? 3. Do I require clean, finished-looking welds? If you have answered yes to all the above questions GMAW may be the p ...
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Lincoln Electric IM822 - page 20
B-9 OPERA TION B-9 MIG PAK HD 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. FIGURE B.11 In the exa ...
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Lincoln Electric IM822 - page 21
B-10 OPERA TION B-10 MIG PAK HD FIGURE B.14 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. Use stringer beads and tip the gun in the directio ...
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Lincoln Electric IM822 - page 22
B-1 1 OPERA TION B-1 1 MIG PAK HD 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 w ...
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Lincoln Electric IM822 - page 23
B-12 OPERA TION 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, whereas when welding on heavy plate, it is necessar ...
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Lincoln Electric IM822 - page 24
B-13 OPERA TION B-13 MIG PAK HD MACHINE SET UP FOR THE GMA W (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. 3. Set the ...
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Lincoln Electric IM822 - page 25
B-14 OPERA TION B-14 MIG PAK HD 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. 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 ...
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Lincoln Electric IM822 - page 26
B-15 OPERA TION 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. NOTE: Always be sure the joint is free from moi ...
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Lincoln Electric IM822 - page 27
B-16 OPERA TION 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 cables. 4. Keep the cable clean. 5. Innershield elect ...
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Lincoln Electric IM822 - page 28
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 the life of the welder and may need to be ordered. See the com ...
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Lincoln Electric IM822 - page 29
MAINTENANCE SAFETY PRECAUTIONS 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 • Dr ...
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Lincoln Electric IM822 - page 30
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 occur: Lay the cable out straight. Blow ...
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Lincoln Electric IM822 - page 31
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 the inside and visible. 5. Replace the Thumbscrew and tighten. GUN ASSEMBL Y REMOV AL 1. Unplug machine. 2. Remove wire drive door and right case side. 3. Remove gas ...
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Lincoln Electric IM822 - page 32
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 your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair possi ...
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Lincoln Electric IM822 - page 33
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 physical or electrical damage is evident. No wir ...
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Lincoln Electric IM822 - page 34
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 wire feed when gun trigger is pulled. POSSIBLE AREA ...
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Lincoln Electric IM822 - page 35
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 is too thin (intermittently). Bead is too thick ( ...
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Lincoln Electric IM822 - page 36
F-1 DIAGRAMS F-1 MIG PAK HD M20242 A. 01 WIRI NG DI AGRAM W ELDER INPUT CABLE S1 1 4 2 5 M1 W B G 0I GREEN LEAD PLUG 3 6 1 2 2 3 T 1 S2 5 4 4 V g g L M2 red black X1 X2 X3 X5 X4 X8 X11 X10 X9 X2 X1 X2 X1 NO GA S GAS X2 X1 X7 X6 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia ...
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Lincoln Electric IM822 - page 37
W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA ...
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Lincoln Electric IM822 - page 38
W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes ...
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Lincoln Electric IM822 - page 39
• 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 • World's Leader in Welding and Cutting Products • ...
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