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IM759
May, 2002
WELD-PAK 3200HD
For use with machine Code Number:10932
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
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
QMS
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
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ii
ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
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.
kill.
3.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 clothing. Wear dry, hole-free
gloves to insulate hands.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases.When welding, keep
your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control.
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.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
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.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
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.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
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SAFETY
CYLINDER may explode
if damaged.
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
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
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.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
•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.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
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.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
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.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
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:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas forte-
ment toxique) ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se pro-
téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis-
positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflamma-
bles.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
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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!
Thank You
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
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vi
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Identify and Locate Components...........................................................................A-2
Select Suitable Location ........................................................................................A-3
Output Connections...............................................................................................A-3
Input Connections..................................................................................................A-6
Code Requirements ..............................................................................................A-6
Undercarriage Assembly .......................................................................................A-7
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description...............................................................................................B-1
Design Features..............................................................................................B-1,B-2
Welding Capability.................................................................................................B-2
Limitations..............................................................................................................B-2
Controls and Settings ............................................................................................B-2
Welding Operations ...............................................................................................B-3
Overload Protection...............................................................................................B-6
Learning to Weld....................................................................................................B-7
Application Chart .................................................................................................B-18
________________________________________________________________________
Accessories.....................................................................................................Section C
Optional Accessories.............................................................................................C-1
Replacement Parts................................................................................................C-2
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Items Requiring No Maintenance ..........................................................................D-1
Routine Maintenance.............................................................................................D-1
Gun and Cable Maintenance.................................................................................D-2
Component Replacement Procedures ..................................................................D-3
Changing Liner ......................................................................................................D-4
Gun Handle Parts..................................................................................................D-4
________________________________________________________________________
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.........................................................................E-2 THRU E-4
________________________________________________________________________
Wiring Diagrams..............................................................................................Section F
SP-135T Wiring Diagram.......................................................................................F-1
________________________________________________________________________
Parts Lists .....................................................................................P442 Series, P202-E
________________________________________________________________________
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – WELD-PAK 3200HD
INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency
Input Current
20 Amps - Rated Output
120V/60Hz
RATED OUTPUT
Duty Cycle
20% Duty Cycle
Amps
Volts at Rated Amperes
90
19
OUTPUT
Maximum-Open Circuit Voltage
29V
Welding Current Range
25-135 Amps
50 - 300 in/min
(1.3 - 7.6 m/min)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse or
Output Mode Input Voltage Breaker Size1 Input Amps
Power Cord
Extension Cord
Three Conductor
#14 AWG
2
(2.1 mm ) or Larger
Up to 25 Ft. (7.6 mm)
RATED
120V/60Hz
20 Amp
20
15 Amp, 125V,
Three Prong Plug
(NEMA Type 5-15P)
Three Conductor
#12 AWG
2
(3.3 mm ) or Larger
Up to 50 Ft. (15.2 mm)
PHYSICAL DIMENSIONS
Height
Width
Depth
Weight
12.0 in
9.75 in
248 mm
16.5 in
419 mm
48 Ibs
305 mm
21.8 kg
1If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.
WELD PAK 3200HD
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A-2
A-2
INSTALLATION
Read entire installation section before starting
installation.
11. Undercarriage:
a) Base
b) Gas bottle support base
c) (2) Gas bottle support brackets
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
For available options and accessories refer to the
Accessories Section of this manual.
• Only qualified personnel should perform
this installation.
1) 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.
• Only personnel that have read and under-
stood 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.
FIGURE A.1
• 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.
2
1
IDENTIFY AND LOCATE
COMPONENTS
If you have not already done so, unpack the WELD-
PAK 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):
4
1. WELD-PAK 3200HD
6
(1)
2. Gun and cable assembly
3
7
3. Literature and miscellaneous including:
a) This operating manual
5
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.
9
4. 10 ft (3.0 m) work cable.
8
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
WELD-PAK 3200HD
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A-3
A-3
INSTALLATION
Work Clamp Installation
SELECT SUITABLE LOCATION
Attach the work clamp per the following:
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.
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 A-3.
STACKING
3. Fasten securely with the bolt and nut provided.
WELD-PAK 3200HD cannot be stacked.
TILTING
FIGURE A.3
Each machine must be placed on a secure, level sur-
face, either directly or on either recommended cart.
The machine may topple over if this procedure is not
followed.
Strain Relief Hole
Work Cable
Nut & Bolt
OUTPUT CONNECTIONS
Refer to Figure A.2.
Work Clamp
1. Work Cable Access Hole.
2. Gun Cable and Control Lead Access Hole.
3. Connector Block.
4. Gun Trigger Lead Connectors.
5. Positive (+) and negative (–) output terminals.
6. Wire Feed Gearbox.
7. Cable Hanger.
8. Thumbscrew.
4
5
+
-
8
6
3
7
1
2
FIGURE A.2
WELD-PAK 3200HD
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A-4
A-4
INSTALLATION
Connecting Gun Cable to the WELD-PAK
Work Cable Installation
Refer to Figure A.2.
3200HD.
1. Refer to Figure A.2. Unplug the machine or turn
power switch to the OFF “O” position.
1. Open the wire feed section door on the right side of
the WELD-PAK 3200HD.
2. Pass the insulated terminals of the gun trigger con-
trol leads, one at a time, through the Gun Cable
and Control Lead Access Slot (2) in the case front.
The leads are to be routed under the Wire Feed
Gearbox (6) and through the Cable Hanger (7) on
the inner panel.
2. Pass the end of the work cable that has the termi-
nal lug with the smaller hole through the Work
Cable Access Hole (1) in the case front.
3. Route the cable under and around the back of the
Wire Feed Gearbox (6).
3. Insert the connector on the gun conductor cable
through the Gun Cable Access Hole (2) in the
WELD-PAK 3200H case front. Make sure the con-
nector is all the way in the brass connector block.
Unscrew thumbscrew on the connector block a few
turns if gun connector will not insert fully. Rotate
the connector so control leads are on the under-
side and tighten the Thumbscrew (8) in the con-
nector block.
4. For Innershield Only: Refer to Figure A.4. As
delivered, The machine is connected for negative
polarity (required for the Innershield process), con-
nect the short cable attached to the connector
block (1) to the negative (–) output terminal (2) and
the work cable (3) to the positive (+) terminal (4).
5. For GMAW Only: Refer to Figure A..2. To wire for
positive electrode polarity. the appropriate configu-
ration for the GMAW (MIG) process use the provid-
ed wing nut to connect the work cable’s terminal
lug to the negative (–) output terminal (5) located
above the Wire Feed Gearbox (6). Make sure that
both wing nuts are tight.
4. Connect the gun trigger control lead terminals to
the two insulated 1/4" (6.4 mm) tab terminal con-
nector bushings located below the “Gun Trigger
Connection” decal in the wire feed section (4).
Either lead can go to either connector. Form the
leads so that they are as close as possible to the
inside panel.
4
3
CAUTION
2
If the gun trigger switch being used is other than
that supplied with the WELD-PAK 3200HD, the
switch must be a normally open, momentary
switch. The terminals of the switch must be insu-
lated from the welding circuit. Malfunction of the
WELD-PAK 3200HD may result if this switch
shorts to the WELD-PAK 3200HD welding output
circuit or is common to any electrical circuit other
than the WELD-PAK 3200HD trigger circuit.
1
GAS CONNECTION
FIGURE A.4
GUN INSTALLATION
When using the GMAW process, a cylinder of shield-
ing gas, must be obtained. For more information about
selecting gas cylinders for use with the WELD-PAK
3200HD refer to the ACCESSORIES section.
As shipped from the factory, the WELD-PAK 3200HD
is ready to feed .023”-.025" (0.6 mm) solid wire. If
.030 (0.8mm) solid wire. If .030" (0.8 mm) solid wire is
to be used, change the contact tip to the appropriate
size.
NOTE: If .035" (0.9 mm) Innershield flux-cored wire is
to be used, assemble the mig nozzle and .035” tip on
to gun and reverse drive roll.
WELD-PAK 3200HD
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A-5
A-5
INSTALLATION
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 an
instant. This blows away any dust or dirt which may
have accumulated in the valve outlet.
WARNING
CYLINDER may explode if dam-
aged. Keep cylinder upright and
chained to support
• Keep cylinder away from areas
where it may be damaged.
WARNING
• Never lift welder with cylinder
attached.
BE SURE TO KEEP YOUR FACE AWAY FROM
THE VALVE OUTLET WHEN “CRACKING” THE
VALVE. Never stand directly in front of or behind
the flow regulator when opening the cylinder
valve. Always stand to one side.
• Never allow welding electrode to
touch cylinder.
• Keep cylinder away from welding
or other live electrical circuits.
3. Attach the flow regulator to the cylinder valve and
tighten the union nut securely with a wrench.
WARNING
NOTE: If connecting to 100% CO cylinder, make
BUILDUP OF SHIELDING GAS may
harm health or kill.
2
certain the plastic washer is seated in the fitting
that attaches to the CO cylinder.
2
• Shut off shielding gas supply
when not in use.
4. Refer to Figure A.6. Attach one end of inlet gas
hose to the outlet fitting of the flow regulator and
tighten the union nut securely with a wrench.
Connect the other end to the WELD-PAK 3200HD
Gas Solenoid Inlet Fitting (5/8-18 female threads
— for CGA —.032 fitting). Make certain the gas
hose is not kinked or twisted.
• SEE AMERICAN NATIONAL
STANDARD Z-49.1, “SAFETY IN
WELDING AND CUTTING” PUB-
LISHED BY THE AMERICAN
WELDING SOCIETY.
1. Chain the cylinder to a wall or other stationary sup-
port to prevent the cylinder from falling over, if not
using undercarriage. Insulate the cylinder from the
work circuit and earth ground. Refer to Figure A.5.
Cylinder Valve
Flow Regulator
Gas Hose
FIGURE A.5
WELD-PAK 3200HD
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A-6
A-6
INSTALLATION
Requirements For Rated Output
INPUT CONNECTIONS
Refer to Figure A.6.
A power cord with a 15 amp, 125 volt, three prong
plug (NEMA Type 5-15P) is factory installed on the
WELD-PAK 3200HD. Connect this plug to a mating
grounded receptacle which is connected to a 20 amp
branch circuit with a nominal voltage rating of 115 to
125 volts, 60 Hertz, AC only.
The WELD-PAK 3200HD has a power input cable
located on the rear of the machine.
The rated output with this installation is 90 amps,19
Volts, 20% duty cycle (2 minutes of every 10 minutes
used for welding).
GAS SOLENOID
INLET FITTING
CAUTION
POWER INPUT
CABLE
Do not connect the WELD-PAK 3200HD to an input
power supply with a rated voltage that is greater
than 125 volts.
Do not remove the power cord ground prong.
FIGURE A.6
CODE REQUIREMENTS FOR INPUT
CONNECTIONS
WARNING
This welding machine must be connected to a
power source in accordance with applicable elec-
trical codes.
The United States National Electrical Code (Article
630-B, 1990 Edition) provides standards for
amperage handling capability of supply conduc-
tors based on duty cycle of the welding source.
If there is any question about the installation
meeting applicable electrical code requirements,
consult a qualified electrician.
WELD-PAK 3200HD
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A-7
A-7
INSTALLATION
10. Tighten Gas Bottle Support Brackets with supplied
1/4"-20 wing screws and wing nuts.
UNDERCARRIAGE ASSEMBLY
WARNING
FIGURE A.7
CYLINDER may explode
if damaged.
3
• Keep cylinder upright and secured
to support.
• Keep cylinder away from areas where it may be
damaged.
• Never lift welder with cylinder attached.
• Never allow welding electrode to touch cylinder.
• Keep cylinder away from welding or other live
electrical circuits.
6
7
• The undercarriage is not intended for transport-
ing the Weld-Pak 3200HD.
• If the Weld-Pak 3200HD is going to be transport-
ed, remove the under-carriage.
• Do not lift the Weld-Pak 3200HD when a gas bot-
tle is connected.
2
1
4
5
• If the Weld-Pak 3200HD is going to be moved or
lifted, remove the gas bottle.
------------------------------------------------------------------------
(Refer to Figure A.7)
Note: The following instructions assume a gas bottle
is going to be used. If a gas bottle is not going to be
used, skip steps 5 and steps 7-10.
1. Remove both sheet metal screws (1) from case.
2. Align undercarriage base (2) with side mount screw
holes as shown. Make sure the two caster mount-
ing holes are located in front of the machine.
3. Replace sheet metal screws removed in step 1
making sure to secure undercarriage to the Weld-
Pak 3200HD (1).
4. Use both supplied black round head screws to
secure door side of the Weld-Pak 3200HD (3) to
undercarriage.
5. Attach Gas Bottle Support Base to rear of undercar-
riage using supplied 1/4"-20 fasteners (4).
6. Attach the supplied fixed casters to the rear of the
undercarriage assembly (5).
7. Attach the supplied swivel caster to the front of the
undercarriage with the supplied 5/16" acorn nuts.
8. Attach both Gas Bottle Support Brackets (6) as
shown.
9. Insert gas bottle if available.
WELD-PAK 3200HD
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B-1
B-1
OPERATION
Read entire operation section before
operating the WELD-PAK 3200HD.
GENERAL DESCRIPTION
The WELD-PAK 3200HD is a complete semiautomatic
constant-voltage DC wire feeder / power source arc
welder. It has been designed for workshop, hobby,
automotive and light maintenance. Included is a tap-
switch controlled, single phase constant voltage trans-
former / rectifier power source and a wire feeder weld-
ing gun for feeding .023 - .025” (0.6 mm) through
.030” (0.8 mm) solid steel electrode and .035” (0.9
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrode with skin or
wet clothing. Insulate yourself
from work and ground.
®
mm) Innershield NR-211-MP flux-cored wire.
The WELD-PAK 3200HD is ideally suited for individu-
als having access to 120 volt AC input power, and
wanting the ease of use, quality and dependability of
both gas metal arc welding or GMAW (also known as
MIG welding) and the Innershield electrode process
(self shielded flux cored or FCAW). The WELD-PAK
3200HD is a rugged and reliable machine that has
been designed for dependable service and long life.
• Always wear dry insulating
gloves.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
RECOMMENDED PROCESSES
The WELD-PAK 3200HD can be used for welding
mild steel using the Gas Metal Arc Welding (GMAW or
MIG, Metal Inert Gas) single pass process, which
requires a supply of shielding gas, or the flux-cored
WELDING SPARKS can
cause fire or explosion.
• Keep flammable material away.
®
arc welding (FCAW) process using Innershield elec-
trode wire. The WELD-PAK 3200HD is configured for
use with the FCAW process as delivered from the fac-
tory.
• Do not weld on closed contain-
ers.
OPERATIONAL CONTROLS
The WELD-PAK 3200HD has the following controls as
standard: Control Power ON/OFF Switch, Voltage
Control, Wire Speed Control, Trigger Switch, and a
Circuit Breaker. With the optional Spot/Stitch Timer Kit
installed, the following controls are also included:
Mode switch and Time Control.
ARC RAYS can burn eyes
and skin.
• Wear eye, ear and body protec-
tion.
DESIGN FEATURES
● Operates on 120 volt input — no special wiring
required.
● “Cold electrode” until gun trigger is pressed for an
added measure of safety.
Observe all safety information throughout
this manual.
● Overload protection — incorporates both a thermo-
stat and a circuit breaker.
● Quality wire drive with electronic overload protec-
tion.
● “Quick Release” idle roll pressure arm is easily
adjusted.
● Reversible, dual groove drive roll. Drive roll will
feed .023 – .025” (0.6 mm) and .030" - .035" (0.8 -
0.9 mm) diameter wire.
WELD-PAK 3200HD
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B-2
B-2
OPERATION
● No external shielding gas is required when used
Refer to Figure B.1b.
4. Circuit Breaker – Protects machine from damage if
®
with Lincoln Innershield .035” (0.9 mm) NR-211-
MP electrode.
maximum output is exceeded. Button will extend
out when tripped (Manual reset) Refer to Figure B.1b
.
● Accommodates both 4” (100 mm) diameter and 8”
(200 mm) diameter spools of wire.
5. Gun Trigger - Activates welding output, wire feed,
and gas solenoid operation. Releasing the trigger
deactivates welding and simultaneously activates
the “burnback” function so that the welding wire
does not stick in the weld puddle.
WELDING CAPABILITY
The WELD-PAK 3200HD is rated at 90 amps, 19
volts, at 20% duty cycle on a ten minute basis. It is
capable of higher output currents at lower duty cycles.
LIMITATIONS
Arc Gouging cannot be performed with the WELD-
PAK 3200HD. The WELD-PAK 3200HD is not recom-
mended for pipe thawing or TIG welding.
CONTROLS AND SETTINGS
Refer to Figure B.1a.
1. Control Power ON/OFF Switch
— When the power is on the
fan motor will run and air will be
exhausted out the louvers in the
front of the machine. The weld-
ing output and wire feeder
remain off until the gun trigger
is pressed.
OFF
2. Wire Speed Control —
ON
Controls the wire feed speed
from 50 – 300 in /min (1.3 –
7.6 m/min). The control can
be preset on the dial to the
setting specified on the
WIRE SPEED
W E L D P A K 3 2 0 0 H D
Application Chart located on
the inside of the wire feed
section door.
3. Voltage Control — A 4-posi-
tion tap selector switch gives
full range adjustment of
power source output voltage.
Do not switch while welding.
ARC VOLTS
WELD-PAK 3200HD
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B-3
B-3
OPERATION
Note:When loading and removing the 8” Spools make
sure that the wing nut (inside the wire spool spindle
hub) is turned 90° from the wire spool spindle locking
tab. If the wing nut is positioned in line with the locking
tab, the tab cannot be depressed to load or unload the
wire spool.
2
1
FIGURE B.2
3
DO NOT SWITCH
WHEN WELDING
Wire Spool Spindle
8” Wire Spool
FIGURE B.1a
Be sure that this stud engages
the hole in the wire spool.
To Wire Drive
Wire Spool must be pushed all the way on the spindle so that the
spindle’s tab will hold it in place. The Wire Spool will rotate clock-
wise when wire is dereeled.
Load an 8” (200 mm) diameter spool on the wire spool
spindle shown in Figure B.2.
To use 4” (100 mm) diameter spools, the 2” (50 mm)
diameter spindle must be removed (See Figure B.3).
Remove the wing nut and spacer at the end of the
shaft and remove the outside plastic wire spool spin-
dle. The spindle can be stored in the wire feed com-
partment. A 4” (100 mm) diameter spool is mounted
directly on the 5/8” (16 mm) diameter shaft and held in
place with the previously removed hardware. Also
make certain the start end of the wire, which may pro-
trude through the side of the spool does not contact
any metallic case parts.
FIGURE B.1b
WELDING OPERATIONS
SEQUENCE OF OPERATION
Wire Loading
Refer to Figures B.2 and B.3.
FIGURE B.3
The machine power switch should be turned to the
OFF (“O”) position before working inside the wire feed
enclosure.
4" Wire Spool
Wire Spindle Shaft
The welder is shipped from the factory ready to feed
8" (200 mm) diameter spools with 2.2" (56 mm) maxi-
mum width. These spools fit on a 2" (51 mm) diameter
spindle that has a built in, adjustable friction brake to
prevent overrun of the spool and excess slack in the
wire.
Wing Nut
and Spacer
To Wire Drive
WELD-PAK 3200HD
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B-4
B-4
OPERATION
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. Tighten
the wing nut an additional 1/4 turn.
2
Note: When properly adjusted, the brake should pro-
vide only enough drag to prevent overrun of the spool
and excess slack in the wire. Too much drag may
result in wire feeding problems, and may cause pre-
mature wear of wire drive system components.
1
4
5
The Wire Drive Feed Roll can
accommodate two wire sizes
by flipping the wire drive feed
roll over.
3
Wire Threading
Refer to Figure B.4
1. Release the Spring Loaded Pressure Arm (1)
rotate the Idle Roll Arm (2) away from. the Wire
Feed Drive Roll (3). Ensure that the groove size in
the feeding position on the drive roll matches the
wire size being used.
FIGURE B.4
7. Refer to Figure B.5. Remove gas nozzle and con-
tact tip from end of gun.
2. Carefully detach the end of the wire from the
spool. To prevent the spool from unwinding,
maintain tension on the wire until after step 5.
8. Turn the WELD-PAK 3200HD ON (“I”).
9. Straighten the gun cable assembly.
3. Cut the bent portion of wire off and straighten the
10. Depress the gun trigger switch and feed welding
wire through the gun and cable. (Point gun away
from yourself and others while feeding wire.)
Release gun trigger after wire appears at end of
gun.
first 4” (100 mm).
4. Thread the wire through the In-going guide tube
(4), over the drive roll (3), and into the out-going
guide tube (5).
11. Turn the WELD-PAK 3200HD OFF (“O”).
5. Close the idle roll arm (2) and latch the spring
loaded pressure arm (1) in place. Rotate the spool
counterclockwise if required in order to take up
extra slack in the wire.
12. Replace contact tip and gas nozzle.
13. Refer to Figure B-6. Cut the wire off 1/4” – 3/8” (6
– 10 mm) from the end of the tip. The WELD-PAK
3200HD is now ready to weld.
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). If feeding problems occur because the wire
is flattened excessively, turn the pressure adjust-
ment counter-clockwise to reduce distortion of the
wire. Slightly less pressure may be required when
using 0.023 – 0.025" (0,6 mm) wire. If the drive roll
slips while feeding wire, the pressure should be
increased until the wire feeds properly.
Gun Handle
Gas Diffuser/
Contact Tip
Gas Nozzle
WARNING
When inching the welding wire, the drive rolls, the
gun connector block and the gun contact tip are
electrically energized relative to work and ground
and remain energized for several seconds after
the gun trigger is released.
FIGURE B.5
WELD-PAK 3200HD
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B-5
B-5
OPERATION
6. Refer to Figure B.7. Connect work clamp to metal
to be welded. Work clamp must make good elec-
trical contact to the workpiece. The workpiece
must also be grounded as stated in “Arc Welding
Safety Precautions” in the beginning of this manu-
al.
Contact Tip
7. Position gun over joint. End of wire may be lightly
touching the work.
Wire Electrode
3/8" – 1/2" Electrical Stickout
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).
FIGURE B.6
9. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.
Making A Weld
1. See “Process Guidelines” in this section for selec-
tion of welding wire and shielding gas and for
range of metal thicknesses that can be welded.
10. When no more welding is to be done, close valve
on gas cylinder (if used), momentarily operate gun
trigger to release gas pressure, and turn off the
WELD-PAK 3200HD.
2. See the Application chart on the inside of the wire
feed compartment door for information on setting
the WELD-PAK 3200HD controls. Refer to Table
B.1 for aluminum and stainless wire.
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 spat-
ter removal.
3. Set the Voltage (“V”) and Wire Speed (“olo’”) con-
trols to the settings suggested for the welding wire
and base metal thickness being used, refer to
Applications chart on the inside of the wire drive
compartment door.
4. Check that the polarity is correct for the welding
wire being used and that the gas supply, if
required, is turned on.
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).
5. When using Innershield electrode, remove the gas
nozzle and install the gasless nozzle. This will
improve visibility of the arc and protect the gas dif-
fuser from weld spatter. Refer to the MAINTE-
NANCE section for details on nozzle replacement.
®
The recommended gases and electrodes for GMAW
are welding grade CO gas or an argon-CO blended
2
2
gas (75 to 80% argon and 25 to 20% CO ) and .025"
2
(0.6 mm) diameter Lincoln L-56 mild-steel welding
wire, supplied on 12-1/2 lb (5.7 kg) spools. The blend-
ed gas is recommended for welding on heavier steel,
14 gauge (2.0 mm), for example.
GUN CABLE
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.
WORKPIECE
ARC
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.
WORK CLAMP
FIGURE B.7
WELD-PAK 3200HD
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B-6
B-6
OPERATION
The WELD-PAK 3200HD is suitable for .035" alu-
minum wire and .030" stainless wire. Refer to Table
B.1 for recommended procedure settings (requires
K499 Argon Regulator Kit).
2. If using a regulator with an adjustable flow meter,
close the gun trigger and adjust the flow to give 15
– 20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20
– 25 CFH (10 – 12 I/min) when welding out of
position or in a drafty location for CO ]. For argon
2
TABLE B.1
mixed gas, trigger to release gas pressure, and
adjust the flow to give 25 – 30 CFH (12 – 14
I/min).
Voltage/Wire Speed
Shielding
Gas
Process Welding Wire
16 ga 14 ga 12 ga 10 ga
MIG DC+ .035 Dia
4043 Aluminum
Wire
100% Argon B-5
D-7
C-7
C-6
D-9
D-9
3. Keep the cylinder valve closed, except when using
the WELD-PAK 3200HD. When finished welding:
MIG DC+ .035 Dia
5356 Aluminum
Wire
100% Argon B-5
D-9
D-10
a) Close the cylinder valve to stop gas flow.
MIG DC+ .030 Dia
308L Stainless
Steel Wire
98% Argon/
2% Oxygen
A-3
D-7.5 D-7.5
b) Depress the gun trigger briefly to release the
pressure in the gas hose.
c) Turn off the WELD-PAK 3200HD.
WELDING WITH FCAW (Innershield)
CHANGING MACHINE OVER TO
FEED OTHER WIRE SIZES
When using the FCAW process, the correct drive roll
and electrode polarity must be used. See Work Cable
Installation in INSTALLATION section for changing
the polarity.
The WELD-PAK 3200HD is shipped from the factory
ready to feed 023”-.025” (0.6 mm) diameter wire. To
operate the WELD-PAK 3200HD 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 Tip and Changing the Drive
Roll, in the MAINTENANCE section, for specific infor-
mation on these procedures.
OVERLOAD PROTECTION
Output Overload
The WELD-PAK 3200HD is equipped with a circuit
breaker and a thermostat which protects the machine
from damage if maximum output is exceeded. The cir-
cuit breaker button will extend out when tripped. The
circuit breaker must be manually reset.
WELDING WITH GMAW (MIG)
Shielding Gas
Thermal Protection
When using the GMAW process, obtain and install a
The WELD-PAK 3200HD has a rated output duty
cycle of 20%. If the duty cycle is exceeded, a thermal
protector will shut off the output until the machine
cools to a reasonable operating temperature. This is
an automatic function of the WELD-PAK 3200HD and
does not require user intervention. The fan continues
to run during cooling.
gas regulator and hose kit; K463 (for CO ) or K499
(Argon mixed) gas regulator and hose kit.
2
1. For CO , open the cylinder very slowly. For argon-
2
mixed gas, open cylinder valve slowly a fraction of
a turn. When the cylinder pressure gauge pointer
stops moving, open the valve fully.
Electronic Wire Drive Motor Protection
The WELD-PAK 3200HD has built-in protection for
wire drive motor overload.
WELD-PAK 3200HD
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B-7
B-7
LEARNING TO WELD
LEARNING TO WELD
WARNING
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 infor-
mation, order a copy of “New Lessons in Arc Welding”
listed at the end of this manual.
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.
THE ARC-WELDING CIRCUIT
• Keep out of reach of children.
The OPERATORS knowledge of arc welding must go
beyond the arc itself. The operator must know how to
control the arc, and this requires a knowledge of the
welding circuit and the equipment that provides the
electric current used in the arc. Figure B.7 illustrates
the welding circuit for a typical welding machine. The
circuit begins where the gun cable is attached to the
welding machine. Current flows through the gun
cable, gun, and contact tip, to the wire and across the
arc. On the work side of the arc, current flows through
the base metal to the work cable and back to the
welding machine. This circuit must be complete for the
current to flow.
• Follow all safety precautions
found in this operating manual.
The gun and cable assembly is held by the operator
who guides the automatically fed wire along the joint,
maintaining a contact tip to work distance of about 3/8
to 1/2 inch (10 – 12 mm) This is called electrical stick-
out. This electrical stickout (ESO) must be properly
maintained by the operator. The electric arc is made
in the gap between the work and the tip end of a small
diameter wire. When the power source is properly set,
the arc gap is maintained automatically.
This machine’s welding circuit has a voltage output of
32 volts DC maximum. This voltage is quite low and is
only present when the gun triggers depressed.
Arc welding is a manual skill requiring a steady hand,
good physical condition, and good eyesight. The oper-
ator controls the welding arc, and, therefore, the quali-
ty of the weld made.
To weld, the work clamp must be tightly connected to
clean base metal. Remove paint, rust, dirt or oil as
necessary and connect the work clamp as close as
possible to the area you wish to weld. This helps pre-
vent current from going through an unwanted path.
Avoid allowing the welding circuit to pass through
hinges, bearings, electronic components, or similar
devices that can be damaged. See Figure B.8. Always
disconnect electrical devices before welding upon
them.
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.
Electronic Components
Burning of core materials
inside wire electrode
results in shield of gas.
Cored Wire
Protective Slag
Arc Stream
Weld Metal
FIGURE B.9
Bearings
Hinges
FIGURE B.8
WELD-PAK 3200HD
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B-8
B-8
LEARNING TO WELD
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 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 GMAW (MIG) WELDING ARC
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.
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.
Gas nozzle
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 ingre-
dients around which a steel sheath has been formed.
It is simply a stick electrode turned inside out in a con-
tinuous wire form.
Solid wire
electrode
Shielding gas
Weld metal
Base metal
FIGURE B.10
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.
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 ingredi-
ents for shielding, and is thus termed Self-Shielded
Flux Cored Arc Welding.
The core materials also melt or burn in the arc and
perform several functions. They make the arc stead-
ier, 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.
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.
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 elec-
trode is recommended for Self-Shielded Flux Cored
Arc Welding.
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:
WELD-PAK 3200HD
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B-9
B-9
LEARNING TO WELD
JOINT TYPES AND POSITIONS
For GMAW (MIG) Process
1. Is most of my welding performed on 16 gauge and
lighter materials?
Five types of welding joints are: Butt Welds, Fillet
Welds, Lap Welds, Edge Welds and Corner Welds.
See Figure B.11.
2. Can I afford the extra expense, space, and lack of
portability required for gas cylinders and gas sup-
ply?
Of these, the Butt Weld and Fillet Weld are the two
most common welds.
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.
Butt weld
Lap weld
For FCAW (Innershield) Process
1. Do I want simplicity and portability?
2. Will welding be performed outdoors or under windy
conditions?
Edge weld
Fillet weld
Corner weld
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?
FIGURE B.11
Butt Welds
5. Weld must be cleaned prior to painting.
Place two plates side by side, leaving a space approx-
imately one half the thickness of the metal between
them in order to get deeper penetration.
COMMON METALS
Securely clamp or tack weld the plates at both ends,
otherwise the heat will cause the plates to move apart.
See Figure B.12.
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 pre-
cautions. Some steels, however, contain higher car-
bon 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”.
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”.
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.
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B-10
B-10
LEARNING TO WELD
45°
FIGURE B.12
FIGURE B.15
Penetration
Welding In The Vertical Position
Unless a weld penetrates close to 100% of the metal
thickness, a butt weld will be weaker than the material
welded together. In the example shown in Figure
B.13, the total weld is only half the thickness of the
material thus the weld is only approximately half as
strong as the metal.
Welding in the vertical position can be done either ver-
tical-up or vertical-down. Vertical-up is used whenever
a larger, stronger weld is desired. Vertical-down is
used primarily on sheet metal 5/32” (3.9 mm) and
under for fast, low penetrating welds.
WARNING
Use of this unit on thicker materials than recom-
mended may result in poor welds. The welds may
“look” good, but may just be “sitting” on top, of
the plate. This is called “Cold Casting” and will
result in weld failure.
FIGURE B.13
FIGURE B.14
Vertical-up And Overhead Welding
The problem, when welding vertical-up, is to put the
molten metal where it is wanted and make it stay
there. If too much molten metal is deposited, gravity
will pull it downwards and make it “drip”. Therefore, a
certain technique has to be followed.
When welding out-of-position, run stringer beads.
Don’t whip, break the arc, move out of the puddle, or
move too fast in any direction. Use Wire Feed Speed
(WFS) in the low portion of the range. The general
technique and proper gun angle is illustrated in Figure
B.16.
In the example shown in Figure B.14, the joint has
been welded so that 100% penetration could be
achieved. The weld, if properly made, is as strong as
or stronger than the original metal.
Generally, keep the electrode nearly perpendicular to
the joint as illustrated. The maximum angle above per-
pendicular may be required if porosity becomes a
problem.
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 B.15.
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B-11
B-11
LEARNING TO WELD
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
PROPER GUN ANGLE
FOR GMAW PROCESS
FOR FCAW PROCESS
WELDING IN THE VERTICAL UP POSITION
WELDING IN THE VERTICAL UP POSITION
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.’’
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.
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.
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.
5. When using Innershield electrode, the gasless noz-
zle may be used instead of a gas nozzle to improve
visibility of the arc.
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.
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 SELF-
SHIELDED 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.)
FIGURE B.17
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.
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B-12
B-12
LEARNING TO WELD
Contact Tip
Wire Electrode
FIGURE B.18
3/8 – 1/2” (10 – 12 mm)
Electrical Stickout (ESO)
WARNING
FIGURE B.19
ARC RAYS can burn eyes and skin.
The easiest way to tell whether the ESO is the cor-
rect 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.
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.
4. The Correct Welding Speed
2. The Correct Way To Strike An Arc
1. Be sure the work clamp makes good electrical
contact to the work.
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 weld-
ing speed. The ridge should be approximately 3/8”
(10 mm) behind the wire electrode.
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 (10 – 12 mm).
Most beginners tend to weld too fast, resulting in a
thin uneven, “wormy” looking bead. They are not
watching the molten metal.
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
Molten puddle
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.
FIGURE B.20
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.
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B-13
B-13
LEARNING TO WELD
Helpful Hints
For the WELD-PAK 3200HD, use the following:
Mild Steel
Electrode
12 gauge or 1/8 inch
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.
(3.0 mm)
0.035" (0.9 mm)
NR-211-MP
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 necessary to go
more slowly in order to get good penetration.
Innershield Wire
Voltage Setting “V”
D
3
Wire Feed Speed “o|o”
3. When welding sheet metal 16 gauge (1.5 mm) and
lighter, heat buildup may cause part warpage and
burn through. One way to eliminate these problems
is to use the back-stepping method illustrated in
Figure B.21.
Refer to Figure B.22.
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.
First weld from A to B; then from C to A; then
from D to C; then from E to D, and so on.
3. Depress gun trigger, hold gun so contact tip to
work distance is about 3/8 to 1/2 inch (10 to 12
mm) and the gun is at proper angle.
B
A
C
D
E
4. After you strike the arc, practice the correct electri-
cal stickout. Learn to distinguish it by its sound.
Back-Stepping
FIGURE B.21
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,
and look at the “ridge” where the metal solidifies.
Practice
The best way of getting practice in the four skills that
enable you to maintain:
6. Run beads on a flat plate. Run them parallel to the
top edge (the edge farthest away from you). This
gives you practice in running straight welds, and
also gives you an easy way to check your
progress. The 10th weld will look considerably bet-
ter than the first weld. By constantly checking on
your mistakes and your progress, welding will soon
be a matter of routine.
1. Correct welding position
2. Correct way to strike an arc
3. Correct electrical stickout
4. Correct welding speed
is to perform the following exercise.
Contact
Tip
ESO
Gun Angle
FIGURE B.22
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B-14
B-14
LEARNING TO WELD
MACHINE SET UP FOR THE GMAW (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.
FIGURE B.23
When using the GMAW process on light gauge mater-
ial, weld from right to left (if you are right handed).
This results in a colder weld and has less tendency for
burn through.
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.’’
2. The Correct Way To Strike An Arc
WARNING
4. Check that the polarity is correct for the welding
wire being used. Set the polarity for DC(+) when
welding with the GMAW (MIG) process. See Work
Cable Installation in the INSTALLATION section for
instructions for changing polarity.
ARC RAYS can burn eyes and skin.
When using an open arc process, it
Is necessary to use correct eye,
head and body protection.
5. Check that the gas nozzle and proper size liner
and contact tip are being used and that the gas
supply is turned on. If adjustable, set for 15 to 20
cubic feet per hour (7 to 10 l/min.) under normal
conditions, increase to as high as 35 CFH (17
I/min.) under drafty (slightly windy) conditions.
Protect yourself and others, read
“ARC RAYS can burn” at the front
of this manual.
1. Be sure the work clamp makes good electrical con-
tact to the work.
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.
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 (10 – 12 mm).
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:
4. To stop welding, release the gun trigger and 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, the ball may be
removed by feeding out a few inches of wire and
cutting off the end of the wire with wire cutters.
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.)
6. When no more welding is to be done, close the
valve on the gas cylinder, momentarily operate the
gun trigger to release gas pressure, then turn off
the machine.
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.)
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B-15
B-15
LEARNING TO WELD
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.
Contact Tip
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 necessary to go
more slowly in order to get good penetration.
Wire Electrode
ESO
3. When welding sheet metal 16 gauge (1.5 mm) and
lighter, heat buildup may cause part warpage and
burn through. One way to eliminate these problems
is to use the back-stepping method illustrated in
Figure B.21.
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.
Practice
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 best way of getting practice in the four skills that
enable you to maintain:
1. Correct welding position
2. Correct way to strike an arc
3. Correct electrical stickout
4. Correct welding speed
The easiest way to tell whether the ESO is the cor-
rect 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.
is to perform the following exercise.
4. The Correct Welding Speed
For the WELD-PAK 3200HD, use the following:
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 weld-
ing speed. The ridge should be approximately 3/8”
(10 mm) behind the wire electrode.
Mild Steel
Electrode
16 gauge or 1/16 inch
(1.6 mm)
Lincolnweld 0.025 L-56
electrode
CO
2
Voltage Setting “V”
C
4
Most beginners tend to weld too fast, resulting in a
thin, uneven, “wormy” looking bead. They are not
watching the molten metal.
Wire Feed Speed “o|o”
Refer to Figure B.22.
1. Learn to strike an arc by positioning the gun over
the joint and touching the wire to the work.
Molten puddle
2. Position face shield to protect face and eyes.
Weld metal ridge
Base metal
3. Depress gun trigger, hold gun so contact tip to
work distance Is about 3/8 to 1/2 inch (10 to 12
mm) and the gun is at proper angle.
FIGURE B.25
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B-16
B-16
LEARNING TO WELD
To Reduce Spatter (in order of importance):
TROUBLESHOOTING WELDS
Good welds have excellent appearance.
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.
To Eliminate Porosity (in order of importance):
To Correct Poor Penetration (in order of impor-
tance):
1. Decrease stickout.
2. Increase WFS (wire feed speed).
3. Increase voltage.
1. Turn on gas supply, if used
2. Decrease voltage.
4. Decrease speed.
3. Increase stickout.
5. Decrease drag angle.
6. Check for correct gas, if used.
4. Increase WFS (wire feed speed).
5. Decrease drag angle.
6. Decrease travel speed.
If Arc Blow Occurs (in order of importance):
NOTE: Try different ground connection locations
before adjusting procedures.
NOTE: Always be sure the joint is free from moisture,
oil, rust, paint or other contaminant's.
1. Decrease drag angle.
2. Increase stickout.
To Eliminate a Ropy Convex Bead
(in order of importance):
3. Decrease voltage.
4. Decrease WFS (wire feed speed.
5. Decrease travel speed.
To Eliminate Stubbing* (in order of importance):
1. Increase voltage
2. Decrease WFS (wire feed speed)
3. Decrease stickout
1. Increase voltage.
2. Decrease stickout.
4. Increase drag angle
3. Decrease WFS (wire feed speed.
4. Decrease travel speed.
5. Decrease drag angle.
6. Check for correct gas, if used.
* Stubbing occurs when the electrode drives through
the molten puddle and hits the bottom plate tending
to push the gun up.
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B-17
B-17
LEARNING TO WELD
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 electrode has proper surface lubrica-
tion. Use only clean, rust-free electrode.
6. Replace contact tip when it becomes worn or the
end is fused or deformed.
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B-18
B-18
APPLICATION CHART
WELD-PAK 3200HD
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C-1
C-1
ACCESSORIES
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.
OPTIONAL ACCESSORIES
1. K664-2 Aluminum Feeding Kit — This kit
required for welding with .035 Aluminum wire.
Included with this kit are a drive roll, liner and con-
tact tip. It is important when changing between
welding with steel wire and aluminum to
exchange these components due to the lubri-
cant applied to steel wire. Failure to do so may
result in contaminated welds when welding alu-
minum.
4. K586-1 Deluxe Adjustable Gas Regulator &
Hose Kit
Accommodates CO or mixed Gas Cylinders.
2
2. KP665-045C Drive Roll – Optional — Knurled
drive roll for feeding .035 (0.9 mm) diameter flux-
cored electrode.
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C-2
C-2
ACCESSORIES
REPLACEMENT PARTS
Liner .035/.045” (0.9/1.2 mm)
M16291-1
Complete Gun and Cable Assembly
L8311-5 (K530-4)
Gas Diffuser
S19728
Contact Tip .025” (0.6 mm)
S19726-1
Gas Nozzle
M16294
Contact Tip .030” (0.8 mm)
S19726-2
Gas Nozzle-Tip Recessed 3/8” (9.5 mm)
Opening I.D.
M16684
Contact Tip .035” (0.9 mm)
S19726-3
Gas Nozzle-Tip Recessed 1/2” (12.7 mm)
Contact Tip-Tapered .025” (0.6 mm)
S20278-1
Opening I.D.
M16684-1
Contact Tip-Tapered .030” (0.8 mm)
S20278-2
Gas Nozzle-Tip Recessed 5/8” (15.9 mm)
Opening I.D.
M16684-2
Contact Tip-Tapered .035” (0.9 mm)
S20278-3
Spot Welding Nozzle
M17846
Liner .023 - .030” (0.6 - 0.8 mm)
M16291-2
Gasless Nozzle (Innershield Only)
M16418
Liner .030 - .035” (0.8 - 0.9 mm)
M16291-6
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D-1
D-1
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 elec-
trically “hot” parts inside WELD-PAK
3200HD.
• Have qualified personnel do the mainte-
nance 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 ther-
mal protection. If so, blow dirt out of the welder with low pres-
sure 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.
FAN MOTOR
Has lifetime lubrication — requires no maintenance.
WIRE REEL SPINDLE
Requires no maintenance. Do not lubricate shaft.
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D-2
D-2
MAINTENANCE
2. Replace worn contact tips as required. A variable
or “hunting” arc is a typical symptom of a worn con-
tact tip. To install a new tip, choose the correct size
contact tip for the electrode being used (wire size is
stenciled on the side of the contact tip) and screw it
snugly into the gas diffuser.
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-cored
wire. Remove the cable from the wire feeder and lay it
out straight on the floor. Remove the contact tip from
the gun. Using low pressure air, gently blow out the
cable liner from the gas diffuser end.
3. Remove spatter from inside of gas nozzle and from
tip after each 10 minutes of arc time or as required.
4. Be sure the gas nozzle is fully screwed onto the
diffuser for gas shielded processes. For the
®
Innershield process, the gasless nozzle should
be screwed onto the diffuser.
CAUTION
5. To remove gun tube from gun, remove gas nozzle
or gasless nozzle and remove diffuser from gun
tube. Remove both collars from each end of the
gun handle and separate the handle halves.
Loosen the locking nut holding the gun tube in
place against the gun end cable connector.
Unscrew gun tube from cable connector. To install
gun tube, screw the locking nut on the gun tube as
far as possible. Then screw the gun tube into the
cable connector until it bottoms. Then unscrew (no
more than one turn) the gun tube until its axis is
perpendicular to the flat sides of the cable connec-
tor and pointed in the direction of the trigger.
Tighten the locking nut so as to maintain the proper
relationship between the gun tube and the cable
connector. Replace the gun handle, trigger and dif-
fuser. Replace the gas nozzle or gasless nozzle.
Excessive pressure at the start may cause the dirt
to form a plug.
Flex the cable over its entire length and again blow
out the cable. Repeat this procedure until no further
dirt comes out.
Contact Tips, Nozzles, and Gun Tubes
1. Dirt can accumulate in the contact tip hole and
restrict wire feeding. After each spool of wire is
used, remove the contact tip and clean it by push-
ing a short piece of wire through the tip repeatedly.
Use the wire as a reamer to remove dirt that may
be adhering to the wall of the hole through the tip.
CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM
Contact Tip
Cable Liner
Drive Roll
Components shipped with
S19726-3
M16291-6
KP665-035
WELD-PAK 3200HD•
.035” (0.9mm)
.035” (0.9mm)
2 Smooth grooves
Small .023-.025 (0.6mm)
Large .030” (0.8mm)
K664-2 .035 (0.9mm)
S24221-1
M18971-1
M19631
Aluminum or Stainless Kit*
.035A (0.9mm)
.035” (0.9mm)
• F0r 0.025 wire feeding use the included S19726-1 contact tip.
• If .030 Solid wire feeding is desired obtain an S19726-2 Contact Tip.
* It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire.
Failure to do so may result in contaminated welds when welding aluminum.
WELD-PAK 3200HD
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D-3
D-3
MAINTENANCE
COMPONENT
REPLACEMENT
PROCEDURES
8. Push a length of straightened welding wire through
the wire feeder guide tubes and adjust the position
of the drive roll so that the groove is centered on
the wire. Make certain the set screw is located on
the flat portion of the shaft and tighten.
CHANGING THE CONTACT TIP
1. Refer to Figure D.2. Remove the gas nozzle from
the gun by unscrewing counter-clockwise.
FIGURE D.1
2. Remove the existing contact tip from the gun by
unscrewing counter-clockwise.
3. Insert and hand tighten desired contact tip.
4. Replace gas nozzle.
3
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.
2
1
If .023" – .025" (0.6 mm) wire is to be used, the drive
roll must be reversed as follows:
1. Connect the machine to its rated input power per
instructions in Installation section.
2. Release the spring-loaded idle arm tensioner Item 2, and
lift the idle roll arm, Item 3, away from the drive roll, Item
1. (See Figure D.1)
3. Turn the power switch to ON (marked “I”).
4. Set the wire speed to minimum and jog the drive
unit with the trigger switch until the drive roll set
screw is facing up.
CAUTION
When inching the welding wire, the drive rolls,
gun connector block, and gun contact tip are
energized relative to work and ground and remain
energized for several seconds after the gun trig-
ger is released.
5. Turn the power switch to OFF (marked “O”).
6. Loosen the drive roll set screw with the 5/64" (2.0
mm) hex wrench supplied.
7. Remove the drive roll, flip over and reinstall with the
.023 – .025" (0.6 mm) groove (the smaller groove)
closest to the gearbox.
WELD-PAK 3200HD
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D-4
D-4
MAINTENANCE
1-1/4 (31.8 mm)
Liner Trim Length
Gas Diffuser
Gas Nozzle or
Gasless Nozzle
Set Screw
Brass Cable
Connector
Liner Assembly
(Liner bushing to be sealed tight
against brass cable connector)
FIGURE D.2
Liner trim length
8. Screw the gas diffuser onto the end of the gun tube
and securely tighten.
CHANGING LINER
9. Replace the contact tip and nozzle.
NOTICE: The variation in cable lengths prevents the
interchangeability of liners. Once a liner has been cut
for a particular gun, it should not be installed in anoth-
er gun unless it can meet the liner cutoff length
requirement. Refer to Figure D.2.
GUN HANDLE PARTS
The gun handle consists of two halves that are held
together with a collar on each end. To open up the
handle, turn the collars approximately 60 degrees
counter-clockwise until the collar reaches a stop. Then
pull the collar off the gun handle. If the collars are diffi-
cult to turn, position the gun handle against a corner,
place a screwdriver against the tab on the collar and
give the screwdriver a sharp blow to turn the collar
past an internal locking rib. See Figure D-3.
1. Remove the gas nozzle from the gun by unscrew-
ing counter-clockwise.
2. Remove the existing contact tip from the gun by
unscrewing counter-clockwise.
3. Remove the gas diffuser from the gun tube by
unscrewing counter-clockwise.
4. Lay the gun and cable out straight on a flat surface.
Loosen the set screw located in the brass connec-
tor at the wire feeder end of the cable. Pull the liner
out of the cable.
5. Insert a new untrimmed liner into the connector end
of the cable. Be sure the liner bushing is stenciled
appropriately for the wire size being used.
Counter-clockwise
6. Fully seat the liner bushing into the connector.
Tighten the set screw on the brass cable connector.
At this time, the gas diffuser should not be installed
onto the end of the gun tube.
7. With the gas nozzle and diffuser removed from the
gun tube, be sure the cable is straight, and then
trim the liner to the length shown in the Figure D.2.
Remove any burrs from the end of the liner.
FIGURE D.3
WELD-PAK 3200HD
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E-1
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP-
TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
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.
WELD-PAK 3200HD
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E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage None
is evident.
Contact your local Authorized Field
Service Facility.
No wire feed, weld output or gas
flow when gun trigger is pulled. Fan
does NOT operate.
1. Make sure correct voltage is
applied to the machine (115vac).
2. Make certain that power switch
is in the ON position.
3. Make sure circuit breaker inside
wire drive compartment is reset.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service
Facility.
No wire feed, weld output or gas
flow when gun trigger is pulled Fan
operates normally.
1. The thermostat may be tripped
due to overheating. Let machine
cool. Weld at lower duty cycle.
2. Check for obstructions in air
flow. Check Gun Trigger connec-
tions. See Installation section.
3. Gun trigger may be faulty.
CAUTION
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.
WELD-PAK 3200HD
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E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FEEDING PROBLEMS
No wire feed when gun trigger is
pulled. Fan runs, gas flows and
machine has correct open circuit
voltage (32VDC maximum) – weld
output.
1. If the wire drive motor is running
make sure that the correct drive
rolls are installed in the machine.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service
Facility.
2. Check for clogged cable liner or
contact tip.
3. Check for proper size cable liner
and contact tip.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
GAS FLOW PROBLEMS
Low or no gas flow when gun
trigger is pulled. Wire feed, weld
output and fan operate normally.
1. Check gas supply, flow regulator
and gas hoses.
2. Check gun connection to
machine for obstruction or leaky
seals.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service
Facility.
CAUTION
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.
WELD-PAK 3200HD
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E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
Arc is unstable – Poor starting
1. Check for correct input voltage
to machine – 115vac.
2. Check for proper electrode
polarity for process.
3. Check gun tip for wear or dam-
age and proper size – Replace.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service
Facility.
4. Check for proper gas and flow
rate for process. (For MIG only.)
5. Check work cable for loose or
faulty connections.
6. Check gun for damage or
breaks.
7. Check for proper drive roll orien-
tation and alignment.
8. Check liner for proper size.
CAUTION
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.
WELD-PAK 3200HD
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F-1
F-1
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.
WELD-PAK 3200HD
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NOTES
WELD-PAK 3200HD
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Now Available...12th Edition
New Lessons in Arc Welding
The Procedure Handbook of Arc Welding
Lessons, simply written, cover manipulatory techniques;
machine and electrode characteristics; related subjects,
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How To Read Shop Drawings
The book contains the latest information and application
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Symbols. Detailed discussion tells how engineers and
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on assembly and welding information to shop personnel.
For details write:
Lincoln Welding School
22801 St. Clair Ave.
Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the reader’s ability
to visualize mechanically drawn objects as they will appear
in their assembled form.
and ask for bulletin ED-80 or call 216-383-2259 and ask for the
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187 pages with more than 100 illustrations. Size 8-1/2” x 11”
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Lincoln Welding School
BASIC COURSE
5 weeks of fundamentals
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● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● Keep flammable materials away.
● Wear eye, ear and body protection.
WARNING
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
● Isolez-vous du travail et de la terre.
German
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
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● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
Spanish
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux
tien.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
● Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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• 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
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