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IM546
WELD-PAK 100 PLUS September,1999
For use with machine Code Numbers 10207 and above

For use with machine Code Numbers 10023
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
WEL
importantly, think before you act D-PA
K 10
0
and be careful.
OPERATOR’S MANUAL
• 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
i SAFETY
WARNING ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur-
chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER-
FORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can ARC RAYS can burn.

2.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
1.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
1.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 2.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or FUMES AND GASES
scaffolds; when in cramped positions such as sitting,
kneeling or Iying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 3.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
• DC Manual (Stick) Welder. 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
1.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
1.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
1.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
1.f. Maintain the electrode holder, work clamp, welding cable and 3.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace coming from degreasing, cleaning or spraying operations.
damaged insulation. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
1.g. Never dip the electrode in water for cooling. products.
1.h. Never simultaneously touch electrically “hot” parts of 3.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage especially in confined areas, to insure breathing air is safe.
of both welders.
3.d. Read and understand the manufacturerʼs instructions for this
1.i. When working above floor level, use a safety belt to protect equipment and the consumables to be used, including the
yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
1.j. Also see Items 4.c. and 6. your welding distributor or from the manufacturer.
3.e. Also see item 7b.
Apr. ʻ93
WELD-PAK 100
SAFETY ii
WELDING SPARKS can CYLINDER may explode

cause fire or explosion. if damaged.
4.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 5.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
4.b. Where compressed gases are to be used at the job site, 5.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 5.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
4.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact • A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
4.d. Do not heat, cut or weld tanks, drums or containers until the 5.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 5.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 5.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
(see address above). use.
4.e. Vent hollow castings or containers before heating, cutting or 5.g. Read and follow the instructions on compressed gas
welding. They may explode. cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
4.f. Sparks and spatter are thrown from the welding arc. Wear oil Cylinders,” available from the Compressed Gas Association
free protective garments such as leather gloves, heavy shirt, 1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area.
powered equipment.
4.g. Connect the work cable to the work as close to the welding 6.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building switch at the fuse box before working on
framework or other locations away from the welding area the equipment.
increase the possibility of the welding current passing
6.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate cir-
Electrical Code, all local codes and the manufacturerʼs
cuits. This can create fire hazards or overheat lifting chains
recommendations.
or cables until they fail.
6.c. Ground the equipment in accordance with the U.S. National
4.h. Also see item 7c.
Electrical Code and the manufacturerʼs recommendations.
Mar. ʻ93
WELD-PAK 100
iii SAFETY
FOR ENGINE ELECTRIC AND MAGNETIC
powered equipment. FIELDS
7.a. Turn the engine off before troubleshooting and maintenance may be dangerous
work unless the maintenance work requires it to be running.
____________________________________________________
8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
7.b. Operate engines in open, well-ventilated current creates EMF fields around welding cables and
areas or vent the engine exhaust fumes welding machines
outdoors.
8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
____________________________________________________ before welding.
8.c. Exposure to EMF fields in welding may have other health

7.c. Do not add the fuel near an open flame effects which are now not known.
welding arc or when the engine is running.
Stop the engine and allow it to cool before 8d. All welders should use the following procedures in order to
refueling to prevent spilled fuel from minimize exposure to EMF fields from the welding circuit:
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling 8.d.1. Route the electrode and work cables together - Secure
tank. If fuel is spilled, wipe it up and do not them with tape when possible.
start engine until fumes have been
eliminated. 8.d.2. Never coil the electrode lead around your body.
____________________________________________________ 8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
7.d. Keep all equipment safety guards, covers
and devices in position and in good repair. 8.d.4. Connect the work cable to the workpiece as close as
Keep hands, hair, clothing and tools away possible to the area being welded.
from V-belts, gears, fans and all other
moving parts when starting, operating or 8.d.5. Do not work next to welding power source.
repairing equipment.
____________________________________________________ Mar. ʻ93
7.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
___________________________________________________
7.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
hot.
WELD-PAK 100
SAFETY iv
5. Toujours porter des lunettes de sécurité dans la zone de

PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
Pour votre propre protection lire et observer toutes les instruc- zones où lʼon pique le laitier.
tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté 6. Eloigner les matériaux inflammables ou les recouvrir afin de
générales suivantes: prévenir tout risque dʼincendie dû aux étincelles.
Sûreté Pour Soudage A LʼArc 7. Quand on ne soude pas, poser la pince à une endroit isolé de
1. Protegez-vous contre la secousse électrique: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours 8. Sʼassurer que la masse est connectée le plus prés possible
tout contact entre les parties sous tension et la peau nue de la zone de travail quʼil est pratique de le faire. Si on place
ou les vétements mouillés. Porter des gants secs et sans la masse sur la charpente de la construction ou dʼautres
trous pour isoler les mains. endroits éloignés de la zone de travail, on augmente le risque
b. Faire trés attention de bien sʼisoler de la masse quand on de voir passer le courant de soudage par les chaines de lev-
soude dans des endroits humides, ou sur un plancher age, câbles de grue, ou autres circuits. Cela peut provoquer
metallique ou des grilles metalliques, principalement dans des risques dʼincendie ou dʼechauffement des chaines et des
les positions assis ou couché pour lesquelles une câbles jusquʼà ce quʼils se rompent.
grande partie du corps peut être en contact avec la
masse. 9. Assurer une ventilation suffisante dans la zone de soudage.
c. Maintenir le porte-électrode, la pince de masse, le câble Ceci est particuliérement important pour le soudage de tôles
de soudage et la machine à souder en bon et sûr état galvanisées plombées, ou cadmiées ou tout autre métal qui
defonctionnement. produit des fumeés toxiques.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir. 10. Ne pas souder en présence de vapeurs de chlore provenant
e. Ne jamais toucher simultanément les parties sous tension dʼopérations de dégraissage, nettoyage ou pistolage. La
des porte-électrodes connectés à deux machines à soud- chaleur ou les rayons de lʼarc peuvent réagir avec les
er parce que la tension entre les deux pinces peut être le vapeurs du solvant pour produire du phosgéne (gas forte-
total de la tension à vide des deux machines. ment toxique) ou autres produits irritants.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions 11. Pour obtenir de plus amples renseignements sur la sûreté,
pour le porte-électrode sʼapplicuent aussi au pistolet de voir le code “Code for safety in welding and cutting” CSA
soudage. 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 nʼimporte quelle
partie du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
TRANSFORMATEUR ET À
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du
rayonnement de lʼarc et des projections quand on soude 1. Relier à la terre le chassis du poste conformement au code
ou quand on regarde lʼarc. de lʼélectricité et aux recommendations du fabricant. Le dis-
b. Porter des vêtements convenables afin de protéger la positif de montage ou la piece à souder doit être branché à
peau de soudeur et des aides contre le rayonnement de une bonne mise à la terre.
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au 2. Autant que possible, Iʼinstallation et lʼentretien du poste
soudage à lʼaide dʼécrans appropriés et non-inflamma- seront effectués par un électricien qualifié.
bles.
3. Avant de faires des travaux à lʼinterieur de poste, la
4. Des gouttes de laitier en fusion sont émises de lʼarc de debrancher à lʼinterrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection
libres de lʼhuile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leur
pantalons sans revers, et chaussures montantes. place.
Mar. ʻ93
WELD-PAK 100
v
for selecting a QUALITY product by Lincoln Electric.

Thank You 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!
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.
Code Number _____________________________________
Serial Number _____________________________________
Model Name _____________________________________
Date of Purchase __________________________________
Whenever you request replacement parts for or information on this equipment always supply the information you
have recorded above.
Read this Operatorʼs 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.
WELD-PAK 100
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
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description ...............................................................................................B-2
Design Features and Advantages...................................................................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
Accessories ...........................................................................................................C-1
Replacement Parts ................................................................................................C-1
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-2
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Wiring Diagrams ..............................................................................................Section F

WELD-PAK 100 Wiring Diagram ...........................................................................F-1
WELD-PAK 100 Parts Manual.........................................................................Appendix
FEB 95 WELD-PAK 100

vii
WELD-PAK 100
INSTALLATION A-1
TECHNICAL SPECIFICATIONS – WELD-PAK 100

INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current
115V/60Hz 20 Amps - Rated Output
115V/60Hz 15 Amps - CSA Rated output
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
20% Duty Cycle 88 18
20% Duty Cycle – CSA Rated Output 62 20
OUTPUT
Welding Current Range (Continuous) Maximum Open Circuit Voltage Auxiliary Power
Rated DC Output: 0 - 88 amps 32 N/A
CSA Rated DC Output: 0 - 62 amps
RECOMMENDED INPUT CABLE AND FUSE SIZES

Fuse or
Output Mode Input Voltage Breaker Size Input Amps Power Cord Extension Cord
RATED 115V/60Hz 20 Amp 20 15 Amp, 125V, Three Conductor

Three Prong Plug #14 AWG
(NEMA Type 5-15P) (2.1 mm2) or Larger
Up to 25 Ft. (7.6 mm)
CSA 115V/60Hz 15 Amp 12 15 Amp, 125V, Three Conductor
Three Prong Plug #12 AWG
(NEMA Type 5-15P) (3.3 mm2) or Larger
Up to 50 Ft. (15.2 mm)
PHYSICAL DIMENSIONS
Height Width Depth Weight
12.0 in 9.75 in 16.5 in 47 Ibs
305 mm 248 mm 419 mm 21.4 kg
WELD-PAK 100
A-2 INSTALLATION
Read entire installation section before starting FIGURE A.1
installation.
SAFETY PRECAUTIONS
WARNING 1 2
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform
this installation.
• Only personnel that have read and under- WEL
D-PA
K 10
0
stood the WELD-PAK 100 Operating
Manual should install and operate this
equipment.
• Machine must be plugged into a receptacle
which is grounded per any national, local
or other applicable electrical codes.
• The WELD-PAK 100 power switch is to be
in the OFF (“O”) position when installing
work cable and gun and when connecting
power cord to input power. 4
3
IDENTIFY AND LOCATE
COMPONENTS
If you have not already done so, unpack the Weld-Pak
100 from its carton and remove all packing material
around the WELD-PAK 100. Remove the following 5 6
loose items from the carton (see Figure A.1):
1. WELD-PAK 100
2. Gun and cable assembly(1)
3. Literature and miscellaneous including:

a) This operating manual
b) 10 extra .035" contact tips
7 8
c) Hex key wrench for removal of drive roll.
4. 10 ft (3,0 m) work cable.
5. Work clamp.
6. Sample 10 lb. spool of Innershield .035" (0,9 mm)

NR-211-MP electrode.
7. Handshield with filter plate and lens.

9 10
8. Instructional video.
9. 8” Spool Adapter (2” Spindle) for mounting 10 lb.

Spools
10. Chipping hammer/wire brush
For available options and accessories refer to the

Accessories Section of this manual.
(1) The gun is ready to feed 0.035" (0,9 mm)
Innershield wire.
WELD-PAK 100 JAN96

INSTALLATION A-3
SELECT SUITABLE LOCATION Work Clamp Installation
Locate the welder in a dry location where there is free Attach the work clamp per the following: Refer to
circulation of clean air into the louvers in the back and Figure A-3.
out the front of the unit. A location that minimizes the
amount of smoke and dirt drawn into the rear louvers FIGURE A.3
reduces the chance of dirt accumulation that can block
SCREW
air passages and cause overheating. PLASTIC HANDLE
STACKING WORK CABLE
BACKING PLATE & NUT

WELD-PAK 100ʼs cannot be stacked.
TILTING
1. Remove the screw, pressure plate and backing nut
Each machine must be placed on a secure, level sur-
from clamp.
face, either directly or on a recommended undercar-
riage. The machine may topple over if this procedure
2. Remove plastic handle from same side of clamp by
is not followed.
pulling steadily on handle until it slides off clamp.
3. Insert the work cable terminal lug with the larger

OUTPUT CONNECTIONS hole through the hole in the end of the plastic han-
dle. Slide plastic handle several inches further onto
Refer to Figure A.2.
cable to allow easy and clear access to terminal
lug.
1. Work Cable Access Hole.
4. Secure work cable to clamp by inserting screw
2. Gun Cable and Control Lead Access Hole.
through hole in clamp, attaching cable lug on inside
of clamp, and installing pressure plate and backing
3. Connector Block.
nut. make sure pressure plate is installed such that
it prevents nut from turning. tighten screw securely.
4. Gun Trigger Lead Connectors.
5. Slide plastic handle back onto clamp and into origi-
5. Positive (+) and negative (–) output terminals.
nal position.
FIGURE A.2
4
5
+
WELD-PAK 100 8
-
3 6 7
1 2
WELD-PAK 100
A-4 INSTALLATION
Work Cable Installation appropriate size. Additionally, the .023 – .030" (0.6 –
0.8 mm) gun liner included in the K610-1 MIG
Refer to Figure A.2. Conversion Kit must be installed. Refer to the MAIN-
TENANCE section for contact tip installation details.
1. Open the wire feed section door on the right side of
the WELD-PAK 100. Connecting Gun Cable to the WELD-PAK
100
2. Pass the end of the work cable that has the termi-
nal lug with the smaller hole through the Work 1. Refer to Figure A.2. Unplug the machine or turn
Cable Access Hole (1) in the case front. power switch to the OFF “O” position.
3. Route the cable under and around the back of the 2. Pass the insulated terminals of the gun trigger con-
Wire Feed Gearbox (6). trol leads, one at a time, through the Gun Cable
and Control Lead Access Slot (2) in the case front.
4. For Innershield Only: Refer to Figure A.2. As The leads are to be routed under the Wire Feed
delivered, the WELD-PAK 100 is connected for Gearbox (6) and through the Cable Hanger (7) on
negative electrode polarity. This is the appropriate the inner panel.
configuration for the Innershield process. To com-
plete installation, use the provided wing nut to con- 3. Insert the connector on the gun conductor cable
nect the work cableʼs terminal lug to the positive (+) through the Gun Cable Access Hole (2) in the
output terminal (5) located above the Wire Feed WELD-PAK 100 case front. Make sure the connec-
Gearbox (6). Make sure that both wing nuts are tor is all the way in the brass connector block.
tight. Unscrew thumbscrew on the connector block a few
turns if gun connector will not insert fully. Rotate
5. For GMAW Only: Refer to Figure A.4. To wire for the connector so control leads are on the under-
positive polarity (required for the MIG process), side and tighten the Thumbscrew (8) in the con-
connect the short cable attached to the connector nector block.
block (1) to the positive (+) output terminal (4) and
the work cable (3) to the negative (–) terminal (2). 4. Connect the gun trigger control lead terminals to
the two insulated 1/4" (6,4 mm) tab terminal con-
FIGURE A.4 nector bushings located above the “Gun Trigger
Connection” decal in the wire feed section (4).
4 Either lead can go to either connector. Form the
leads so that they are as close as possible to the
3 inside panel.
2
CAUTION
1 If the gun trigger switch being used is other than
that supplied with the WELD-PAK 100, the switch
must be a normally open, momentary switch. The
terminals of the switch must be insulated from the
welding circuit. Malfunction of the WELD-PAK 100
may result if this switch shorts to the WELD-PAK
100 welding output circuit or is common to any
electrical circuit other than the WELD-PAK 100
trigger circuit.
GAS CONNECTION (OPTIONAL)

GUN INSTALLATION When using the GMAW process, a K610-1 MIG con-
version kit and a cylinder of carbon dioxide (CO2) or
As shipped from the factory, the WELD-PAK 100 gun
is ready to feed 0.035” (0,9 mm) wire. If .023" – .025" argon-carbon dioxide mixed shielding gas must be
(0,6 mm) or .030" (0.8 mm) wire is to be used for the obtained. For more information about the K610-1 MIG
GMAW (MIG) process, change the contact tip to the Conversion Kit for use with the WELD-PAK 100, refer
to the ACCESSORIES section.
WELD-PAK 100
INSTALLATION A-5
2. With the cylinder securely installed, remove the

WARNING cylinder cap. Stand to one side away from the out-
let and open the cylinder valve very slightly for an
CYLINDER may explode if dam-
instant. This blows away any dust or dirt which may
aged. Keep cylinder upright and
have accumulated in the valve outlet.
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 allow welding electrode to
Never stand directly in front of or behind the flow
touch cylinder.
regulator when opening the cylinder valve. Always
• Keep cylinder away from welding stand to one side.
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% CO2 cylinder, insert
BUILDUP OF SHIELDING GAS may
regulator adapter (provided with MIG Conversion
harm health or kill.
Kit for the WELD-PAK 100) between regulator and
• Shut off shielding gas supply cylinder valve. If adapter is equipped with a plastic
when not in use. washer, be sure it is seated for connection to the
• SEE AMERICAN NATIONAL CO2 cylinder.
STANDARD Z-49.1, “SAFETY IN
WELDING AND CUTTING” PUB- 4. Refer to Figure A.6. Attach one end of inlet gas
LISHED BY THE AMERICAN hose to the outlet fitting of the flow regulator and
WELDING SOCIETY. tighten the union nut securely with a wrench.
Connect the other end to the WELD-PAK 100 Gas
Solenoid Inlet Fitting (5/8-18 female threads — for
CGA — 032 fitting). Make certain the gas hose is
1. Chain the cylinder to a wall or other stationary sup- not kinked or twisted.
port to prevent the cylinder from falling over.
Insulate the cylinder from the work circuit and earth
ground. Refer to Figure A.5.
FIGURE A.5
Flow Regulator Cylinder Valve
Gas Hose
WELD-PAK 100
A-6 INSTALLATION
INPUT CONNECTIONS Requirements For Rated Output
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 100. 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 rated output with this installation is 88 amps, 18

Volts, 20% duty cycle (2 minutes of every 10 minutes
OPTIONAL GAS
SOLENOID INLET FITTING
used for welding).
POWER INPUT
CABLE
CAUTION
Do not connect the WELD-PAK 100 to an input
power supply with a rated voltage that is greater
than 125 volts.
Do not remove the power cord ground prong.
Requirements For CSA Rated Output

Refer to Figure A.6.
A line cord with a 15 amp, 125 volt, three-prong plug
The WELD-PAK 100 has a power input cable located (NEMA Type 5-15P) is factory installed. Connect this
on the rear of the machine. plug to a mating grounded receptacle which is con-
nected to a 15 amp branch circuit with a nominal volt-
age rating of 115 volts to 125 volts, 60 hertz, AC only.
CODE REQUIREMENTS FOR INPUT With this installation, the WELD-PAK 100 can be used
CONNECTIONS at an output of 62 amps, 20 volts, 20% duty cycle.
WARNING
This welding machine must be connected to
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 100
OPERATION B-1
Read entire operation section before

operating the WELD-PAK 100.
WARNING
• Do not touch electrically live
parts or electrode with skin or
wet clothing. Insulate yourself
from work and ground.
• Always wear dry insulating
gloves.
FUMES AND GASES can be

dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
WELDING SPARKS can

cause fire or explosion.
• Keep flammable material away.
• Do not weld on closed contain-
ers.
ARC RAYS can burn eyes

and skin.
• Wear eye, ear and body protec-
tion.
Observe all safety information throughout

this manual.
WELD-PAK 100
B-2 OPERATION
GENERAL DESCRIPTION ● No external shielding gas is required when used
with Lincoln Innershield .035” (0,9 mm) NR®-211-
The WELD-PAK 100 is a compact lightweight DC wire MP electrode.
feeder/power source. It has been designed for work-
● Accommodates 4” (100 mm) diameter spool of
shop, hobby, and light maintenance. It is capable of
wire. Will accommodate 8” (200 mm) diameter with
general purpose welding with self-shielded flux-cored
optional spindle.
(Innershield®) wire. When combined with the optional
K610-1 MIG Conversion Kit, the WELD-PAK 100 is
suitable for GMAW (MIG) welding applications.
WELDING CAPABILITY
The WELD-PAK 100 is ideally suited for individuals The WELD-PAK 100 is rated at 88 amps, 18 volts, at
having access to 115 volt AC input power, and wanti- 20% duty cycle on a ten minute basis. CSA rated out-
ng the ease of use, quality and dependability of both put at 62 amps at 20 volts at 20% duty cycle. It is
gas metal arc welding or GMAW (also known as MIG capable of higher output currents at lower duty cycles.
welding) and the Innershield electrode process (self
shielded flux cored or FCAW). The WELD-PAK 100 is
a rugged and reliable machine that has been LIMITATIONS
designed for dependable service and long life.
Arc Gouging cannot be performed with the WELD-
PAK 100. The WELD-PAK 100 is not recommended
RECOMMENDED PROCESSES for pipe thawing or TIG welding.
The WELD-PAK 100 can be used for welding mild

steel using the self shielded, Innershield electrode CONTROLS AND SETTINGS
process (FCAW) or it can be used for the GMAW, sin-
gle pass, process which requires a supply of shielding Refer to Figure B.1a.
gas and the K610-1 MIG Conversion Kit. The WELD-
PAK 100 is configured for use with the FCAW process 1. Power ON/OFF Switch —
as delivered from the factory. When the power is on the
fan motor will run and air will
be exhausted out the louvers
OPERATIONAL FEATURES AND in the front of the machine. OFF
CONTROLS The welding output and wire
feeder remain off until the
The WELD-PAK 100 has the following controls as gun trigger is pressed.
standard: Power ON/OFF Switch, Voltage Control,
Wire Speed Control, Trigger Switch, and a Circuit
ON
2. Wire Speed Control —
Breaker. Controls the wire feed speed
from 50 – 300 in /min (1.3 –
7.6 m/min). The control can
DESIGN FEATURES AND be preset on the dial to the
ADVANTAGES setting specified on the WIRE SPEED
WELD-PAK 100 Application
● Operates on 115 volt input — no special wiring Chart located on the inside
required. of the wire feed section door.
● “Cold electrode” until gun trigger is pressed for an
added measure of safety. 3. Voltage Control — A 4-posi-
tion tap selector switch gives
● Overload protection — incorporates both a thermo- full range adjustment of
stat and a circuit breaker. power source output voltage. ARC VOLTS
● Quality wire drive with electronic overload protec- Do not switch while welding.
tion.
● “Quick Release” idle roll pressure arm is easily Refer to Figure B-1b.
adjusted.
● Reversible, dual groove drive roll. Drive roll will 4. Circuit Breaker – Protects machine from damage if
feed .023 – .025” (0.6 mm) and .030" and .035" maximum output is exceeded. Button will extend
(0.8 mm and 0.9 mm) diameter wire.
WELD-PAK 100 JAN96

OPERATION B-3
out when tripped (Manual reset).
Wire Spindle Shaft

4" Wire Spool
2
1
Wing Nut
WELD-PAK 100 and Spacer
FIGURE B.2
to prevent overrun of the spool and excess slack in the
wire. The wing nut at the end of the shaft is used to
adjust the tension on the wire spool.
FIGURE B.1a To use 8" (200 mm) diameter spools, the 2" (51 mm)
diameter M15445 spindle must be used. Remove the
FIGURE B.1b spacer and wing nut at the end of the shaft. Insert
spindle as shown in figure B.3. Reattach spacer and
4 wing nut.
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.
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.3
WELDING OPERATIONS
SEQUENCE OF OPERATION
Wire Spool Spindle
LOCKING TAB
Wire Loading
Refer to Figure B.2 AND B3. 8” Wire Spool
The machine power switch should be turned to the

OFF (“O”) position before working inside the wire feed
enclosure.
The machine is shipped from the factory ready to feed Be sure that this stud engages
4” (100 mm) diameter spools. A 4" (100 mm) diameter the hole in the wire spool.
spool is mounted directly on the 5/8" (16 mm) diame-
ter spindle that has a built-in adjustable friction brake
To Wire Drive
Wire Spool must be pushed all the way on the spindle so that the
spindleʼs tab will hold it in place. The Wire Spool will rotate clock-
wise when wire is dereeled.
WELD-PAK 100
B-4 OPERATION
FIGURE B.4
Friction Brake Adjustment
1. With wire spool installed, check free movement
and coast of the spool.
2. To tighten the brake turn the wing nut clockwise in

1/4 turn increments until coasting stops.
2
3. To loosen the brake turn the wing nut counter-
clockwise in 1/4 turn increments until the wire spool
moves freely without coasting.
1
5 4
Wire Threading 3 The Wire Drive Feed Roll can
accommodate two wire sizes by
Refer to Figure B-4 flipping the wire drive feed roll
over.
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.
2. Carefully detach the end of the wire from the 7. Refer to Figure B.5. Remove gas nozzle and con-
spool. To prevent the spool from unwinding, tact tip from end of gun.
maintain tension on the wire until after step 5.
8. Turn the WELD-PAK 100 ON (“I”).
3. Cut the bent portion of wire off and straighten the
first 4” (100 mm). 9. Straighten the gun cable assembly.
4. Thread the wire through the In-going guide tube 10. Depress the gun trigger switch and feed welding
(4), over the drive roll (3), and into the out-going wire through the gun and cable. (Point gun away
guide tube (5). from yourself and others while feeding wire.)
Release gun trigger after wire appears at end of
5. Close the idle roll arm and latch the spring loaded gun.
pressure arm (2) in place . Rotate the spool coun-
terclockwise if required in order to take up extra 11. Turn the WELD-PAK 100 OFF (“O”).
slack in the wire.
12. Replace contact tip and gas nozzle.
6. The idle roll pressure adjustment wing nut is nor-
mally set for mid-position on the pressure arm 13. Refer to Figure B-6. Cut the wire off 1/4” – 3/8” (6
threads. If feeding problems occur because the – 10 mm) from the end of the tip. The WELD-PAK
wire is flattened excessively, turn the pressure
adjustment counter-clockwise to reduce distortion
of the wire. Slightly less pressure may be required
FIGURE B.5
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
WARNING
When inching the welding wire, the drive rolls, the Gas Diffuser/
gun connector block and the gun contact tip are Contact Tip
electrically energized relative to work and ground
and remain energized for several seconds after Gas Nozzle
the gun trigger is released.
WELD-PAK 100
OPERATION B-5
FIGURE B.6 NANCE section for details on nozzle replacement.
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
Contact Tip
must also be grounded as stated in “Arc Welding
Safety Precautions” in the beginning of this manu-
al.
Wire Electrode 7. Position gun over joint. End of wire may be lightly
touching the work.
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).
100 is now ready to weld. 9. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
Making A Weld out.
1. See “Process Guidelines” in this section for selec-
tion of welding wire and shielding gas and for 10. When no more welding is to be done, close valve
range of metal thicknesses that can be welded. on gas cylinder (if used), momentarily operate gun
trigger to release gas pressure, and turn off the
2. See the Application chart on the inside of the wire WELD-PAK 100.
feed compartment door for information on setting
the WELD-PAK 100 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
3. Set the Voltage (“V”) and Wire Speed (“oloʼ”) con- between the nozzle and contact tip which can result in
trols to the settings suggested for the welding wire a shorted nozzle, poor welds and an overheated gun.
and base metal thickness being used, refer to Hint: Anti-stick spray or gel, available from a welding
Applications chart on the inside of the wire drive supply distributor, may reduce buildup and aid in spat-
compartment door. ter removal.
4. Check that the polarity is correct for the welding

wire being used and that the gas supply, if PROCESS GUIDELINES
required, is turned on.
The WELD-PAK 100 can be used for welding mild
5. When using Innershield electrode, remove the gas steel using the self shielded, Innershield electrode
nozzle and install the gasless nozzle. This will process or it can be used for the GMAW (MIG), single
improve visibility of the arc and protect the gas dif- pass, process which requires a supply of shielding gas
fuser from weld spatter. Refer to the MAINTE- and the K610-1 MIG Conversion Kit.
FIGURE B.7
The recommended electrode for the self-shielded
process is 0.035” (0,9 mm) diameter Lincoln
Innershield NR-211-MP on 10 Ib (4,5 kg) spools.
Requires optional spindle – refer to Accessories sec-
WELD-PAK 100
tion. This electrode can be used for all position weld-
ing of 20 gauge through 5/16” (1,0 – 8,0 mm) thick
GUN CABLE steel [multiple passes are required for 1/4” and 5/16”
(6,0 and 8,0 mm)].
The recommended gas and electrode for GMAW is

welding grade CO2 gas and 0.025” (0 6 mm) diameter
Lincoln L-56 mild-steel welding wire [supplied on
WORKPIECE
ARC
12-1/2 Ib (6 kg) spools]. For 14 gauge (2,0 mm) and
WORK CLAMP
WELD-PAK 100
B-6 OPERATION
thinner, CO2 gas is recommended because it gives stops moving, open the valve fully.
equal or better performance than a blended gas at a
lower cost. A mixed gas consisting of 75 to 80% Argon 2. If using a regulator with an adjustable flow meter,
and 20 to 25% CO2 is recommended for welding on close the gun trigger and adjust the flow to give 15
heavier gauge [12 gauge (2,5 mm) for example] steel. – 20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20
– 25 CFH (10 – 12 I/min) when welding out of
The WELD-PAK 100 is suitable for .035" aluminum position or in a drafty location for CO2]. For argon
wire and .030" stainless wire. Refer to Table B.1 for mixed gas, trigger to release gas pressure, and
recommended procedure settings. turn off the adjust the flow to give 25 – 30 CFH
Shielding Voltage/Wire Speed (12 – 14 I/min).
Process Welding Wire Gas 16 ga 14 ga 12 ga 10 ga
MIG DC+ .035 Dia 100% Argon B-5 D-7 D-9 D-9 3. Keep the cylinder valve closed, except when using
4043 Aluminum the WELD-PAK 100. When finished welding:
Wire
MIG DC+ .035 Dia 100% Argon B-5 C-7 D-9 D-10 a) Close the cylinder valve to stop gas flow.
5356 Aluminum
Wire b) Depress the gun trigger briefly to release the
MIG DC+ .030 Dia 98% Argon/ A-3 C-6 D-7.5 D-7.5
308L Stainless 2% Oxygen
pressure in the gas hose.
Steel Wire
c) Turn off the WELD-PAK 100.
TABLE B.1
OVERLOAD PROTECTION
Output Overload
CHANGING MACHINE OVER TO The WELD-PAK 100 is equipped with a circuit breaker
FEED OTHER WIRE SIZES and a thermostat which protects the machine from
damage if maximum output is exceeded. The circuit
The WELD-PAK 100 is shipped from the factory ready breaker button will extend out when tripped. The cir-
to feed 0.035” (0,9 mm) diameter wire. To operate the cuit breaker must be manually reset.
WELD-PAK 100 with other sizes of wire, it is neces-
sary to change the contact tip and change the drive
roll over to other sizes. Refer to Changing the Contact Thermal Protection
Tip and Changing the Drive Roll, in the MAINTE- The WELD-PAK 100 has a rated output duty cycle of
NANCE section, for specific information on these pro- 20%. If the duty cycle is exceeded, a thermal protector
cedures. will shut off the output until the machine cools to a rea-
sonable operating temperature. This is an automatic
function of the WELD-PAK 100 and does not require
user intervention. The fan continues to run during
WELDING WITH GMAW (MIG) cooling.
Shielding Gas
When using the GMAW process, obtain and install the Electronic Wire Drive Motor Protection
K610-1 MIG Conversion Kit and a cylinder of carbon The WELD-PAK 100 has built-in protection for wire
dioxide (CO2) or argon-carbon dioxide mixed shielding drive motor overload.
gas. Refer to the ACCESSORIES section for more
information about installing the K610-1 Kit for use with
the WELD-PAK 100.
1. For CO2, open the cylinder very slowly. For argon-

mixed gas, open cylinder valve slowly a fraction of
a turn. When the cylinder pressure gauge pointer
WELD-PAK 100
LEARNING TO WELD B-7
LEARNING TO WELD WARNING

No one can learn to weld simply by reading about it. Fumes and slag generated from
Skill comes only with practice. The following pages will Innershield type electrodes recom-
help the inexperienced operator to understand weld- mended for use with this welding
ing and develop this skill. For more detailed informa- machine can be toxic.
tion, order a copy of “New Lessons in Arc Welding”
listed at the end of this manual. • Avoid contact with eyes and skin.
• Do not take internally.

THE ARC-WELDING CIRCUIT
• Keep out of reach of children.
The operatorʼs knowledge of arc welding must go
beyond the arc itself. The operator must know how to • Follow all safety precautions
control the arc, and this requires a knowledge of the found in this operating manual.
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 The gun and cable assembly is held by the operator
circuit begins where the gun cable is attached to the who guides the automatically fed wire along the joint,
welding machine. Current flows through the gun cable, maintaining a contact tip to work distance of about 3/8
gun, and contact tip, to the wire and across the arc. to 1/2 inch (10 – 12 mm) This is called electrical stick-
On the work side of the arc, current flows through the out. This electrical stickout (ESO) must be properly
base metal to the work cable and back to the welding maintained by the operator. The electric arc is made in
machine. This circuit must be complete for the current the gap between the work and the tip end of a small
to flow. diameter wire. When the power source is properly set,
the arc gap is maintained automatically.
This machineʼs welding circuit has a voltage output of
32 volts DC maximum. This voltage is quite low and is Arc welding is a manual skill requiring a steady hand,
only present when the gun triggers depressed. good physical condition, and good eyesight. The oper-
ator controls the welding arc, and, therefore, the quali-
To weld, the work clamp must be tightly connected to ty of the weld made.
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. THE SELF-SHIELDED FCAW WELDING
Avoid allowing the welding circuit to pass through ARC
hinges, bearings, electronic components, or similar
devices that can be damaged. See Figure B.8. Always Figure B.9 illustrates the action taking place in the self
disconnect electrical devices before welding upon shielded FCAW (Innershield) welding arc. It closely
them. resembles what is actually seen while welding.
FIGURE B.9
FIGURE B.8
Electronic Components
Burning of core materials

Cored Wire inside wire electrode
results in shield of gas.
Protective Slag
Arc Stream
Weld Metal
Bearings
Hinges
WELD-PAK 100
B-8 LEARNING TO WELD
The “arc stream” is seen in the middle of the picture. THE GMAW (MIG) WELDING ARC
This is the electric arc created by the electric current
flowing through the space between the end of the wire Figure B.10 illustrates the GMAW (MIG) welding arc.
electrode and the base metal. The temperature of this Solid wire does not contain fluxes or ingredients to
arc is about 6000°F, which is more than enough to form its own shielding and no slag forms to protect the
melt metal. The arc is very bright, as well as hot, and molten weld metal. For this reason, a continuous even
cannot be looked at with the naked eye without risking flow of shielding gas is needed to protect the molten
painful injury. The very dark lens, specifically designed weld metal from atmospheric contaminants such as
for arc welding must be used with the hand or face oxygen and nitrogen. Shielding gas is supplied
shield whenever viewing the arc. 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 FIGURE B.10
digs into the earth. The molten metal forms a molten
pool or crater and tends to flow away from the arc. As
it moves away from the arc, it cools and solidifies.
The function of the Innershield cored wire electrode is

much more than simply to carry current to the arc. The
Gas nozzle
wire core is composed of fluxes and/or alloying ingre-
dients around which a steel sheath has been formed. Solid wire Shielding gas
It is simply a stick electrode turned inside out in a con- electrode
tinuous wire form.
Weld metal
Base metal
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 When comparing the GMAW and FCAW processes,
pieces of base metal. you can see that the principal difference between the
two lies in the type of shielding used. GMAW uses gas
The core materials also melt or burn in the arc and for shielding, thus we have Gas Metal Arc Welding.
perform several functions. They make the arc stead- FCAW uses the melting or burning of the core ingredi-
ier, provide a shield of smoke-like gas around the arc ents for shielding, and is thus termed Self-Shielded
to keep oxygen and nitrogen in the air away from the Flux Cored Arc Welding.
molten metal, and provide a flux for the molten pool.
The flux picks up impurities and forms the protective The recommended wire for Gas Metal Arc Welding
slag on top of the weld during cooling. (MIG) is Lincolnweld 0.025” L-56 electrode.
Lincolnweld” L-56 is capable of welding a wide range
After running a weld bead, the slag may be removed of mild steels in all positions, however, more skill IS
with a chipping hammer and wire brush. This required for out-of-position welding with the GMAW
improves appearance and allows for inspection of the process.
finished weld.
Since machine size and output characteristics limit the PROCESS SELECTION
size and type of wire electrode which can be used,
Lincoln 0.035ʼ (0.9 mm) NR-211-MP Innershield elec- By gaining knowledge of the differences between the
trode is recommended for Self-Shielded Flux Cored two processes, you will be able to select the best
Arc Welding. process for the job you have at hand. In selecting a
process, you should consider:
For GMAW (MIG) Process

1. Is most of my welding performed on 16 gauge and
lighter materials?
WELD-PAK 100
2. Can I afford the extra expense, space, and lack of MACHINE SET UP FOR THE
portability required for gas cylinders and gas sup- SELF-SHIELDED FCAW PROCESS
ply?
1. See PROCESS GUIDELINES in the OPERATION
3. Do I require clean, finished-looking welds? section for selection of welding wire and shielding
gas, and for range of metal thicknesses that can be
If you have answered yes to all the above questions welded.
GMAW may be the process for you. If you have
answered no to any of the above questions, then you 2. See the Application Guide on the inside of wire
should consider using the FCAW process. feed section door for information on setting the
controls.
For FCAW (Innershield) Process
1. Do I want simplicity and portability? 3. Set the “Voltage” and “Wire Speed” controls to the
settings suggested on the Application Guide for the
2. Will welding be performed outdoors or under windy welding wire and base metal thickness being used.
conditions? The voltage control is marked “V” and the wire feed
speed is marked ʻʼolo.ʼʼ
3. Do I require good all position welding capability?
4. Will most welding be performed on 16 gauge and wire being used. Set the polarity for DC(–) when
heavier, somewhat rusty or dirty materials? welding with NR-211-MP Innershield electrode.
See Work Cable Installation in the INSTALLATION
5. Weld must be cleaned prior to painting. section for instructions on changing polarity.
5. When using Innershield electrode, the gasless noz-

COMMON METALS zle may be used instead of a gas nozzle to improve
visibility of the arc.
Most metals found around the farm, small shop or
home are low carbon steel, sometimes referred to as 6. Connect work clamp to metal to be welded. Work
mild steel. Typical items made with this type of steel clamp must make good electrical contact to the
include most sheet metal, plate, pipe and rolled work piece. The work piece must also be grounded
shapes such as channels and angle irons. This type of as stated in the “Arc Welding Safety Precautions”
steel can usually be easily welded without special pre- at the beginning of this manual.
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 WELDING TECHNIQUES FOR THE SELF-
you can easily cut the metal with a file, chances are
SHIELDED FCAW PROCESS
good that the metal is mild steel and that you will be
able to weld the material. In addition, aluminum and
Four simple manipulations are of prime importance
stainless steel can be welded using the K664-1
when welding. With complete mastery of the four,
Aluminum Welding Kit. For further information on iden-
welding will be easy. They are as follows:
tifying various types of steels and other metals, and
for proper procedures for welding them, we again sug-
1. The Correct Welding Position
gest you purchase a copy of “New Lessons in Arc
Figure B.11 illustrates the correct welding position
Welding”.
for right handed people. (For left handed people, it
is the opposite.)
Regardless of the type of metal being welded, in order
to get a quality weld, it is important that the metal is
Hold the gun (of the gun and cable assembly) in
free of oil, paint, rust or other contaminants.
your right hand and hold the shield with your left
hand. (Left handers simply do the opposite.)
When using the FCAW Process, weld from left to

right (if you are right handed). This enables you to
clearly see what you are doing. (Left handers do
the opposite.) Tilt the gun toward the direction of
travel holding the electrode at an angle as shown
in Figure B.11.
WELD-PAK 100
FIGURE B.11 FIGURE B.12
Contact Tip
Wire Electrode
3/8 – 1/2” (10 – 12 mm)

Electrical Stickout (ESO)
WARNING
ARC RAYS can burn eyes and skin.
When using an open arc process, it The easiest way to tell whether the ESO is the cor-
Is necessary to use correct eye, rect length is by listening to its sound. The correct
head and body protection. ESO has a distinctive “crackling” sound, very much
like eggs frying in a pan. A long ESO has a hollow,
Protect yourself and others, read blowing or hissing sound. If the ESO is too short,
“ARC RAYS can burn” at the front you may stick the contact tip or nozzle to the weld
of this manual. puddle and/or fuse the wire to the contact tip.
4. The Correct Welding Speed

2. The Correct Way To Strike An Arc The important thing to watch while welding is the
1. Be sure the work clamp makes good electrical puddle of molten metal right behind the arc. See
contact to the work. Figure B.13. Do not watch the arc itself. It is the
appearance of the puddle and the ridge where the
2. Position gun over joint. End of wire may be molten puddle solidifies that indicates correct weld-
lightly touching the work. ing speed. The ridge should be approximately 3/8”
(10 mm) behind the wire electrode.
3. Position face shield to protect face and eyes,
close gun trigger, and begin welding. Hold the Most beginners tend to weld too fast, resulting in a
gun so that the contact tip to work distance is thin uneven, “wormy” looking bead. They are not
about 3/8 to 1/2 inch (10 – 12 mm). watching the molten metal.
4. To stop welding, release the gun trigger and

the pull the gun away from the work after the FIGURE B.13
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.
See Figure B.12.
Once the arc has been established, maintaining

the correct ESO becomes extremely important.
The ESO should be approximately 3/8 to 1/2 inch
(10 to 12 mm) long.
WELD-PAK 100
Helpful Hints For the WELD-PAK 100, use the following:
1. For general welding, it is not necessary to weave Mild Steel 12 gauge or 1/8 inch
the arc, neither forward or backward nor sideways. (3.0 mm)
Weld along at a steady pace. You will find it easier. Electrode 0.035" (0.9 mm)
NR-211-MP
2. When welding on thin plate, you will find that you Innershield Wire
will have to increase the welding speed, whereas
when welding on heavy plate, it is necessary to go Voltage Setting “V” D
more slowly in order to get good penetration. Wire Feed Speed “o|o” 3
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 Refer to Figure B.15.
is to use the back-stepping method illustrated in
Figure B.14. 1. Learn to strike an arc by positioning the gun over
the joint and touching the wire to the work.
FIGURE B.14
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
B A C D E
mm) and the gun is at proper angle.
4. After you strike the arc, practice the correct electri-

Back-Stepping cal stickout. Learn to distinguish it by its sound.
5. When you are sure that you can hold the correct
Practice electrical stickout, with a smooth “crackling” arc
start moving. Look at the molten puddle constantly.
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
1. Correct welding position gives you practice in running straight welds, and
also gives you an easy way to check your
2. Correct way to strike an arc progress. The 10th weld will look considerably bet-
ter than the first weld. By constantly checking on
3. Correct electrical stickout your mistakes and your progress, welding will soon
be a matter of routine.
4. Correct welding speed
is to perform the following exercise.
FIGURE B.15
Contact
Tip
Gun Angle
WELD-PAK 100
MACHINE SET UP FOR THE GMAW (MIG) FIGURE B.16
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.
When using the GMAW process on light gauge mater-
3. Set the “Voltage” and “Wire Speed” controls to the ial, weld from right to left (if you are right handed).
settings suggested on the Application Guide for the This results in a colder weld and has less tendency for
welding wire and base metal thickness being used. burn through.
The voltage control is marked “V” and the wire
feed speed is marked ʻʼolo.ʼʼ 2. The Correct Way To Strike An Arc

wire being used. Set the polarity for DC(+) when WARNING
welding with the GMAW (MIG) process. See Work
Cable Installation in the INSTALLATION section ARC RAYS can burn eyes and skin.
for instructions for changing polarity.
When using an open arc process, it
5. Check that the gas nozzle and proper size liner Is necessary to use correct eye,
and contact tip are being used and that the gas head and body protection.
supply is turned on. If adjustable, set for 15 to 20
cubic feet per hour (7 to 10 l/min.) under normal Protect yourself and others, read
conditions, increase to as high as 35 CFH (17 “ARC RAYS can burn” at the front
I/min.) under drafty (slightly windy) conditions. of this manual.
6. Connect work clamp to metal to be welded. Work

clamp must make good electrical contact to the 1. Be sure the work clamp makes good electrical con-
work piece. The work piece must also be grounded tact to the work.
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.
WELDING TECHNIQUES FOR THE GMAW 3. Position face shield to protect face and eyes, close
(MIG) PROCESS gun trigger, and begin welding. Hold the gun so
that the contact tip to work distance is about 3/8 to
Four simple manipulations are of prime importance 1/2 inch (10 – 12 mm).
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.
1. The Correct Welding Position
Figure B.16 illustrates the correct welding position 5. A ball may form at the tip end of the wire after
for right handed people. (For left handed people, it welding. For easier restrikes, the ball may be
is the opposite.) removed by feeding out a few inches of wire and
cutting off the end of the wire with wire cutters.
When GMAW (MIG) welding on sheet metal, it is
important to use the “forehand” push technique. 6. When no more welding is to be done, close the
valve on the gas cylinder, momentarily operate the
Hold the gun (of the gun and cable assembly) in gun trigger to release gas pressure, then turn off
your right hand and hold the shield with your left the machine.
hand. (Left handers simply do the opposite.)
WELD-PAK 100
FIGURE B.17 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
Wire Electrode when welding on heavy plate, it is necessary to go
more slowly in order to get good penetration.
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
3. The Correct Electrical Stickout (ESO) Figure B.14.
The electrical stickout (ESO) is the distance from
the end of the contact tip to the end of the wire.
See Figure B.17. Practice
Once the arc has been established, maintaining The best way of getting practice in the four skills that
the correct ESO becomes extremely important. enable you to maintain:
The ESO should be approximately 3/8 to 1/2 inch
(10 to 12 mm) long. 1. Correct welding position
The easiest way to tell whether the ESO is the cor- 2. Correct way to strike an arc
rect length is by listening to its sound. The correct
ESO has a distinctive “crackling” sound, very much 3. Correct electrical stickout
like eggs frying in a pan. A long ESO has a hollow,
blowing or hissing sound. If the ESO is too short, 4. Correct welding speed
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

The important thing to watch while welding is the
For the WELD-PAK 100, use the following:
puddle of molten metal right behind the arc. See Mild Steel 16 gauge or 1/16 inch
Figure B.18. Do not watch the arc itself. It is the (1.6 mm)
appearance of the puddle and the ridge where the
Electrode Lincolnweld 0.025 L-56
molten Puddle solidifies that indicates correct weld-
electrode
ing speed. The ridge should be approximately 3/8”
CO2
(10 mm) behind the wire electrode.
Voltage Setting “V” C
Most beginners tend to weld too fast, resulting in a
Wire Feed Speed “o|o” 4
thin, uneven, “wormy” looking bead. They are not
watching the molten metal.
FIGURE B.18 Refer to Figure B.15.
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.
WELD-PAK 100
4. After you strike the arc, practice the correct electri- Watch the molten metal to be sure it distributes itself
cal stickout. Learn to distinguish it by its sound. evenly on both edges and in between the plates.
5. When you are sure that you can hold the correct
electrical stickout, with a smooth “crackling” arc, FIGURE B.20
start moving. Look at the molten puddle constantly,
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. Penetration
Unless a weld penetrates close to 100% of the metal
thickness, a butt weld will be weaker than the material
JOINT TYPES AND POSITIONS welded together. In the example shown in Figure
B.21, the total weld is only half the thickness of the
Five types of welding joints are: Butt Welds, Fillet material thus the weld is only approximately half as
Welds, Lap Welds, Edge Welds and Corner Welds. strong as the metal.
See Figure B.19.
FIGURE B.21
Of these, the Butt Weld and Fillet Weld are the two
most common welds.
FIGURE B.19
Butt weld Lap weld
FIGURE B.22
Edge weld Fillet weld Corner weld
Butt Welds
Place two plates side by side, leaving a space approx- In the example shown in Figure B.22, the joint has
imately one half the thickness of the metal between been welded so that 100% penetration could be
them in order to get deeper penetration. achieved. The weld, if properly made, is as strong as
or stronger than the original metal.
Securely clamp or tack weld the plates at both ends,
otherwise the heat will cause the plates to move apart. Fillet Welds
See Figure B.20. When welding fillet welds, it is very important to hold
the wire electrode at a 45° angle between the two
Now weld the two plates together. Weld from left to sides or the metal will not distribute itself evenly. The
right (if right handed). Point the wire electrode down in gun nozzle is generally formed at an angle to facilitate
the crack between the two plates, keeping the gun this. See Figure B.23.
slightly tilted in the direction of travel.
WELD-PAK 100
FIGURE B.23 FIGURE B.24
45°
PROPER GUN ANGLE PROPER GUN ANGLE

FOR GMAW PROCESS FOR FCAW PROCESS
WELDING IN THE VERTICAL UP POSITION WELDING IN THE VERTICAL UP POSITION
Welding In The Vertical Position Vertical-down Welding

Refer to Figure B.25 Vertical-down welds are applied
Welding in the vertical position can be done either ver- at a fast pace. These welds are therefore shallow and
tical-up or vertical-down. Vertical-up is used whenev- narrow and, as such, are excellent for sheet metal.
era larger, stronger weld is desired. Vertical-down is Vertical-down welds may be applied to 5/32” (3.9 mm)
used primarily on sheet metal 5/32” (3.9 mm) and and lighter material.
under for fast, low penetrating welds.
Use stringer beads and tip the gun in the direction of
travel so the arc force helps hold the molten metal in
WARNING the joint. Move as fast as possible consistent with
desired bead shape.
Use of this unit on thicker materials than recom-
mended may result in poor welds. The welds may The important thing is to continue lowering the entire
“look” good, but may just be “sitting” on top, of arm as the weld is made so the angle of the gun does
the plate. This is called “Cold Casting” and will not change. Move the electrode wire fast enough that
result in weld failure. 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
Vertical-up And Overhead Welding required.
The problem, when welding vertical-up, is to put the
molten metal where it is wanted and make it stay FIGURE B.25
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.

Donʼt 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.24.
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.
WELD-PAK 100
TROUBLESHOOTING WELDS To Reduce Spatter (in order of importance):
Good welds have excellent appearance.
1. Increase voltage.
2. Increase drag angle.
3. Decrease stickout.
To Eliminate Porosity (in order of importance):
4. Increase WFS (wire feed speed).
5. Decrease travel speed.
6. Check for correct gas, if used.
To Correct Poor Penetration (in order of impor-

tance):
1. Turn on gas supply, if used 2. Increase WFS (wire feed speed).
2. Decrease voltage. 3. Decrease voltage.
3. Increase stickout. 4. Increase speed.
4. Increase WFS (wire feed speed). 5. Decrease drag angle.
5. Decrease drag angle. 6. Check for correct gas, if used.
If Arc Blow Occurs (in order of importance):
NOTE: Always be sure the joint is free from moisture,
oil, rust, paint or other contaminants. NOTE: Try different ground connection locations
before adjusting procedures.
To Eliminate a Ropy Convex Bead 1. Decrease drag angle.
(in order of importance):
2. Increase stickout.
3. Decrease voltage.
4. Decrease WFS (wire feed speed.
To Eliminate Stubbing* (in order of importance):

1. Increase voltage
1. Increase voltage.
2. Decrease WFS (wire feed speed)
3. Decrease stickout
3. Decrease WFS (wire feed speed.
4. Increase drag angle
* Stubbing occurs when the electrode drives through
5. Decrease drag angle. the molten puddle and hits the bottom plate tending
6. Check for correct gas, if used. to push the gun up.
WELD-PAK 100
Proper Gun Handling

Most feeding problems are caused by improper han-
dling of the gun cable or electrodes.
1. Do not kink or pull the gun around sharp corners
2. Keep the gun cable as straight as practical when
welding.
3. Do not allow dolly wheels or trucks to run 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.
WELD-PAK 100
B-18 APPLICATION CHART
WELD-PAK 100
ACCESSORIES C-1
OPTIONAL ACCESSORIES
3. Change drive roll orientation (if required)
1. K520 Utility Cart — Designed to trans- for the wire size selected. See “Changing
port the Lincoln family of small welders. Drive Roll” in Maintenance section for
Has provisions for mounting a single gas details.
cylinder. Has front casters and large rear
wheels. Handle height is easily 4. Install the proper gun liner and tip for the
adjustable. Bottom tray provided for tools wire size selected. See “Component
and accessories. Easy assembly Replacement” in Maintenance section for
required; takes less than 15 minutes. details.
2. K664-1 Aluminum Feeding Kit — This 5. Remove gasless nozzle (if installed) and
kit required for welding with .035 install gas nozzle. To remove, simply
Aluminum wire. This kit may also be unscrew.
used for feeding .035 stainless wire.
Included with this kit are a drive roll, liner 6. Load wire into machine and thread into
and contact tip. It is important when gun and cable per “Welding Wire
changing between welding with steel Loading” section.
wire and aluminum to exchange these
components due to the lubricant
applied to steel wire. Failure to do so
may result in contaminated welds
when welding aluminum.
3. K610-1 MIG Conversion Kit for the

WELD-PAK 100 — Complete kit for use
with .025" (0.6 mm) electrode wire and
either CO2 or Argon-mixed gas. Includes
.025-.030" (0.6-0.8 mm) cable liner, two
.025" (0.6 mm) contact tips, gas nozzle,
2 lb. spool of .025" (0.6 mm) L-56 elec-
trode, gas regulator, gas hose, regulator
adapter for CO2 cylinders and gas sole-
noid assembly, with all necessary hard-
ware and easy instructions for installing
gas solenoid. Use with .030" (0.8 mm)
wire requires additional .030" (0.8 mm)
contact tip and electrode wire.
MIG CONVERSION
Several changes are needed to convert the

unit for operation with the MIG (GMAW)
process. The K610-1 MIG Conversion Kit
for the WELD-PAK 100 includes all the nec-
essary accessories for this conversion and
is provided for this purpose. The following
conversions should be made using the con-
tents of this kit:
1. Install the gas solenoid. Complete

instructions are included with the kit.
2. Change the output polarity to DC(+). See

“Work Cable Installation” in Installation
section for details.
WELD-PAK 100
C-2 NOTES
WELD-PAK 100
MAINTENANCE D-1
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
• Disconnect input power by removing

plug from receptacle before working
inside WELD-PAK 100. Use only ground-
ed receptacle. Do not touch electrically
“hot” parts inside WELD-PAK 100.
• 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
100. Take the unit to an authorized Lincoln Service Center if
you experience problems. NO maintenance is required.
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 is 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.
WELD-PAK 100
D-2 MAINTENANCE
GUN AND CABLE 5. To remove gun tube from gun, remove
MAINTENANCE gas nozzle or gasless nozzle and
remove diffuser from gun tube. Remove
FOR MAGNUM™ 100L GUN both collars from each end of the gun
handle and separate the handle halves.
Gun Cable Cleaning Loosen the locking nut holding the gun
Clean cable liner after using approximately tube in place against the gun end cable
300 lbs (136 kg) of solid wire or 50 lbs (23 connector. Unscrew gun tube from cable
kg) of flux-cored wire. Remove the cable connector. To install gun tube, screw the
from the wire feeder and lay it out straight locking nut on the gun tube as far as
on the floor. Remove the contact tip from possible. Then screw the gun tube into
the gun. Using low pressure air, gently blow the cable connector until it bottoms.
out the cable liner from the gas diffuser end. Then unscrew (no more than one turn)
the gun tube until its axis is perpendicu-
lar to the flat sides of the cable connector
CAUTION and pointed in the direction of the trigger.
Excessive pressure at the start may Tighten the locking nut so as to maintain
cause the dirt to form a plug. the proper relationship between the gun
tube and the cable connector. Replace
the gun handle, trigger and diffuser.
Flex the cable over its entire length and Replace the gas nozzle or gasless noz-
again blow out the cable. Repeat this proce- zle.
dure until no further dirt comes out.
Contact Tips, Nozzles, and Gun Tubes COMPONENT

1. Dirt can accumulate in the contact tip REPLACEMENT
hole and restrict wire feeding. After each PROCEDURES
spool of wire is used, remove the contact
tip and clean it by pushing a short piece CHANGING THE CONTACT TIP
of wire through the tip repeatedly. Use
the wire as a reamer to remove dirt that 1. Refer to Figure D.2. Remove the gas
may be adhering to the wall of the hole nozzle from the gun by unscrewing
through the tip. counter-clockwise.
2. Replace worn contact tips as required. A 2. Remove the existing contact tip from the
variable or “hunting” arc is a typical gun by unscrewing counter-clockwise.
symptom of a worn contact tip. To install
a new tip, choose the correct size con- 3. Insert and hand tighten desired contact
tact tip for the electrode being used (wire tip.
size is stenciled on the side of the con-
tact tip) and screw it snugly into the gas 4. Replace gas nozzle.
diffuser.
3. Remove spatter from inside of gas noz-

zle 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 screws
onto the diffuser.
WELD-PAK 100
MAINTENANCE D-3
CHANGING DRIVE ROLL FIGURE D.1
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.
3
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

2
power per instructions in Installation sec-
tion.
1 Wire size is stenciled on
the ends of the drive roll.
2. Release the spring-loaded pressure arm
and lift the idle roll arm away from the
drive roll.
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 con-
tact tip are energized relative to work
and ground and remain energized for
several seconds after the gun trigger 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 rein-

stall with the .023 – .025" (0.6 mm)
groove (the smaller groove) closest to the
gearbox.
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.
WELD-PAK 100
D-4 MAINTENANCE
FIGURE D.2 CHANGING LINER
Liner trim length
NOTICE: The variation in cable lengths pre-
1-1/4 (31.8 mm) vents the interchangeability of liners. Once
Liner Trim Length
a liner has been cut for a particular gun, it
should not be installed in another gun
unless it can meet the liner cutoff length
requirement. Refer to Figure D.2.
1. Remove the gas nozzle from the gun by

unscrewing counter-clockwise.
Gas Diffuser
2. Remove the existing contact tip from the
gun by unscrewing counter-clockwise.
Gas Nozzle or
Set Screw Brass Cable Gasless Nozzle 3. Remove the gas diffuser from the gun
Connector tube by unscrewing counter-clockwise.
4. Lay the gun and cable out straight on a

flat surface. Loosen the set screw located
Liner Assembly in the brass connector at the wire feeder
(Liner bushing to be sealed tight end of the cable. Pull the liner out of the
against brass cable connector) cable.
5. Insert a new untrimmed liner into the con-

nector end of the cable. Be sure the liner
bushing is stenciled appropriately for the
wire size being used.
6. Fully seat the liner bushing into the con-

nector. 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.
8. Screw the gas diffuser onto the end of

the gun tube and securely tighten.
9. Replace the contact tip and nozzle.
WELD-PAK 100
MAINTENANCE D-5
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-clock-
wise until the collar reaches a stop. Then
pull the collar off the gun handle. If the col-
lars are difficult to turn, position the gun
handle against a corner, place a screwdriv-
er 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.
FIGURE D.3
➣
Counter-clockwise
WELD-PAK 100
D-6 NOTES
WELD-PAK 100
TROUBLESHOOTING E-1
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 remedy possible prob- Step 2. PERFORM EXTERNAL TESTS.
lems with machine setup or operation. The second column labeled “POSSIBLE
Simply follow the three-step procedure AREAS OF MISADJUSTMENT(S)” lists the
listed below. obvious external possibilities that may con-
tribute to the machine symptom. Perform
Step 1. LOCATE PROBLEM (SYMPTOM). these tests/checks in the order listed. In
Look under the column labeled “PROBLEM general, these tests can be conducted with-
(SYMPTOMS)”. This column describes pos- out removing the case wrap-around cover.
sible symptoms that the machine may
exhibit. Find the listing that best describes Step 3. PERFORM COMPONENT TESTS.
the symptom that the machine is exhibiting. If you have exhausted all of the recom-
mended tests in Step 2, Consult your Local
Symptoms are grouped into three main cat- Authorized Field Service Facility.
egories: output problems, function prob-
lems, welding problems.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC
FIELD SERVICE FACILITY for assistance before you proceed.
_____________________________________________________________________
WELD-PAK 100
E-2 TROUBLESHOOTING
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) 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 1. Make sure correct voltage is

flow when gun trigger is pulled. Fan applied to the machine (115vac).
does NOT operate.
2. Make certain that power switch
is in the ON position.
3. Make sure circuit breaker inside

wire drive compartment is reset. Contact your local Lincoln
Authorized Field Service Facility.
No wire feed, weld output or gas 1. The thermostat may be tripped
flow when gun trigger is pulled Fan due to overheating. Let machine
operates normally. 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 AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.
WELD-PAK 100
TROUBLESHOOTING E-3
Observe Safety Guidelines TROUBLESHOOTING GUIDE


FEEDING PROBLEMS
No wire feed when gun trigger is 1. If the wire drive motor is running
pulled. Fan runs, gas flows and make sure that the correct drive
machine has correct open circuit rolls are installed in the machine.
voltage (32vcd maximum) – weld Contact your local Lincoln
output. 2. Check for clogged cable liner or Authorized Field Service Facility.
contact tip.
3. Check for proper size cable liner

and contact tip.

GAS FLOW PROBLEMS
Low or no gas flow when gun 1. Verify that gas solenoid is prop-
trigger is pulled. Wire feed, weld erly installed. Refer to instruc-
output and fan operate normally. tions included with K610-1 MIG
(Optional MIG Conversion Kit only.) conversion kit.
Contact your local Lincoln
2. Check gas supply, flow regulator Authorized Field Service Facility.
and gas hoses.
3. Check gun connection to

machine for obstruction or leaky
seals.
CAUTION
WELD-PAK 100
E-4 TROUBLESHOOTING
TROUBLESHOOTING GUIDE Observe Safety Guidelines

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.
Contact your local Lincoln
4. Check for proper gas and flow Authorized Field Service Facility.
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
WELD-PAK 100
WELD-PAK 100 WIRING DIAGRAM
Do not operate with covers removed.
GAS SOLENOID IS PART OF MIG CONVERSION KIT.
Disconnect input power by unplugging
power cord before servicing
Do not touch electrically live parts

J1
CONTROL P.C. BOARD Only qualified persons should install, use or
H2 LS1
HIGH VOLTAGE service this machine.
H2 can kill
S1
ON-OFF H2 1 2 3 4 5 6 7 8 9 10
N.O.
SWITCH
209 213 208 203 WIRE SPEED

N.C.
F1 CR1 5K N.C.
541 214 204 539 THERMOSTAT
115V/60HZ H1 R2 GUN TRIGGER (MOUNTED TO
115V/60HZ GAS
SEC. COIL)
FAN MOTOR SOLENOID
H1 208
24V 213
209
AUXILIARY
WINDING
214
(W)
WELD-PAK 100 WIRING DIAGRAM
539 - WIRE
FEED
541 + MOTOR
(B)
OUTPUT
CIRCUIT
204
203 CHOKE
BREAKER
204
+
S2 TO
SELECTOR 204
H1 D1 WORK
SWITCH D2 204
X2 202
+ 59,000 mf
X3
X4 N.B. C1 N.D. 40V
X5
N.D.
WIRING DIAGRAMS
203
H2 X1 GUN CABLE
T1 N.A.
D4 CONDUCTOR
CASE BLOCK
N.A. DIODES D2 & D4 ARE MOUNTED D3 203
GROUNDING
ON THE OUTSIDE HEATSINK.
STUD -
N.B. DIODES D1 & D3 ARE MOUNTED 203
ON THE INSIDE HEATSINK, WHICH

IS CLOSEST TO THE CENTER PANEL.
TO EARTH GROUND PER
NATIONAL, LOCAL OR N.C. COMPONENT VIEWED FROM REAR.
J1
OTHER APPLICABLE 1 2 3 4 5 N.D. BOLTED ALUMINUM CONNECTIONS ELECTRICAL SYMBOLS PER E1537
ELECTRICAL CODES. REQUIRE T12837 JOINT COMPOUND LEAD COLOR CODE:
(DOW CORNING 340) WHEN REATTACHING.
6 7 8 9 10
B-BLACK
LATCH
W-WHITE
CAVITY NUMBERING SEQUENCE
( COMPONENT SIDE OF BOARD ) CRM22787
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
M15732
CLEVELAND, OHIO U.S.A.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
WELD-PAK 100
F-1
F-2 NOTES
WELD-PAK 100
PARTS
WELD-PAK 100
PARTS MANUAL
NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the Lincoln
Electric Parts List.
WELD-PAK 100
2 PARTS
MAIN EXPLODED DIAGRAM
WELD-PAK 100
PARTS 3
MAIN EXPLODED DIAGRAM
No. No.
Item Description Part No. Reqʼd Item Description Part No. Reqʼd
1 Case Back & Bottom Assembly, S20156-6 1 14e Decal, “Lincoln Logo”, Purchase NSS 1
Includes 1a – 1g decal package Item 19
1a Case Back & Bottom (Sheet Metal) NSS 1 14f Decal, “3-Year Warranty”, Purchase NSS 1
1b Door Stop Button (if present) T14659-1 2 decal package Item 19
1c Hole Plug (Large) Back (if present) M15820 1 14g Decal, “Warning: Electrical Shock NSS 1
1d Hole Plug (Small) Back T10397-22 1 Hazard, Fume Hazard, Spark
1e Capacitor Cushion (Foam), Sits on NSS 1 Hazard, Arc Ray hazard”,
bottom Purchase decal package Item 19
1f Decal, “Electrical Shock Hazard” NSS 1 14h Wiring Diagram M15732 1
(Purchase Decal Pkg. Item 19) 15 Case Door Assembly, Includes S20156-5 1
1g Capacitor Fastener Button Bottom T14659-1 1 15a – 15c
Tap 15a Case Door (Sheet Metal) NSS 1
2 Center Panel Assembly See Center 1 15b Decal, “Lincoln Logo”, Purchase NSS 1
Panel Assby decal package Item 19
2b Slotted Hex Head Screw, #10-3/8" S8025-70 2 15c Welder Application Chart, Purchase L8623-1 1
long, blunt point decal package Item 19
2c Slotted Hex Head Screw, #10-1/2" S8025-65 2 16 Door Hinge M15451 2
long, gimlet point 17 Power Plug Grommet T9724-3 1
9 Complete Drive Assembly/Motor See Drive 1 18 Power Plug & Cord S15254 1
Assby/Motor 19 Decal Package (not shown) S20156-1 1
9a Fastener Button T14659-3 2
9b Slotted Hex Head Screw, #10-3/8 S8025-70 1
long, gimlet point, fine thread
10 Capacitor, Includes 10a – 10c S13490-109 1
10a Hex Head Cap Screw, 1/4"-28, T8833-54 2
0.50" long
10b 1/4" Lock Washer E106A-2 2
10c 1/4" Plain Washer S9262-93 2
11 Transformer & Choke Assembly Contact 1
Factory
11a Slotted Hex Head Screw, #10-3/8" S8025-70 4
long, blunt point
12 Case Front Assembly See Case 1
Front Assby
12a Slotted Hex Head Screw #10-3/8" S8025-65 2
long, blunt point
12b Slotted Hex Head Screw, #10-3/8" S8025-70 1
long, gimlet point, fine thread
13 Rectifier, Fan Motor & Bracket See Rectifier, 1
Assembly Fan & Bracket
Assby
13a Slotted Hex Head Screw #10-3/8" S8025-65 2
long, blunt point
14 Case Side Assembly, Includes L7572-2 1
14a – 14h
14a Side Panel (Sheet Metal) NSS 1
14b Hex/Slotted Screws S8025-65 8
14c Handle, 3/8-16, 0.31" long M15446 2
14d Indented hex Head Washer S9225-53 2
WELD-PAK 100
4 PARTS
COMPLETE DRIVE ASSEMBLY/MOTOR
No. No.
Complete New Drive Assembly/ M15759-3 1 6b Spring T11862-41 1

Motor, Includes All Items 6c 1/4" Plain Washer S9262-98 1
1 – 10 below 6d Plain Washer S9262-70 1
1 Gearbox Mounting Plate L7829 1 6e Wing Nut T9968-1 1
1a Guide Tube Retainer S19127 2 6f Roll Pin T9967-48 1
1b Round Head Screw, #8-32, 0.75" CF000096 4 7 Drive Roll, Includes 7a M16190 1
Long 7a Drive Roll Set Screw S18436 1
1c #8 Shakeproof Lockwasher T9695-3 4 8 Guide Tube S18685-6 2
1d #8 Flatwasher S9262-3 4 9 Conductor Block S18879 1
2 Motor & Gearbox Assembly, L7801 1 9a Hose Nipple S18884 1
Includes 1 – 1d and 2a 9b Thumb Screw T9078-3 1
2a Motor Leads NSS 2 9c Hex Head Cap Screw, 1/4"-20, CF0000170 1
3 Idle Roll Arm L7562 1 0.375" Long
4 Idle Roll Shaft S18436 1 9d 1/4" Lock Washer E106A-2 1
5 Idle Roll M9300-55 1 9e 1/4" Plain Washer S9262-23 1
6 Idle Roll Pressure Parts, Includes S20156-3 1 10 Gearbox Insulation Plastic S19133 1
6a – 6f
6a Idle Roll Arm Clevis S18442 1
WELD-PAK 100
PARTS 5
CASE FRONT ASSEMBLY
No. No.
1 Molded Case Front A464 1 7e #8 Hex Self Tapping Screws .62" S8025-77 1
2 Nameplate M16930-1 1 7f Knob for Voltage Switch M15796 1
3 Fastener Buttons T14659-1 4 8 Output Polarity Stud Mountings, S20156-4 2
4 On/Off Switch, Includes 4a T10800-32 1 Includes 8z – 8i
4a Line Switch Mounting Bracket M15793 1 8a Polarity Stud S18432 1
5 Wire Speed Potentiometer, 5k, 2w, T10812-37 1 8b Plain Washer, .41ID/.81OD/.081" S9262-120 1
Linear (Includes lock washer, thick
hex nut) 8c 3/8" Shakeproof Washer T9695-15 1
6 Wire Speed Potentiometer Knob S18425-1 1 8d 3/8"-16 Hex Jam Nut CF000121 1
7 Arc Volts Selector Switch Assembly, M15750 1 8e 1/4"-20 Brass Hex Nut CF000300 1
Includes 7a – 7e 8f 1/4"-20 Hex Cap Screw 0.50" long CF000012 1
7a Rotor S18873 1 8g 1/4" Plain Washer S9292-98 1
7b Spring T6778 1 8h 1/4" Lock Washer E106A-2 1
7c Moving Contact S18923 1 8i 1/4"-20 Nut CF000017 1
7d Indexing Cam S18872 1
WELD-PAK 100
6 PARTS
RECTIFIER, FAN AND BRACKET ASSEMBLY
No.
Item Description Part No. Reqʼd
Complete Assembly, Includes L7680-2 1

Items 1 – 5 below
1 Bracket for Fan & Rectifier G1839 1
2 Rectifier Assembly (both sides M15447-1 1
with leads)
2a Rectifier Plate M15444 2
2b Rectifier Diode, 70A, 300V, Anode M9661-40R 2
Stud
2c Rectifier Diode, 70A, 300V, M9661-40 2
Cathode Stud
3 Fan Motor M15787-1 1
4 Fan Blade M15432 1
5 Sems Screw to mount motor T10082-27 2
WELD-PAK 100
PARTS 7
CENTER PANEL ASSEMBLY
No. No.
2 Center Panel (Sheet Metal), L7569-8 1 4a Spindle Shaft NSS 1

Includes 2a – 2i, and Items 4, 5, 6 4b Plain Washer, .41ID/.81OD/.081" NSS 1
2a Center Panel (Sheet Metal) NSS 1 thick
2b Slotted Hex Head Screw, #10-3/8" S8025-70 2 4c 3/8" Split Ring Type Lock Washer NSS 1
long, blunt point 4d 3/8"-16 Hex Nut NSS 1
2c Slotted Hex Head Screw, #10-1/2" S8025-65 2 4e Bow Washer T10781-10 1
2d P.C. Board Snap-In Support S19300-2 7 4f Wear Plate S18423 1
2e Cable Hanger T13496-2 1 4g Hollow Lock Screw (not shown) T12932-2 1
2f Gun & Trigger Connection T14530-1 2 5 Wire Spool Thumb Screw S18438 1
Receptacle 6 Circuit Breaker/Lock Washer & T12287-21 1
2g Ground Screw, Pan Head Phillips, S9225-36 1 Hex Nut (25A, 250VAC)
#10-24 Thread Forming Screw 7 Control P.C. Board L8317-1 1
2h Ground, #10 Shakeproof Lock T9695-1 1 8 Plug and Lead Assembly, Includes S18250-52 1
Washer 8a and 8b
2i Ground, #10-24 Hex Nut CF000010 2 8a Control P.C. Board Plug (10-pin) S18249-10 1
3 8" Spool Adapter M15445 1 8b Control P.C. Board Plug Terminals S8053-123 8
4 Spindle Shaft Mountigns, Includes S20156-2 1 (pins)
4a – 4g
WELD-PAK 100
8 PARTS
MAGNUM 100L ASSEMBLY
ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 100L
DESCRIPTION PART NUMBER SIZE

COMPLETE GUN & CABLE ASSEMBLY L8311-3 (K530-3)
1. CABLE LINER M16291-1 .035 – .045" (0.9 – 1.2 mm)

For cables 15' (4.5 m) and less M16291-2 .025 – .030" (0.6 – 0.8 mm)
2. CONTACT TIPS S19726-1 .025" (0.6 mm)

Standard Duty S19726-2 .030" (0.8 mm)
S19726-3 .035" (0.9 mm)
S19726-4 .045" (1.2 mm)
CONTACT TIPS S20278-1 .025" (0.6 mm)

Tapered S20278-2 .030" (0.8 mm)
S20278-3 .035" (0.9 mm)
S20278-4 .045" (1.2 mm)
3. GAS DIFFUSER S19728
4. GAS NOZZLE — Fixed M16294 .50" (12.7 mm)
GAS NOZZLE — Tip Recessed M16684 .375" (9.5 mm)

M16684-1 .50 (12.7 mm)
M16684-2 .625 (15.9 mm)
5. GASLESS NOZZLE M16418
6. GUN TUBE — 60° S19703
WELD-PAK 100
NOTES
SQUARE WAVE TIG 255

NOTES
SQUARE WAVE TIG 255

Now Available...12th Edition New Lessons in Arc Welding
The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques;
With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects,
since 1933, the Procedure Handbook is considered by many to such as distortion; and supplemental information on arc
be the “Bible” of the arc welding industry. welding applications, speeds and costs. Practice materials,
This printing will go fast so donʼt delay. Place your exercises, questions and answers are suggested for each
order now using the coupon below. lesson.
The hardbound book contains over 750 pages of welding 528 pages, well illustrated, 6” x 9” size, bound in simulated,
information, techniques and procedures. Much of this material gold embossed leather.
has never been included in any other book. $5.00 postage paid U.S.A. Mainland
A must for all welders, supervisors, engineers and

designers. Many welding instructors will want to use the book
as a reference for all students by taking advantage of the low
quantity discount prices which include shipping by
4th class parcel post.
$15.00 postage paid U.S.A. Mainland
Need Welding Training?
The Lincoln Electric Company operates the oldest and
How To Read Shop Drawings most respected Arc Welding School in the United States at its
corporate headquarters in Cleveland, Ohio. Over 100,000 stu-
dents have graduated. Tuition is low and the training is
The book contains the latest information and application
“hands on”
data on the American Welding Society Standard Welding
Symbols. Detailed discussion tells how engineers and For details write: Lincoln Welding School
draftsmen use the “short-cut” language of symbols to pass 22801 St. Clair Ave.
on assembly and welding information to shop personnel. Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the readerʼs ability and ask for bulletin ED-80 or call 216-383-2259 and ask for the
to visualize mechanically drawn objects as they will appear Welding School Registrar.
in their assembled form.
187 pages with more than 100 illustrations. Size 8-1/2” x 11” Lincoln Welding School
Durable, cloth-covered board binding. BASIC COURSE $700.00
$4.50 postage paid U.S.A. Mainland 5 weeks of fundamentals
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.
Prices include shipment by 4 th Class Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:
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For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders) Name: _______________________________________________
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USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
Lincoln Welding School Titles: Price Code Quantity Cost

(ED-80) New Lessons in Arc Welding $5.00 L
Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH
(ED-45) How to Read Shop Drawings $4.50 H
Educational Video Information Incentive Management $5.00 IM
(ED-93) A New Approach to Industrial Economics $5.00 NA
James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
Foundation Book Information Welding Preheat Calculator $3.00 WC-8
(JFLF-515) Pipe Welding Charts $4.50 ED-89
SUB TOTAL
Additional Shipping Costs if any
TOTAL COST
● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.

● Insulate yourself from work and
ground.
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.
PRECAUCION ● Aislese del trabajo y de la tierra.
French ● Ne laissez ni la peau ni des vête- ● Gardez à l’écart de tout matériel ● Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
German ● Berühren Sie keine stromführenden ● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec- ● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
● 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.
19
● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or
● Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
● Los humos fuera de la zona de res- Spanish
● Desconectar el cable de ali- ● No operar con panel abierto o
piración.
● Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant ● N’opérez pas avec les panneaux French
● Utilisez un ventilateur ou un aspira- l’entretien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
● Vermeiden Sie das Einatmen von ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
● Mantenha seu rosto da fumaça. ● Não opere com as tampas removidas. ● Mantenha-se afastado das partes
● Use ventilação e exhaustão para ● Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. ● Não opere com os paineis abertos ATENÇÃO
● Não toque as partes elétricas nuas. ou guardas removidas.
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.
LIMITED WARRANTY
STATEMENT OF LIMITED WARRANTY CONDITIONS OF WARRANTY
The Lincoln Electric Company (Lincoln) warrants to the TO OBTAIN WARRANTY COVERAGE:
end user (purchaser) of all new welding and cutting equip-
ment, electrode and flux (collectively called the “Goods”) The purchaser must contact Lincoln or Lincolnʼs Authorized
that it will be free of defects in workmanship and material. Service Facility about any defect claimed under Lincolnʼs
warranty.
This warranty is void if Lincoln or its Authorized Service
Facility finds that the equipment has been subjected to
improper installation, improper care or abnormal opera- Determination of warranty on welding and cutting equip-
tions. ment will be made by Lincoln or Lincolnʼs Authorized
Service Facility.
WARRANTY PERIOD (1) (2) (3)
Lincoln will assume both the parts and labor expense of

correcting defects during the full warranty period. All war- WARRANTY REPAIR:
ranty periods date from the date of purchase to the original If Lincoln or Lincolnʼs Authorized Service Facility confirms
end user or from the date of manufacture if the original the existence of a defect covered by this warranty, the
invoice cannot be provided and are as follows:
ed
defect will be corrected by repair or replacement at
7 Years Lincolnʼs option.
1 sed
• Main power rectifiers on all non-inverter low frequency
(50 and 60 Hz) type welders. At Lincolnʼs request, the purchaser must return, to Lincoln
or its Authorized Service Facility, any “Goods” claimed
3 Years
w er
• All Lincoln welding machines, wirefeeders and plasma defective under Lincolnʼs warranty.
cutting machines unless listed below.
im p
FREIGHT COSTS:
2 Years
e su
The purchaser is responsible for shipment to and from the
s
• Power Arc 4000, Power Arc 5000
Pro-Cut 25, Weldanpower 125
se yLincoln Authorized Service Facility.
1 Year WARRANTY LIMITATIONS

nt
• AC-100
Lincoln will not accept responsibility or liability for repairs
Invertec V100-S, Invertec V130-S, Invertec V200-T
made outside of a Lincoln Authorized Service Facility.
ra
Handy MIG 101, Handy Core 100
• All water coolers (internal or external models) Lincolnʼs liability under this warranty shall not exceed the
ar
cost of correcting the defect of the Lincoln product.

• All stick electrode, welding wire and flux.
w
• Arc welding and cutting robots and robotic controllers Lincoln will not be liable for incidental or consequential
damages (such as loss of business, etc.) caused by the
• All Environmental Systems equipment, including portable
defect or the time involved to correct the defect.
units, central units and accessories. (Does not include
consumable items listed under 30 day warranty.)
This written warranty is the only express warranty provided
• All welding and cutting accessories including wire feed by Lincoln with respect to its products. Warranties implied
modules, undercarriages, field installed options that are
by law such as the warranty of merchantability are limited
sold separately, unattached options, welding supplies,
standard accessory sets, replacement parts, and to the duration of this limited warranty for the equipment
Magnum products. (Does not include expendable parts involved.
and guns/torches listed under 90 and 30 day warranties)
90 Days This warranty gives the purchaser specific legal rights. The
• All gun and cable assemblies, TIG and plasma torches purchaser may also have other rights which vary from state
and spool guns. to state.
30 Days (1)
Equipment manufactured for the Lincoln Electric Company is subject to
• All consumable items that may be used with the environ-
mental systems described above. This includes hoses, the warranty period of the original manufacturer.
filters, belts and hose adapters.
(2)
All engines and engine accessories are warranted by the engine or
• Expendable Parts - Lincoln is not responsible for the engine accessory manufacturer and are not covered by this warranty.
replacement of any expendable part that is required due
to normal wear.
(3)
SAE400 WELD Nʼ AIR compressor is warranted by the compressor man-
ufacturer and not covered by this warranty.
May, ʻ99
• 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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For use with machine Code Numbers 10207 and above

Safety Depends on You

• World's Leader in Welding and Cutting Products •

ELECTRIC SHOCK can ARC RAYS can burn.

3.e. Also see item 7b.

WELDING SPARKS can CYLINDER may explode

8.c. Exposure to EMF fields in welding may have other health

____________________________________________________ Mar. ʻ93

7.e. In some cases it may be necessary to remove safety

7.g. To prevent accidentally starting gasoline engines while

7.h. To avoid scalding, do not remove the

5. Toujours porter des lunettes de sécurité dans la zone de

2. Dans le cas de travail au dessus du niveau du sol, se pro-

for selecting a QUALITY product by Lincoln Electric.

Please Examine Carton and Equipment For Damage Immediately

Serial Number _____________________________________

Model Name _____________________________________

Date of Purchase __________________________________

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Wiring Diagrams ..............................................................................................Section F

WELD-PAK 100 Parts Manual.........................................................................Appendix

FEB 95 WELD-PAK 100

TECHNICAL SPECIFICATIONS – WELD-PAK 100

RECOMMENDED INPUT CABLE AND FUSE SIZES

RATED 115V/60Hz 20 Amp 20 15 Amp, 125V, Three Conductor

2. Gun and cable assembly(1)

3. Literature and miscellaneous including:

4. 10 ft (3,0 m) work cable.

6. Sample 10 lb. spool of Innershield .035" (0,9 mm)

7. Handshield with filter plate and lens.

9. 8” Spool Adapter (2” Spindle) for mounting 10 lb.

10. Chipping hammer/wire brush

For available options and accessories refer to the

WELD-PAK 100 JAN96

SELECT SUITABLE LOCATION Work Clamp Installation

STACKING WORK CABLE

BACKING PLATE & NUT

3. Insert the work cable terminal lug with the larger

GAS CONNECTION (OPTIONAL)

2. With the cylinder securely installed, remove the

3. Attach the flow regulator to the cylinder valve and

Flow Regulator Cylinder Valve

The rated output with this installation is 88 amps, 18

Requirements For CSA Rated Output

The United States National Electrical Code (Article

If there is any question about the installation

Read entire operation section before

FUMES AND GASES can be

WELDING SPARKS can

ARC RAYS can burn eyes

Observe all safety information throughout

The WELD-PAK 100 can be used for welding mild

WELD-PAK 100 JAN96

out when tripped (Manual reset).

Wire Spindle Shaft

Note:When loading and removing the 8” Spools make

The machine power switch should be turned to the