Lincoln Electric SVM189-B service manual Issues Maintenance Section

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F-9

TROUBLESHOOTING & REPAIR

F-9

 

 

 

 

 

 

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

RECOMMENDED

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

SPOOL GUN PROBLEMS

 

 

Intermittent wire feed when the

1. Wire is mechanically binding

1. Check that wire is properly

 

Spool Gun trigger is pulled.

along its feed path inside gun.

aligned inside gun.

 

 

 

2. Drive roll has become loose on

2. Check that drive roll is

 

 

 

hub and output shaft.

securely fastened in place by

 

 

3. Drive roll has become galled

SHCS (socket head cap

 

 

 

screw); replace hub and twist-

 

 

with aluminum.

 

 

lock if worn.

 

 

 

 

 

 

 

4. Wire has become kinked along

3. Remove and then clean or

 

 

 

its feed path.

 

 

 

replace drive roll. (See

 

 

 

 

 

 

 

5. Liner assembly is shaving

Maintenance Section).

 

 

 

 

 

 

 

wire.

4. Manually pull wire slowly thru

 

 

 

 

 

 

gun until unkinked wire

 

 

 

 

emerges.

 

 

 

 

5. Check that wire is properly

 

 

 

 

aligned at liner inlet; realign

 

 

 

 

gun tube with wire drive. (See

 

 

 

Correcting Wire Shaving

 

 

 

 

Issues Maintenance Section)

 

 

 

 

Frequent occurrences of contact

1. Improper welding parameters

1. See Operation Section for

 

tip burnback when using the

or technique. ( Example:

proper Welding information.

 

Spool Gun.

 

CTWD (Contact Tip to Work

2. See symptoms on intermittent

 

 

Distance) is incorrect.

 

 

or sluggish wire feed.

 

 

 

 

 

 

 

2. Wire may be feeding

 

 

 

 

intermittently.

 

 

 

 

 

Poor weld bead appearance

1. No gas flow.

1. See symptom “Low or no gas

(porosity or dull grey oxidized

2. Low gas flow.

flow”

 

surface) When using the Spool

2. See symptom “Low or no gas

Gun.

 

3. Improper or contaminated

 

 

flow”

 

 

 

shielding gas.

 

 

 

 

 

 

 

4. Welding in a windy

3. Check that the gas supply’s

 

 

 

labeling reads 100% argon.

 

 

 

environment.

 

 

 

Temporarily use alternate,

 

 

 

 

 

 

 

5. Improper electrode polarity.

known gas supply and check

 

 

for appearance improvement.

 

 

 

 

 

6. Improper welding parameters

4. Erect a wind shield or move to

 

 

or technique.

 

 

a non-windy location before

 

 

 

 

 

 

 

 

welding.

 

 

 

 

5. Reconnect machine’s welding

 

 

 

output to electrode positive

 

 

 

 

polarity.

 

 

 

 

6. See Operation Section for

 

 

 

 

information.

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

COMPACT WIRE WELDERS

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Contents SVM189-B Safety Depends on YouCalifornia Proposition 65 Warnings SafetyElectric Shock can kill ARC Rays can burn Welding Cutting For ElectricallyIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications InstallationTilting Safety PrecautionsSelect Suitable Location StackingIdentify and Locate Components Table of Contents Operation Section Wear eye, ear and body protec- tion OperationProduct Description Product Capabilities Common Welding AbbreviationsControls and Settings See Figure B.1See Figure B.2 Drive Roll Tension Thumbscrew Turning See Figure B.3Number Part Number Wire Diameter Drive Roll Drive Roll Part Inner Wire GuideItems Needed for Flux Cored Welding Setting UP and Making a FLUX-CORED WeldLoad Wire Spool Connect Leads and Cables onMachine Figure B.9 025 MIG Conversion Kit K2526-1Shielding GAS Install Shielding GASConnect Leads and Cables on the Machine 11OPERATIONDo not Remove or Conceal Warning Labels 12OPERATIONFigure B.20 Compact Wire Welders Table of Contents Accessories Section K2377-1 Small Canvas Cover AccessoriesK2525-1 Spot Timer Kit K2532-1 Magnum 100SG Spool GunK520-Utility Cart K2275-1 Welding Cart Unpacking the Spool GUN Technical Specifications Magnum 100SG Spool GUN K2532-1Locating Spool GUN Components Features Safety PrecautionsFigure C.3 Assembly of Items Inside the Magnum Spool GUNSafety Precautions Welding Machines Recommended Welding MachinesSpool GUN Spool GUN / Wire Drive Selector Switch Installation Disconnect input power from the machineOpen the Machine Electrical Connections 11.B. Connect P5 6-pin to harness J8 6-pin11.C. Connect harness P8 6-pin to board J5 6- pin 544A 543A If Machine does have Optional Spot Timer .A. thru 12.DRE-ASSEMBLE Machine AS Follows Mounting the SwitchPreparing the Spool GUN ACCESSORIESC-13Disconnect input power to the machine Routine Welding Machine PreparationFigure C.5 Loading Aluminum WireFigure C.11 Figure C.17 Connecting the GUN to the Welding MachineTable of Contents Maintenance Section Maintenance Maintenance Safety PrecautionsRoutine Maintenance GUN and Cable Maintenance Overload ProtectionFor Magnum 100L GUN Changing Liner GUN Handle PartsLiner trim length Major Component Locations Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 General Description Theory of OperationInput Line VOLTAGE, FAN Motor & Main Transformer Figure E.3 Input Power CircuitsFigure E.4 Output Circuits Output CONTROL, Rectification & Voltage FeedbackFigure E.5 TRIGGER, GAS Solenoid & Wire Drive TRIGGER, GAS Solenoid and Wire DriveFigure E.6 SCR Operation SCR OperationElectronic Wire Drive Motor Protection Compact Wire Welders Table of Contents Troubleshooting & Repair HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board Troubleshooting Procedures Wiring Diagram OUTPUT/FEEDING Problems Feeding Problems Welding Problems Maintenance Section Issues Maintenance Section Cone or gas diffuser Case Cover Removal and Replacement Procedure Test DescriptionMaterials Needed Figure F.1 Case Removal ProcedureGAS Solenoid Test GasSolenoid Leads Wire Drive Motor Test MOT-MOT+ Test ProcedureMain Transformer Test Secondary Test Procedure Secondary Lead Compact Wire Welders FAN Motor Test Figure F.5. Control Board Lead Locations Scope Settings Typical Output Voltage Waveform Machine LoadedVolts 10Volts 20ms Abnormal Open Circuit Voltage Waveform Control Board Removal and Replacement Procedure See Figure F.7 Nameplate Control Knob Compact Wire Welders Power Module Removal and Replacement Procedure Viewed from Rear of Machine Center Panel PolarityPanel CenterPanelScrews OutputStuds Compact Wire Welders Misc. Hand Tools Dow Corning Fine Steel Wool See Figure F.12 Dow Corning Figure F.12 DOW Corning Application Areas Transformer Compact Wire Welders Wire Drive Motor Removal and Replacement Procedure Lincolnelectric Phillips Mounting Screws Compact Wire Welders FAN Motor Assembly Removal and Replacement Procedure Viewed from Rear of Machine Center Panel CenterPanelScrews Locking Tabs Fan Open Circuit Voltage Troubleshooting & Repair Retest After Repair 125 AMP UnitsWire Speed Range Retest After Repair 140 AMP UnitsTroubleshooting & Repair Retest After Repair 180 AMP Units Table of Contents Diagram Section COmpacT WirE WElDErS Wiring DiagramSpool GUN Interface Wiring Diagram Wiring Diagram Thermostat TMP FAN TS1 M20410-3 a COmpacT WirE WElDErSSchEmaTic cOmplETE machiNE m21240 C12 R1Feed R24
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