Lincoln Electric SVM157-A service manual Liner Removal and REPLACE- Ment, Cause poor wire feeding

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D-3

MAINTENANCE

D-3

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CAUTION

Excessive pressure at the start may cause the dirt to form a plug.

Flex the cable over its entire length and again blow out the cable. Repeat this procedure until no further dirt comes out. If this has been done and feed problems are experienced, try liner replacement, and refer to the trouble shooting section on rough wire feeding.

LINER REMOVAL AND REPLACE- MENT

NOTE: Changing the liner for a different wire size requires replacement of the gas diffuser per Table D.1 to properly secure the different liner.

4.Insert a new untrimmed liner into the connector end of the cable. Be sure the liner bushing is stencilled appropriately for the wire size bing used.

5.Fully seat the liner bushing into the connector. tight- en the set screw on the brass cable connector. the gas diffuser, at this time, should not be installed onto the end of the gun tube.

6.With the gas diffuser still removed from the gun tube, be sure the cable is straight, and then trim the liner to the length shown in Figure D.1. Remove any burrs from the end of the liner.

7.Screw the gas diffuser onto the end of the gun tube and securely tighten. Be sure the gas diffuser is cor- rect for the liner being used. (See table and diffuser stencil.)

TABLE D.1

 

 

 

Fixed

Adjustable

 

 

 

Nozzle

Nozzle

 

Replacement

Size Stencilled

Gas Diffuser

Gas Diffuser

Diameter of

Liner Part

on End of

Part No.

Part No.

Electrodes Used

Number

Liner Bushing

(and Stencil)

(and Stencil)

.025-.030" Steel

M16087-2

.030 (0.8 mm)

S19418-3

S19418-2

(0.6-0.8 mm)

 

 

 

 

.035-.045" Steel

M16087-1

.045 (1.2 mm)

S19418-3

S19418-1

(0.9-1.2 mm)

 

 

 

 

3/64" Aluminum

M17714-1

3/64" (1.2 mm)

S19418-3

S19418-1

(1.2 mm)

 

 

 

 

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LINER REMOVAL, INSTALLATION AND TRIMMING INSTRUCTIONS FOR

MAGNUM 250L

NOTE: The variation in cable lengths prevents the interchangeability of liners between guns. Once a liner has been cut for a particular gun, it should not be installed in another gun unless it can meet the liner cut- off length requirement. Liners are shipped with the jacket of the liner extended the proper amount.

1.Remove the gas nozzle and nozzle insulator, if used, to locate the set screw in the gas diffuser which is used to hold the old liner in place. Loosen the set screw with a 5/64" (2.0 mm) Allen wrench.

8.Tighten the set screw in the side of the gas diffuser against the cable liner using a 5/64" (2.0 mm) Allen wrench.

FIGURE D.1

SET SCREW

BRASS CABLE CONNECTOR

1-1/4"

(31.8mm)

LINER

TRIM

LENGTH

SET SCREW

GAS DIFFUSER

NOZZLE INSULATOR (IF USED)

GAS NOZZLE

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2.Remove the gas diffuser from the gun tube.

3.Lay the gun and cable out straight on a flat surface.

Loosen the set screw located in the brass connec-

 

 

CAUTION

tor at the feeder end of the cable and pull the liner

 

 

 

out of the cable.

This screw should only be gently tightened.

 

Overtightening will split or collapse the liner and

 

cause poor wire feeding.

POWER MIG 200

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Contents Safety Depends on You Power MIGCalifornia Proposition 65 Warnings SafetyARC Rays can burn Electric Shock can killIii Cylinder may explode if damagedSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation Section Table of ContentsTechnical Specifications Power MIG Installation3INSTALLATIONA-3 Figure A.1 Dual Voltage Machine Input Connections Figure A.2 Triple Voltage Machine Input Connections Output Polarity ConnectionsShielding GAS GUN and Cable InstallationCylinder may explode if damaged Operation Section B Operation SectionWear eye, ear and body protec- tion OperationWire Size Conversion Parts Wire Drive RollProduct Description Recommended Processes and EquipmentWire Reel Loading READI-REELS, Spools or Coils Procedure for Changing Drive and Idle Roll SetsTo Start the Welder Idle Roll Pressure Setting Feeding Wire Electrode Making a WeldWire Feed Overload Protection Avoiding Wire Feeding ProblemsFAN Control Input Line Voltage VariationsAccessories Section Drive Roll Kits AccessoriesK363P READI-REEL Adapter Dual Cylinder Mounting KIT K1702-1Adapter KIT and Spool GUN InstalledPower MIG Maintenance Section Maintenance Liner Removal and REPLACE- Ment Cause poor wire feedingThis screw should only be gently tightened Overtightening will split or collapse the linerEnglish Metric Description Size GUN Handle DisassemblyMaintenance Power MIG Theory of Operation Section Line SwitchTheory of Operation Motor Control Board Output Rectification Contactor and Control BoardFigure E.4 Optional Circuits Control BOARD, GUN Trigger and Wire Drive MotorThermal and Overload Protection Wirefeed Overload ProtectionPower MIG Troubleshooting and Repair Section F Troubleshooting and Repair SectionHow To Use Troubleshooting Guide Troubleshooting and RepairPC Board Troubleshooting Procedures Perform the Main Transformer Perform the Output Contactor Avoid contact with any portion These capacitors is toxicYour body Function Problems Tachometer Feedback Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Test Description Main Transformer TestMaterials Needed Main Transformer Test ON/OFF Power Switch will be hot during these testsX10 Input Voltage Test Points Table F.1. Test PointsWire Drive Motor and Tachometer Feedback Test Figure F.4. Plug J4 Test ProcedureTest for Supply Voltage to Tachometer Disconnect the main AC input power to the machineVDC Test for Feedback Voltage to Control BoardOutput Bridge Rectifier Test Output Bridge Rectifier Test Test ProcedureContactor Test Figure F.7. Contactor Terminals and Leads Contactor TestTypical Output Voltage Waveform Machine Loaded MAX TAP G Volts 10.0Normal Open Circuit Voltage Waveform MAX TAP G Volts 20.0Machine Loaded to 180 Amps AT 16 VDC Scope Settings Volts 20.0 Description Control Board ReplacementProcedure Control Board ReplacementWire Drive Motor Assembly Replacement Wire Drive Wire Drive Motor Assembly ReplacementBolt Gas Hose TOC Output Diode Bridge Rectifier Replacement Output Diode Bridge Rectifier Mounting Bracket Mounting Bolts Rectifier Power MIG Output Capacitors Replacement Figure F.14. Capacitor Bank Location Output Capacitors ReplacementLead Mounting Bolts Nuts & Lock washers Places Power MIG Main Transformer Replacement 41TROUBLESHOOTING and REPAIRF-41See Figure F.17 Main Transformer ReplacementFigure F.17. Leads X9, X10, 104B,104C, & H1B ReplacementX2 X3 X4 X5 X6 X7 Lead Power MIG FAN BLADE/MOTOR Replacement Perform the Output Capacitor Bank Removal Procedure FAN BLADE/MOTOR ReplacementOutput Contactor Replacement Figure F.24 Output Contactor ReplacementMounting Bolts Retest After Repair Table of Contents Electrical Diagrams Section Electrical DiagramsWiring Diagram Power MIG 200 208/230VSchematic Control PC Board G3851-1 PC Board ASSEMBLY-CONTROLSVM Error Reporting Form
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