Lincoln Electric SVM167-A service manual Liner Removal and Replace Ment, Table D.1

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D-3

MAINTENANCE

D-3

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.

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

KP1934-2

.030 (0.8 mm)

KP2026-3

KP2026-2

(0.6-0.8 mm)

 

 

 

 

.035-.045" Steel

KP1934-1

.045 (1.2 mm)

KP2026-3

KP2026-2

(0.9-1.2 mm)

 

 

 

 

 

 

 

 

 

3/64" Aluminum

KP1955-1

3/64" (1.2 mm)

KP2026-3

KP2026-2

(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 cutoff length requirement. Liners are shipped with the jacket of the liner extended the proper amount.

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.)

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

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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.

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- tor at the feeder end of the cable and pull the liner out of the cable.

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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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.

CAUTION

This screw should only be gently tightened. Overtightening will split or collapse the liner and cause poor wire feeding.

POWER MIG® 215

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Contents Safety Depends on You Power MIGCalifornia Proposition 65 Warnings SafetyCan be dangerous Electric Shock can kill ARC Rays can burnWelding and Cutting Sparks can cause fire or explosion Cylinder may explode if damagedIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation SECTION  Table of ContentsTechnical Specifications Power MIG InstallationLocation Safety PrecautionsUncrating the Power MIG InstallationOutput Polarity Connections Cylinder may explode if damaged GUN and Cable InstallationAUXILIARY POWER RECEPTACLES Shielding GASPower MIG Operation SECTION  Wear eye, ear and body protec- tion OPERATIONB-2Operation Procedure for Changing Drive AND IDLE Roll Sets Wire Reel Loading READI-REELS, Spools or CoilsTo Start the Welder Feeding Wire Electrode Idle Roll Pressure SettingWire Drive Configuration Figure B.2b Making a WeldInput Line Voltage Variations Avoiding Wire Feeding ProblemsWire Feed Overload Protection FAN ControlPower MIG Accessories SECTION  Accessories Adapter KIT and Spool GUN 3ACCESSORIESC-3Installed Making a Weld with the Spool GUNPower MIG Maintenance SECTION  Maintenance Table D.1 Liner Removal and Replace MentEnglish Metric Description Size GUN Handle DisassemblyFigure D.2 Major Component Locations Power MIG Theory of Operation SECTION  Line SwitchTheory of Operation Figure E.2 Input Power CircuitFigure E.3 Control Circuits Output Rectification Contactor and Control BoardFigure E.4 Optional Circuits Control BOARD, GUN Trigger and Wire Drive MotorWirefeed Overload Protection Protective Devices and CircuitsThermal and Overload Protection Power MIG TROUBLESHOOTING AND REPAIR SECTION  How To Use Troubleshooting Guide Troubleshooting and RepairPC Board Troubleshooting Procedures Perform the Main Transformer Perform the Output Contactor These capacitors is toxic Avoid contact with any portionYour body Function Problems Wire Speed Potentiometer Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Main Transformer Test Test DescriptionMaterials Needed Test Procedure ON/OFF Power Switch will be hot during these testsMain Transformer Test X10 Input Voltage Test Points Table F.1. Test PointsWire Drive Motor and Wire Speed Potentiometer Test White BlackTest for Feedback Voltage to Control Board 1109 aVDC Power MIG Output Bridge Rectifier Test Output Bridge Rectifier Test Negative LeadContactor 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 Motor Assembly Replacement Wire DriveBolt 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 3 places Power MIG Main Transformer Replacement 41TROUBLESHOOTING and Repair F-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 DiagramsPOWEr miG Power MIG 215 208/220/230VPower MIG 215 208/220/230V for Codes 11099 L12308 SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG1SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG2 ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS
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