Lincoln Electric SVM114-C service manual Figure F.26

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F-42	TROUBLESHOOTING AND REPAIR		F-42
	CONTACTOR REPLACEMENT	(continued)
	FIGURE F.26.

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11/16" BRASS

NUTS

IN-LINE

CONNECTORS

POLARITY

SWITCH

ELECTRODE

CABLE

VOLTAGE SENSING

LEAD #67

ELECTRODE

LEAD

WELDING CABLES

CONTACTOR

WORK SENSING LEAD

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REPAIR PROCEDURE

1. Open the case door. Remove the wire reel by removing the retaining collar. See Figure F.5.

2. Remove the screws holding the control box cover in place and remove the control box cover.

3. Remove the two fiber baffles from the area in front of the contactor. See Figure F.25.

4. With a 3/4” wrench, remove the electrode lead. See Figure F.26.

5. Using the 11/16” wrench, remove the two brass nuts from the contactor terminals. Remove the heavy leads and lead #67 from the terminals. Note location of lead #67. See Figure F.26.

6. Remove the 5/16” screw holding the contactor bracket to the spindle bracket.

7. Disconnect the contactor coil leads by separating the two in-line connectors behind the reel stand assembly.

8. Cut or remove any cable ties or harness tape as necessary.

9.Carefully remove the contactor assembly from the LN-25™.

10.Install a new contactor in the LN-25™.

11.Connect the contactor coil lead in-line connectors behind the reel stand assembly. See Figure F.26.

12.Place contactor assembly in position.

13.Install the 5/16" screw to secure the contactor to the spindle assembly.

14.Install the welding cables and voltage sensing lead #67 to the contactor and secure with the two 11/16" brass nuts. See Figure F.26. Be sure brass nuts are tight. 11 ft-lb torque is recommended.

15.Install the baffles in front of the contactor.

16.Install the control box cover and secure by installing the screws previously removed.

17.Install the wire reel and retaining collar and close the case door.

18.Install the two 5/8” screws previously removed from the bottom of the machine.

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LN-25™

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Contents Semiautomatic Wire Feeder Safety California Proposition 65 WarningsCan be dangerous Electric Shock can killFumes and Gases Iii Welding and Cutting Sparks can Cause fire or explosionCylinder may explode if damaged Précautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SectionInstallation Technical Specifications LN-25Wire Feed Speed CurrentrentSafety Precautions Power Source ConnectionINVERTEC, CV300 and Other Newer Lincoln Power Sources GUN Cable Connection to FeederWith CV Adapter For GMA GUN and CablesWire Feed Drive Roll and Guide Tube Kits Weld Cable ConnectionElectrode Cable Connection Work Cable ConnectionLN-25 Operation Section Read and Understand Entire Section Before Operating Machine OperationWelding Capability Electrode Polarity Switch Wire Feed Mode SwitchWire Speed Dial and Range Switch LN-25 Instruments ControlsGAS Post PRE-FLOW Timers Optional Work Clip LeadAWG Remote ARC Voltage Control OptionalSequence of Operation Loading ElectrodeMounting 22 to 30 LB READI-REELCOILS Mounting 10 to 30 LB SpoolsLoading Wire Drive Idle Roll Pressure SettingGrooves READI-REEL Inside Cage Wires 6OPERATIONB-6Presetting Wire Feed Speed Setting Constant Wire Feed Speed CV ModeSetting ARC Sensing Wire Feed Speed CC Mode Minimum Arc VoltsFigure B.4 VV CC Wire Speed Setting Making a WeldCylinder may explode if damaged Procedure AT END of CoilWelding Motor Overload Shutdown Circuit Protection and Automatic ShutdownOvervoltage Shutdown Accessories Section Accessories Section CAccessories LN-25 Option ChartHow to use Table C.1 Table C.1GAS Solenoid KIT K430-2 for Codes Optional AccessoriesK434-1 GAS Flow Timer KIT K433 Power Source Remote BOX K432 Remote Control Cable AssemblyRemote Output Control Options and Control Cable Assemblies LN-25 Contactor KIT K443-1 for CodesK439 Remote Extension Cable Assembly K625, K626, K627 Remote Control Cable AssemblyK624-1 42V Remote Output Control Module K444, K444-1 or K444-2 Remote Voltage Control KITConnector Must be Insulated in this Area To GUN Switch Connect Leads to Pins a and CStyle a DIA. HoleMaintenance Section Adjusting Speed Sensor Module MaintenanceRoutine Maintenance Calibration of LN-25 Wire Speed Dial LN-25 Figure E.1 Theory of Operation Block Diagram Theory of Operation SectionInput Power Circuit Theory of OperationGeneral Description Control Circuit OperationFeedback and Control Circuits Trigger CircuitOptional Circuits ContactorGAS Solenoid Later ModelsProtective Devices Circuits Control PC Board FusesLN-25 Troubleshooting and Repair Section 2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting GuideTroubleshooting and Repair PC Board Troubleshooting ProceduresFeeding Problems Feeding Problems Hall Effect GAS Solenoid Valve and Solenoid PC Board Test Test DescriptionMaterials Needed For Codes below 10500 onlyTest Procedure Screw Wire Reel Retaining CollarCase Door GAS Solenoid ValveFigure F.2 Solenoid Leads Troubleshooting and Repair GAS Solenoid Valve and Solenoid PC Board Test 512624A 621 J11 PC Board for K430 GAS Solenoid KITLN-25 GAS Solenoid Valve and Control PC Board Test For Codes Above 10500 onlyFor Codes Above 10500 only Figure F.5 Control BOX Cover RemovalSolenoid Leads Figure F.6. Solenoid LeadsFigure F.7. Applied Voltage Polarity Control PC Board Solenoid Circuitry TestG3425 667 555 691 621 500 512 690LN-25 Hall Effect Module Test 539 G1757 Hall Effect Module TestG2196 539 541 500 Figure F.11 Control PC Board Codes Above LN-25 Wire Drive Motor Test Drive Motor Lead IN-LINE Connector Hall Effect Module Contactor & Contactor PC Board Test Contactor Test Procedure Contactor & Contactor PC Board TestS20963 Contactor Coil Leads667 28TROUBLESHOOTING and Repair F-28Contactor PC Board Test J14 LN-25 Contactor PC Board Replacement Tools RequiredContactor PC Board Replacement Repair Procedure33TROUBLESHOOTING and Repair F-33 Figure F.17 Control PC Board Replacement Control PC Board Replacement Figure F.21. Control PC Board Codes 9812 and belowFigure F.22. Plug Locations for L12253- Control Board J14Figure F.24. Control Board Replacement PC Board Screw Contactor Replacement For Codes below40TROUBLESHOOTING and Repair F-40 Contactor ReplacementFor Codes Above Figure F.26 Phillips Head Screwdriver Wrench Pliers Present Replacement Purge Switch Leads Solenoid Plug J11GAS Solenoid Valve AND/OR Solenoid PC Board if GAS SolenoidFigure F.29. Solenoid Assembly Wiring Codes 9812 and below Figure F.31. GAS Solenoid Assembly for Earlier Codes Phillips Head Screwdriver Wrench Slot Head Screwdriver 48TROUBLESHOOTING and Repair F-48 Drive Motor and Gearbox Replacement and Access toHall Effect Module Mylar Insulation Electrode CableG1757 Figure F.34. Drive Motor Replacement Retest After Repair LN-25 Electrical Diagrams Table of Contents Electrical Diagrams SectionWiring Diagram Above Code 11140 G4679 Optional 42 Volt Remote Output ControlWiring Diagram Code 10556 Thru 10500 L10925 Wiring Diagram Code 10100 Thru 10500 L9644 Wiring Diagram below Code 9900 L7545 Schematic Complete Machine Codes Above 11140 G5366 LN-25 Across the ARC ModelSchematic Complete Machine below Code 9900 only G1833 Schematic Control PC BD Above Code 11140 G4616-5 Schematic Control PC BD Code 10556 Thru 10558 G3424-3 Schematic Control PC BD Code 10100 Thru 10500 G2194 L12253-3 PC Board Assembly Control Abovr Code 11140 L12253-3L12253 PC Board Assembly Control Code 10556 Thru 10558 G3425-3 G3425PC Board Assembly Control Code 10100 Thru 10500 G2196-1 PC Board Assembly Control below Code 9900 G1757-6 LN-25 ControlSchematic Contactor PC BD Above Code 10500 M10965 ContactorSchematic Contactor PC BD Code 10100 Thru 10500 M17621 Electrical Diagrams Electrical Diagrams PC Board Assembly Contactor Above Code 10500 L10863-1 L10863PC Board Assembly Contactor Code 10100 Thru 10500 L9670-1 PC Board Assembly Contactor below Code 9900 L9185-2