Lincoln Electric Guide to Lincoln SP-100 Drive Roller and Wire Drive Assembly Removal

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F-13

TROUBLESHOOTING & REPAIR

 

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WIRE DRIVE ASSEMBLY REMOVAL

PROCEDURE DESCRIPTION

The following procedure will aid in the removal of the entire wire drive unit for possible motor or gear box replacement.

TOOLS REQUIRED

5/16” nutdriver or socket wrench

1/4” nutdriver or socket wrench

Phillips head screwdriver

Needle nose pliers

Knife or side cutters

Screwdriver (slot head)

PROCEDURE

Refer to Figure F.5.

1A. FOR CODES ABOVE 10000

Cut heads off of two plastic fastener buttons locat- ed on the front panel. (Order new fastener buttons

– Part No. T14659-3)

1B. FOR CODES BELOW 10000

Remove two flat head screws holding conductor block to front panel.

2.Remove gas hose from Connector block.

3.Remove cable running from output terminal to Connector block (1).

4.With 5116’’ nutdriver, remove mounting screw at rear of wire drive assembly.

5.With 5/16” nutdriver, remove screw holding the front panel to the case bottom. Carefully move front panel forward 1/2”.

6.Carefully slide out wire drive unit until motor leads are visible. Using needle nose pliers, remove motor leads, taking note of lead positions.

7.Remove wire drive unit from machine.

MOTOR REMOVAL PROCEDURE

Refer to Figure F.6

1.Remove one Phillips head screw connecting front to rear housing (1).

2.Using 1/4” nutdriver, remove two 8-32X1” thread forming screws connecting front to rear housing

(2).

Refer to Figure F-7

FIGURE F.5

1

Two plastic fastener buttons attach the Connector Block to the Front Panel at these points. To remove the Connector Block, cut the heads off of the two fastener buttons.

FIGURE F.6

FIGURE F.7

Note: Slight resistance as rear housing is separated from the front is caused by the bearing, which will remain attached to the front housing.

3.Remove motor with rear housing.

4.Remove two screws holding motor to rear hous- ing.

5.Separate motor from rear housing.

SP-100

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Contents SP-100 ARC Rays can burn SafetyElectric Shock can kill Fumes and Gases can be dangerousCylinder may explode if damaged Welding Sparks can cause fire or explosionElectric and Magnetic Fields May be dangerousPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SectionInstallation Technical Specifications SP-100Installation Safety PrecautionsRead entire installation section before starting Identify and Locate ComponentsOutput Connections Work Clamp InstallationSelect Suitable Location TiltingGAS Connection GUN InstallationConnecting GUN Cable to the SP-100 Gas Solenoid Inlet Fitting PowerInput Connections InputRequirements for CSA Rated Output Code Requirements for Input ConnectionsRequirements for Maximum Output Requirements for Rated OutputSP-100 Table of Contents Operation Wear eye, ear and body protec- tionGeneral Description Operational Features and ControlsDesign Features Advantages OffProcess Guidelines Wire LoadingWelding Operations Sequence of OperationFriction Brake Adjustments Refer to Figure B-4Shielding GAS Making a WeldOverload Protection SP-100 Accessories Section Lincoln GAS Regulator Kits K467 Input Line Cord 1ACCESSORIESReplacement Parts Innershield Welding KitsMaintenance Section Routine and Periodic Maintenance MaintenanceItems Requiring no Maintenance Liner trim length for the Magnum 100L gun red trigger Changing the Contact TIPChanging Drive Roll Figure D.3 SP-100 SUB Assemblies SP-100 Theory of Operation Figure E.1 Input Power Circuits Input Line VOLTAGE, FAN Motor and Main TransformerOutput CONTROL, RECTIFICA- Tion and Voltage Feedback Figure E.2 Output CircuitsTRIGGER, GAS Solenoid and Wire Drive 3THEORY of OperationSCR Operation Figure E.4 SCR OperationThermostat protects the machine from Troubleshooting Section Oscilloscope Waveforms1TROUBLESHOOTING & Repair HOW to USE Troubleshooting GuideTroubleshooting & Repair PC Board Troubleshooting ProceduresFacility Troubleshooting GuideAuthorized Field Service Below Code 9794 only Recommended Course of Action Problems SymptomsPossible Areas of Misadjustments Code 9794 and AboveFeeding Problems Troubleshooting Guide PC Board Connector Locations Codes 9794 and above 6J1 10J2 1J1 1J2 Codes below SP-100Volts Volts/Div 9TROUBLESHOOTING & RepairScope Settings Normal Open Circuit Voltage WaveformVolts Typical Output Voltage Waveform Machine LoadedAbnormal Open Circuit Voltage Waveform FAN Blade and Motor Removal Procedure DescriptionProcedure Tools Required1A. for Codes Above Wire Drive Assembly RemovalMotor Removal Procedure 1B. for Codes belowMain Transformer Secondary Voltages Test Points Wire Speed RangeRetest After Repair Input Amps AT Rated Output Input Amps AC @ Output DCSP-100 Electrical Diagrams Section Diagram Wiring DiagramsWiring SP-100 Wiring Diagram Codes Below 4 5 1 MElectrical Diagrams Electrical Diagrams Control P.C. Board G1842Control P.C. Board G2314 Control P.C. Board G2314 SCR1, SCR2 SCR 81 Heatsink AsblyMachine Schematic Codes 9794 and Above ErrorMachine Schematic Codes Below 86R R63R64 1 5 KSVM Error Reporting Form