E-3
TROUBLESHOOTING
E-3
SYNERGIC 7F & FH
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
3. Poor arc striking with sticking or
“blast-offs”, weld porosity, narrow
and ropy looking bead, or elec-
trode stubbing into plate while
welding.
4. Tip seizes in diffuser.
5. Unit shuts off while welding and
“HXX” appears on display.
6. Drive roll does not turn although
arc voltage is present and sole-
noid is on.
a. Improper procedures or tech-
niques.
b. Improper gas shielding.
a. Tip overheating due to prolonged
or excessive high current and/or
duty cycle welding.
a. See Problem 1.
b.
Defective wire feed motor or gearbox.
a. Defective Wire Feed Unit to
Control box cable or harnessing.
b. Defective wire feed motor or con-
trol PC board.
a. See “Gas Metal Arc Welding
Guide” (GS-100).
b. Clean gas nozzle. Make certain that gas
diffuser is not restricted. Make certain that
gas cylinder is not empty or turned off.
Make certain gas solenoid valve is operat-
ing and gas flow rate is proper.
Remove gun liner and check rubber seal
for any sign of deterioration or damage. Be
sure set screw in brass connector is in
place and tightened against the liner bush-
ing.
a. Do not exceed current and duty
cycle rating of gun.
A light application of high temper-
ature antiseize lubricant (such as
Lincoln E2607 Graphite Grease)
may be applied to tip threads.
a. Correct problems causing motor
overload.
b. Replace.
a. Remove Wire Feed Unit to Control
Box Cable and Check A to A and
B to B for continuity. If there is no
continuity in either or both cases,
replace cable. Otherwise, check
Harnessing from A and B of MS
connector on control box to con-
trol board and A and B at Wire
Feed Unit MS connector to Motor
leads for continuity. If harnessing
is O.K. proceed to b.
b. Set Run-In speed to maximum.
Disconnect wire drive plug P4
from PC board. Measure voltage
across pin 9(+) of J4 and pin 8(-)
of J4 on PC board with pins 2 &
12 jumpered together. If voltage
is > 24V DC, then replace motor
assembly. If < 24V DC, replace
Control PC board (see Procedure
for Replacing PC Boards).