Maintenance Section | Lincoln Electric SP-100 manual

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Return to Master TOC

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TABLE OF CONTENTS	Section D
– MAINTENANCE SECTION –

Maintenance	Section D
Safety Precautions	D-1
Items Requiring No Maintenance	D-1
Routine and Periodic Maintenance	D-1
Before Each Use	D-1
After 5 Minutes of Welding	D-1
After Each Spool of Wire Feed	D-1
Component Replacement Procedures	D-2
Changing The Contact Tip	D-2
Changing Drive Roll	D-2
Replace Liner	D-3
Replace Internal Gun Handle Parts As Necessary	D-3
Location of Components	D-4

SP-100

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Lincoln Electric SP-100 service manual Maintenance Section

Contents

SP-100 Electric Shock can kill SafetyARC Rays can burn Fumes and Gases can be dangerous Welding Sparks can cause fire or explosion Cylinder may explode if damaged May be dangerous Electric and Magnetic Fields Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Master Table of Contents for ALL Sections Installation Section Table of Contents Technical Specifications SP-100 Installation Read entire installation section before starting Safety PrecautionsInstallation Identify and Locate Components Select Suitable Location Work Clamp InstallationOutput Connections Tilting Connecting GUN Cable to the SP-100 GUN InstallationGAS Connection Input Connections PowerGas Solenoid Inlet Fitting Input Requirements for Maximum Output Code Requirements for Input ConnectionsRequirements for CSA Rated Output Requirements for Rated Output SP-100 Table of Contents Wear eye, ear and body protec- tion Operation Design Features Advantages Operational Features and ControlsGeneral Description Off Welding Operations Wire LoadingProcess Guidelines Sequence of Operation Refer to Figure B-4 Friction Brake Adjustments Making a Weld Shielding GAS Overload Protection SP-100 Accessories Section Replacement Parts 1ACCESSORIESLincoln GAS Regulator Kits K467 Input Line Cord Innershield Welding Kits Maintenance Section Items Requiring no Maintenance MaintenanceRoutine and Periodic Maintenance Changing Drive Roll Changing the Contact TIPLiner trim length for the Magnum 100L gun red trigger Figure D.3 SP-100 SUB Assemblies SP-100 Theory of Operation Input Line VOLTAGE, FAN Motor and Main Transformer Figure E.1 Input Power Circuits Figure E.2 Output Circuits Output CONTROL, RECTIFICA- Tion and Voltage Feedback 3THEORY of Operation TRIGGER, GAS Solenoid and Wire Drive Figure E.4 SCR Operation SCR Operation Thermostat protects the machine from Oscilloscope Waveforms Troubleshooting Section HOW to USE Troubleshooting Guide 1TROUBLESHOOTING & Repair PC Board Troubleshooting Procedures Troubleshooting & Repair Authorized Field Service Troubleshooting GuideFacility Below Code 9794 only Possible Areas of Misadjustments Problems SymptomsRecommended Course of Action Code 9794 and Above Feeding Problems Troubleshooting Guide Codes 9794 and above 6J1 10J2 1J1 1J2 Codes below SP-100 PC Board Connector Locations Scope Settings 9TROUBLESHOOTING & RepairVolts Volts/Div Normal Open Circuit Voltage Waveform Typical Output Voltage Waveform Machine Loaded Volts Abnormal Open Circuit Voltage Waveform Procedure Procedure DescriptionFAN Blade and Motor Removal Tools Required Motor Removal Procedure Wire Drive Assembly Removal1A. for Codes Above 1B. for Codes below Retest After Repair Wire Speed RangeMain Transformer Secondary Voltages Test Points Input Amps AT Rated Output Input Amps AC @ Output DC SP-100 Electrical Diagrams Section Wiring Wiring DiagramsDiagram 4 5 1 M SP-100 Wiring Diagram Codes Below Electrical Diagrams Control P.C. Board G1842 Electrical Diagrams Control P.C. Board G2314 SCR1, SCR2 SCR 81 Heatsink Asbly Control P.C. Board G2314 Error Machine Schematic Codes 9794 and Above 86R R63R64 1 5 K Machine Schematic Codes Below SVM Error Reporting Form