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Lincoln Electric SP-100 service manual Figure D.3

Models: SP-100

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D-3	MAINTENANCE
	CHANGING LINER	REPLACE INTERNAL GUN
		HANDLE PARTS AS NECESSARY

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NOTICE: The variation in cable lengths pre- vents the interchangeability of liners. 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. Refer to Figure D.2.

1.Remove gun and cable assembly from machine.

2.Remove the gas nozzle from the gun by unscrewing counter-clockwise.

3.Remove the existing contact tip from the gun by unscrewing counter-clockwise.

4.Remove the gas diffuser from the gun tube by unscrewing counter-clockwise.

5.Lay the gun and cable out straight on a flat surface. Loosen the set screw locat- ed in the brass connector at the wire feeder end of the cable. Pull the liner out of the cable.

6.Insert a new untrimmed liner into the connector end of the cable. Be sure the liner bushing is stenciled appropriately for the wire size being used.

7.Fully seat the liner bushing into the con- nector. Tighten the set screw on the brass cable connector. At this time, the gas diffuser should not be installed onto the end of the gun tube.

8.With the gas nozzle and diffuser removed from the gun tube, be sure the cable is straight, and then trim the liner to the length shown in the Figure D.2. Remove any burrs from the end of the liner.

9.Screw the gas diffuser onto the end of the gun tube and securely tighten.

The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counter-clock- wise (the same direction as removing a right hand thread) until the collar reaches a stop. Then pull the collar off the gun handle. If the collars are difficult to turn, position the gun handle against a corner, place a screwdriv- er against the tab on the collar and give the screwdriver a sharp blow to turn the collar past an internal locking rib. See Figure D-3.

FIGURE D.3

Counter-clockwise

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10. Replace the contact tip and nozzle.

SP-100

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Lincoln Electric SP-100 service manual Figure D.3

Contents

SP-100 Safety Electric Shock can killARC Rays can burn Fumes and Gases can be dangerous Cylinder may explode if damaged Welding Sparks can cause fire or explosion Electric and Magnetic Fields May be dangerous Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications SP-100 Safety Precautions Read entire installation section before startingInstallation Identify and Locate Components Work Clamp Installation Select Suitable LocationOutput Connections Tilting Connecting GUN Cable to the SP-100 GUN InstallationGAS Connection Power Input ConnectionsGas Solenoid Inlet Fitting Input Code Requirements for Input Connections Requirements for Maximum OutputRequirements for CSA Rated Output Requirements for Rated Output SP-100 Table of Contents Operation Wear eye, ear and body protec- tion Operational Features and Controls Design Features AdvantagesGeneral Description Off Wire Loading Welding OperationsProcess Guidelines Sequence of Operation Friction Brake Adjustments Refer to Figure B-4 Shielding GAS Making a Weld Overload Protection SP-100 Accessories Section 1ACCESSORIES Replacement PartsLincoln 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 Figure E.1 Input Power Circuits Input Line VOLTAGE, FAN Motor and Main Transformer Output CONTROL, RECTIFICA- Tion and Voltage Feedback Figure E.2 Output Circuits TRIGGER, GAS Solenoid and Wire Drive 3THEORY of Operation SCR Operation Figure E.4 SCR Operation Thermostat protects the machine from Troubleshooting Section Oscilloscope Waveforms 1TROUBLESHOOTING & Repair HOW to USE Troubleshooting Guide Troubleshooting & Repair PC Board Troubleshooting Procedures Authorized Field Service Troubleshooting GuideFacility Below Code 9794 only Problems Symptoms Possible Areas of MisadjustmentsRecommended Course of Action Code 9794 and Above Feeding Problems Troubleshooting Guide PC Board Connector Locations Codes 9794 and above 6J1 10J2 1J1 1J2 Codes below SP-100 9TROUBLESHOOTING & Repair Scope SettingsVolts Volts/Div Normal Open Circuit Voltage Waveform Volts Typical Output Voltage Waveform Machine Loaded Abnormal Open Circuit Voltage Waveform Procedure Description ProcedureFAN Blade and Motor Removal Tools Required Wire Drive Assembly Removal Motor Removal Procedure1A. for Codes Above 1B. for Codes below Wire Speed Range Retest After RepairMain Transformer Secondary Voltages Test Points Input Amps AT Rated Output Input Amps AC @ Output DC SP-100 Electrical Diagrams Section Wiring Wiring DiagramsDiagram SP-100 Wiring Diagram Codes Below 4 5 1 M Electrical Diagrams Electrical Diagrams Control P.C. Board G1842 Control P.C. Board G2314 Control P.C. Board G2314 SCR1, SCR2 SCR 81 Heatsink Asbly Machine Schematic Codes 9794 and Above Error Machine Schematic Codes Below 86R R63R64 1 5 K SVM Error Reporting Form