Liner Removal, Installation And Trimming Instructions For Linc Gun 240 & 360 Torch; Accessories; Ground Test Procedure; Procedure For Replacing Pc Boards - Lincoln Electric REDI-MIG Plus 215C Operator's Manual

6.5 Liner Removal, Installation and Trimming
Instructions for LINC Gun
N ote: The variation in cable lengths prevents the inter-
changeability of liners between guns. 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.
1. R emove the gas nozzle and gas diffuser, (if used), to locate
the set screw in the gas diffuser which is used to hold the
old liner in place. Loosen the set screw with an Allen key.
2. R emove the contact tip holder from the gun tube.
3. L ay the gun and cable out straight on a flat surface. Loosen
the liner nut cap located in the brass connector at the
feeder end of the cable and pull the liner out of the cable.
° D rive Rolls for mild steel, stainless steel and aluminium for
solid wires as well as for flux cored wires. See your nearest
Lincoln distributor for details.
These procedures refer to the REDI-MIG
WARNING
This procedure is only suitable for applications using DC
mega testers up to 500V.
ELECTRIC SHOCK
can kill
Note: This procedure is for 'machines as built' many modifications
could have taken place over the life of a particular machine, so
details of this procedure may need to be 'adjusted' to suit these
modifications.
For prompt service contact your local Lincoln Field Service Shop.
The insulation resistance values listed below are from Australian
Standard AS60974-.1.
1) Disconnect input cable from power outlet.
2) Disconnect all output cables (control & weld).
3) Remove the roof panel.
4) J umper the three (3) AC terminals and the (+) & (-)
terminals of the three phase bridge rectifier (A total of five
(5) places).

Procedure for Replacing PC Boards

Before replacing a PC board suspected of being defective,
visually inspect the PC board in question for any visible damage
to any of its components and conductors on the back of the board.
1. I f there is no visible damage to the PC board, install a new
one and see if this remedies the problem. If the problem
is remedied, reinstall the original PC board to see if the
problem still exists. If the problem no longer exists with the
old PC board:
a. C heck the PC board harness connector pins for
corrosion, contamination, or looseness.
Changing Settings for Motor Acceleration
If Motor Acceleration needs to be altered from factory setting,
because of the welding procedure being used, locate the PCB
in the REDI-MIG 325c or REDI-MIG
®
Page 22
®
240 & 360 Torch
Section 7 - ACCESSORIES
Section 8 - GROUND TEST PROCEDURE
4s Remote Wire Feeder.
®
REDI-MIG Plus 215C, 255C, 255S
®
4. I nsert a new untrimmed liner into the connector end of the
cable.
5. F ully seat the liner bushing into the Euro connector.
Tighten the liner nut cap on the brass cable connector. The
contact tip holder, at this time, should not be installed onto
the end of the gun tube.
6. W ith the contact tip holder still removed from the gun tube,
be sure the cable is straight, and then trim the liner to
length. Remove any burrs from the end of the liner.
7. S crew the contact tip holder onto the end of the gun tube
and securely tighten. Be sure the contact tip holder is
correct for the tips being used.
8. T ighten the set screw in the side of the gas diffuser against
the cable liner using an Allen key. Do not overtighten.
250s, 325c & 325s
®
5) Jumper the four (4) meter terminals together.
6) S witch the fine control rotary switch to position '1' & switch
the coarse control rotary switch to position '1'.
P rimary test: Connect one lead of the mega tester to the
7)
frame of the machine and the other lead to each of the
three (3) input conductors and to the main transformer
primary leads L1A, L2A & L3A. Apply the test(s).
W elding circuit test: Connect one lead of the mega
8)
tester to the frame of the machine and the other lead to
the positive output stud. Apply the test. (Min resistance
5.0MΩ).
W elding circuit to primary test: Connect one lead of the
9)
mega tester to the positive output stud and the other lead
to each of the three (3) input conductors and to the main
transformer primary leads L1A, L2A & L3A. Apply the test.
(Min resistance 2.5MΩ).
10) T ransformer thermostat test: Connect one lead of the
mega tester to the frame of the machine and the other lead
to the positive output stud. Apply the test.(Min resistance
1MΩ).
11) Remove all jumper leads.
12) Refit the roof panel.
b. C heck leads in the plug harness for loose or intermittent
connection.
2. I f PC board is visibly damaged, before possibly subjecting
the new PC board to the same cause of failure, check for
possible shorts, opens or grounds caused by:
a. D amaged lead insulation.
b. P oor lead termination, such as a poor contact or a short
to adjacent connection or surface.
c. S horted or open motor leads, or other external leads.
d. F oreign matter or interference behind the PC board.
3. I f PC board is visibly damaged, inspect for cause, then
remedy before installing a replacement PC board.
On the PCB there is a trimmer labelled 'Rampa', this trimmer
controls the acceleration rate of the drive motor from stationary
to the set wire feed speed. Maximum acceleration when fully
counter-clockwise to minimum acceleration when fully clockwise.
This is particularly important when welding aluminium wire. The
factory setting is fully clockwise.
IM6016