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6. MAINTENANCE
6.1. Wire feed unit Check the wire feed unit at regular intervals. The feed roller wire guide plays an
important part in obtaining consistent results. Poor wire feed affects welding. Clean the rollers
weekly, especially the feed roller groove, removing all dust deposits.
6.2. Torch Protect the torch cable assembly from mechanical wear. Clean the liner from the machine
forwards by using compressed air.If the liner is blocked it must be replaced.
6.3. Turning feed roller IMPORTANT: Turn the feed roller to suit the wire size.There are two
grooves on the feed roller, 0.6mm and 0.8mm. Always have the groove that is being used on the
outside of the roller (nearest to you). To turn the feed roller, undo the two screws and remove
the plastic cover (fig.12). Clean and turn the feed roller and then replace the plastic cover.
6. 4. Contact tip (to remove tip follow steps in 3.3.) The contact tip is a consumable item and
must be replaced when the bore becomes enlarged or oval. The contact tip MUST be kept free
from spatter to ensure an unimpeded flow of gas.
6.5. Gas cup (to remove cup follow steps in 3.3.) The gas cup must also be kept clean and free
from spatter. Build-up of spatter inside the gas cup can cause a short circuit at the contact tip which
will result in either the fuse blowing on the printed circuit card, or expensive machine repairs. To keep
the contact tip free from spatter, we recommend the use of Sealey anti-spatter spray (MIG/722307)
available from your Sealey dealer.
6.6. Replacing wire liner Wind the wire back onto the spool and secure it. Remove three screws
securing the torch cable clamp to the wire feed unit (fig.13). Take off the clamp. Undo the torch case
and disconnect wire liner from torch head. Pull out the liner (fig. 13) and insert the new one. Reverse
the process to re-assemble and trim the liner as close to the feed roller as possible.
6.7. Replacing gears An inexperienced welder can allow spatter to build up in the tip and shroud.
In severe cases this can block the wire feed causing gear damage in the wire drive. To check if the
gears are worn depress the button on the torch with the set switched on. If the gears are worn,
a grating sound will be heard coming from the wire feed motor and you may also observe the
feed roller vibrating instead of rotating smoothly. In this case, open the gearbox, remove the worn
or damaged gears and replace with new ones.
6.8. Wire drive fuse (PM140XT & PM150XT)
The fuse (250V 1.5/1.6A) is located on the small printed circuit board inside the welder and the
following may cause it to blow:
# Spatter collecting in the gas cup, causing contact tip to short circuit. # Wire tension too great.
# Sudden surge of current.
7. TROUBLESHOOTING
PROBLEM
Weld current interrupted
No weld current, fuse blowing in 13amp plug
No weld current
Feed motor not working
Wire does not feed, feed roller rotates
Wire feeds unevenly
Unstable arc
Porous weld
Wire sticking in gas cup (nozzle)
Irregular weld head
Weld bead too narrow and raised
Weld bead too wide
Poor penetration
Excessive penetration
Wire drive fuse blowing
POSSIBLE CAUSE
Overheating protection activated due to overload
Rectifier blown
Bad connection between clamp and workpiece
Break in earth lead
Break in torch lead
Fuse blown
Gear damaged or worn
Motor defective
Pressure roller improperly adjusted
Dirt, copper, dust, etc. have collected in torch liner
Gas cup (nozzle) or tip defective
Deformed wire
Dirt, etc, in liner
Gas cup (nozzle) or tip defective
Gas cup (nozzle) spattered
Feed roller groove clogged
Feed roller groove deformed
Pressure roller tension incorrect
Incorrect settings
Impurities in weld area
Worn or defective gas cup (nozzle)
No gas
Gas cup clogged
Draft blowing away shielding gas
Rusty/dirty joints
Torch too far from, or at wrong angle to, workpiece
Gas leak
Worn or defective gas cup (nozzle)
Wire deformed
Wire speed too slow
Torch incorrectly held
Wire weaving in weld pool
Weld current too low
Weld speed too fast
Weld current too high
Weld speed too slow
Arc too long
Weld current too low
Arc too long
Weld current too high
Weld speed too slow
Incorrect distance of torch to workpiece
Wire tension too great
Gas cup contact tip clogged
fig. 13
REMEDY
Protection automatically resets when transformer has cooled (approx. 15 min).
Replace rectifier.
Clean or grind contact surface and weld area.
Repair or replace earth lead.
Repair or replace.
Replace fuse 1.5 amp (Section 6).
Replace gears (Section 6).
Replace motor (Contact service agent).
Adjust tension.
Clean the liner from the machine forward. Use compressed air. If too much dirt,
replace the liner (Section 6).
Replace gas cup (nozzle) and/or tip (Section 6). Check roller tension (Section 3).
Clean the liner from the machine forward using compressed air.
Replace gas cup (nozzle) and/or tip (Section 6).
Clean or replace gas cup (nozzle) (Section 6).
Clean feed roller (Section 6).
Replace feed roller (Section 6).
Adjust tension (Section 3).
Check settings (Section 4).
Clean and/or grind workpiece (Section 4).
Replace gas cup (nozzle) (Section 6).
Open gas cylinder, regulate gas flow.
Clean or replace cup (Section 6).
Screen off welding site or increase gas flow.
Clean or grind the workpiece (Section 4).
Gas cup to workpiece should be 8-10mm. Torch angle approx 75
Check hoses, connections and torch assembly (Section 6).
Replace gas cup (nozzle) (Section 6).
Check roller tension (Section 3).
Increase wire speed.
Use correct torch angle.
Check roller tension and adjust (Section 3).
Increase power and wire speed (Section 4).
Move torch slower and weave a little more.
Decrease current and wire speed (Section 4).
Move torch faster and weave less.
Bring torch closer to workpiece.
Increase current and wire speed (Section 4).
Bring torch closer to workpiece.
Decrease current and wire speed (Section 4).
Move torch faster.
Torch distance should be 8-10mm.
Reduce tension (Section 3).
Clean gas cup and contact tip (Section 6).
EM130XT.V3, PM140XT.V2, PM150XT.V2 - 3 - 130206
fig. 12
.
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