Lincoln Electric K2532-1 Operator's Manual page 34

L i n c o l n A u t h o r i z e d F i e l d S e r v i c e F a c i l i t y f o r t e c h n i c a l t r o u b l e s h o o t i n g a s s i s t a n c e b e f o r e y o u p r o c e e d . w i r e w i t h o u t p u l l i n g t h e g u n t r i g g e r . W i r e f e e d e r r u n s o r b e g i n s f e e d i n g I f f o r a n y r e a s o n y o u d o n o t u n d e r s t a n d t h e t e s t p r o c e d u r e s o r a r e u n a b l e t o p e r f o r m t h e t e s t s / r e p a i r s s a f e l y , c o n t a c t y o u r L o c a l O t h e r w i s e , m a c h i n e s 2 . S e e m a c h i n e s i n s t r u c t i o n m a n u a l 1 . R e p l a c e M a i n t e n a n c e S e c t i o n ) c i r c u i t s . a r e s h o r t e d t o g e t h e r o r c o m m o n l y C A U T I O N ( S e e b o t h . t h e w e l d i n g m a c h i n e . 3 . T r i g g e r l e a d ( s ) i n s i d e g u n c a b l e p l y . s h o r t e d t o e i t h e r w e l d i n g o r m o t o r 9 . G a s l e a k a g e i n g u n b e t w e e n l i n e r 9 . R e p l a c e a s s e m b l y a n d c a b l e c o n n e c t o r . 1 0 . D a m a g e d o - r i n g s : r e p l a c e b o t h 1 0 . G a s l e a k a g e a t g u n - t o - f e e d e r M a i n t e n a n c e S e c t i o n ) c o n n e c t i o n . 3 . D a m a g e d c o n t r o l l e a d s b e t w e e n 1 . D e f e c t i v e t r i g g e r . ( c o n t a c t s c l o s e d ) c a b l e ; 2 . D e f e c t i v e ( c l o s e d ) t r i g g e r c i r c u i t i n c a b l e . i n s e r t e d i n t o M a i n t e n a n c e S e c t i o n ) f o r ( S e e m a c h i n e a s s e m b l y . g u n P 6 ( S e e a n d c o n n e c t o r r e p a i r i f p o s s i b l e . s e a l s . G u n c o n n e c t o r n o t f u l l y t r i g g e r . ( S e e I n s t a l l a t i o n S e c t i o n ) . l i n e r r e p l a c e
P R O B L E M S L o w o r n o s h i e l d i n g g a s f l o w . ( S Y M P T O M S ) P O S S I B L E 1 . O u t o f g a s . n e c t e d . s u p p l y r e g u l a t o r 4 . M a c h i n e s g a s s o l e n o i d v a l v e h a s 5 . B l o c k a g e i n g u n a l o n g g a s p a t h . 5 . G e n t l y b l o w o u t d e b r i s f r o m c o r e 3 . C h e c k t h a t g a s f l o w i s s e t b e t w e e n d i f f u s e r . a r e o p e n . 2 . C h e c k t h a t a l l g a s s u p p l y v a l v e s p l y i s a v a i l a b l e . O b s e r v e a l l S a f e t y G u i d e l i n e s d e t a i l e d t h r o u g h o u t t h i s m a n u a l t u b e . 1 . C h e c k t h a t a n a d e q u a t e g a s s u p - 6 . A t t e m p t t o s t r a i g h t e n o u t c a b l e , o r m a l f u n c t i o n e d . r e p l a c e c a b l e . ( S e e M a i n t e n a n c e i s S e c t i o n ) f l o w 7 . C l e a n o r r e p l a c e g a s c o n e o r g a s 3 . G a s d i f f u s e r . 2 . G a s s u p p l y i s t u r n e d o f f o r d i s c o n - 8 . F i n d a n d r e p a i r a l l l e a k s . C A U S E a c c u m u l a t i o n o n g a s c o n e o r g a s P R O B L E M S 6 . G u n c a b l e k i n k e d o r f l a t t e n e d . 2 0 t o 5 0 S C F H . 8 . E x c e s s i v e g a s l e a k a g e f r o m s u p - i m p r o p e r l y s e t . 4 . S e e m a c h i n e s i n s t r u c t i o n m a n u a l . 7 . B l o c k a g e d u e t o e x c e s s i v e s p a t t e r C O U R S E O F A C T I O N R E C O M M E N D E D
PROBLEMS
(SYMPTOMS)
Low or no shielding gas flow.
Wire feeder runs or begins feeding
wire without pulling the gun trigger.
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.
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
1. Out of gas.
2. Gas supply is turned off or discon-
nected.
3. Gas supply flow regulator is
improperly set.
4. Machine s gas solenoid valve has
malfunctioned.
5. Blockage in gun along gas path.
6. Gun cable kinked or flattened.
7. Blockage due to excessive spatter
accumulation on gas cone or gas
diffuser.
8. Excessive gas leakage from sup-
ply.
9. Gas leakage in gun between liner
assembly and cable connector.
10. Gas leakage at gun-to-feeder
connection.
1. Defective trigger. (contacts closed)
2. Defective (closed) trigger circuit in
the welding machine.
3. Trigger lead(s) inside gun cable
are shorted together or commonly
shorted to either welding or motor
circuits.
POSSIBLE
CAUSE
PROBLEMS
CAUTION
E-4
RECOMMENDED
COURSE OF ACTION
1. Check that an adequate gas sup-
ply is available.
2. Check that all gas supply valves
are open.
3. Check that gas flow is set between
20 to 50 SCFH.
4. See machine s instruction manual.
5. Gently blow out debris from core
tube.
6. Attempt to straighten out cable, or
replace cable. (See Maintenance
Section)
7. Clean or replace gas cone or gas
diffuser.
8. Find and repair all leaks.
9. Replace liner assembly. (See
Maintenance Section)
10. Damaged o-rings: replace both
seals. Gun connector not fully
inserted into machine
Installation Section).
1. Replace trigger.
Maintenance Section)
2. See machine s instruction manual
3. Damaged control leads between
machine s P6 connector and
cable; repair if
Otherwise, replace gun cable.
(See Maintenance Section) for
both.
(See
(See
possible.