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MAGNUM PRO
®
100L
PROBLEM
(SYMPTOMS)
Drive rolls turn, but wire will
not feed or wire feeding is
rough.
Variable or "hunting" arc.
Poor arc striking with
sticking or "Blast-offs",
weld porosity, narrow and
ropy looking bead, or
electrode stubbing into plate
while welding.
Tip seizes in diffuser.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE AREAS OF
MISADJUSTMENT(S)
Gun cable kinked and/or twisted.
Wire jammed in gun and cable.
Incorrect drive rolls and guide tubes.
Gun cable liner dirty.
Worn drive rolls.
Electrode rusty and/or dirty.
Worn or improper size cable liner.
Partially flashed, melted, or improper size
contact tip.
Incorrect diffuser.
Contact tip worn or incorrect size.
Worn or undersize ground cables or poor
ground connections.
Loose electrode connections.
Improper procedures or techniques.
Improper gas shielding.
Tip overheating due to prolonged or
excessive high current and/or duty cycle
welding.
RECOMMENDED COURSE OF ACTION
Keep as straight as possible. Inspect cable and replace
if necessary.
Remove wire from gun and cable - feed in new wire.
Note any obstruction. Replace liner if necessary.
Be sure the wire diameter being used is stamped on
drive rolls and guide tubes. Replace if necessary.
Clean liner or replace.
Replace or reverse split drive roll type.
Replace the electrode if it is rusty.
Replace cable liner.
Replace the contact tip.
Be sure diffuser size is correct for the electrode being
used.
Replace contact tip.
Inspect - repair or replace as necessary.
Be sure the following connections are tight: electrode
cable to power source, work cable to power source
and work, gun cable to power source contact
block, gun nozzle to body, and contact tip to
nozzle.
See "Gas Metal Arc Welding Guide" (GS-100).
Clean gas nozzle. Make certain that gas diffuser is not
restricted. Make certain that gas cylinder is not
empty or turned off. Make certain gas solenoid
valve is operating and gas flow rate is proper.
Remove gun liner and check rubber seal for any sign of
deterioration or damage. Be sure set screw in
brass connector is in place and tightened against
the liner bushing.
Do not exceed current and duty cycle rating of gun.
D-2
TROUBLESHOOTING
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