Troubleshooting - Sealey MIGHTYMIG100.V2 Manual

7.3.2. Pull the roller off the drive spindle, flip it over and put it back on the drive spindle. (See fig.10) The groove size you require should now
be visible on the face of the roller. Push the roller retainer back onto the drive spindle with the opening facing right. Ensure that the
flanges at the base of the retainer, seat fully into the circular recess in the main moulding and then rotate the retainer through 90° to lock it
in place.
7.4. CONTACT TIP (to remove tip follow steps in 4.3.10.):
7.4.1. 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.
7.5. GAS CUP (to remove cup follow steps in 4.3.10.):
7.5.1. 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 expensive machine repairs. To keep the contact tip free from spatter, we recommend the use of anti-spatter spray
(MIG/722307) available from your Sealey stockist.
7.6. REPLACING WIRE LINER
7.6.1. A worn or damaged wire liner will seriously affect the performance of the welder and should be immediately replaced. First wind the wire
back onto the spool and secure it. Remove the four screws securing the torch cable clamp to the wire feed unit (fig.11) and take off the
clamp.
7.6.2. Open the torch case by gripping the torch with one hand and turning the grooved ring at the base of the torch anticlockwise until it stops,
then pull it off the torch onto the torch cable. See fig.12-1.
7.6.3. Take hold of the back end of the moulding which contains the switch and pull it outwards and downwards to release it from the other
moulding as shown in fig.12.
7.6.4. Push the liner lock ring (2) firmly towards the brass nut and withdraw the liner from the nut. With the
torch cable as straight as possible pull the liner from the torch cable.
7.6.5. Insert the new liner into the torch cable and secure it in the wire drive unit by replacing the torch cable
clamp. See fig.11. Insert the other end of the liner through the locking ring and fully into the brass nut
in the torch head, see 2 in fig.12.
7.6.6. Check that the torch inner parts are properly seated in their respective mouldings then close the torch
by inserting the tongue on the switch moulding (fig.12-5) into the slot at the front of the other moulding.
Swing the switch moulding downwards and forwards until both parts have closed around the torch
cable. Slide the ribbed ring (fig.12-1) onto the end of the torch handle and turn it clockwise to lock.
7.7.
7.8.

8. TROUBLESHOOTING

PROBLEM
Weld current interrupted
.
No weld current
No weld current
Feed motor not working
Wire does not feed, feed roller rotates
Wire feeds unevenly
© Jack Sealey Limited
fig.11
POSSIBLE CAUSE
Overheating protection activated due to overload
Rectifier blown
Bad connection between clamp and workpiece
Break in earth lead
Break in torch lead
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
Original Language Version
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 gears
Replace motor (Contact service agent)
Adjust tension
Clean the liner from the machine forward. Use compressed air.
Replace gas cup (nozzle) and/or tip. Check roller tension (Section 3)
Adjust roller tension
Clean the liner from the machine forward using compressed air
Replace gas cup (nozzle) and/or tip
Clean or replace gas cup (nozzle)
Clean feed roller
Replace feed roller
Adjust tension
fig.12