Lincoln Electric POWER MIG 216 Service Manual
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Lincoln Electric POWER MIG 216 Service Manual

Lincoln Electric POWER MIG 216 Service Manual

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POWER MIG
216
®
For use with machines having Code Numbers:
11558, 11817
SERVICE MANUAL
SVM219-A
| Issue D ate 12-Apr
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

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  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. POWER MIG ® For use with machines having Code Numbers: 11558, 11817 SERVICE MANUAL SVM219-A | Issue D ate 12-Apr ©...

  • Page 2: Electric And Magnetic Fields

    Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. explosion. 7.a. Use only compressed cylinders containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and from starting a fire.
  • Page 5 SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
  • Page 6 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda- tions.
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-vi Installation .

  • Page 9: Table Of Contents

    TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .

  • Page 10: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – POWER MIG® 216 INPUT – SINGLE PHASE ONLY Standard Voltage/Phase/Frequency Input Current @ 170 Amp Rated Output Input Current @ 216 Amp Rated Output 208/230/1/60 Hz 33/29 Amps 40/36 Amps 220/1/50 Hz 30 Amps 37 Amps RATED OUTPUT Duty Cycle Amps...

  • Page 11: Safety Precautions

    INSTALLATION Read entire installation section before starting INPUT POWER, GROUNDING AND installation. CONNECTION DIAGRAM SAFETY PRECAUTIONS WARNING WARNING ELECTRIC SHOCK can kill. ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as • Only qualified personnel should output terminals or internal wiring.

  • Page 12: Output Polarity Connections

    INSTALLATION FIGURE A.1 — DUAL VOLTAGE MACHINE INPUT CONNECTIONS WARNING ADVERTISSEMENT ADVERTENCIA ELECTRIC SHOCK can kill Disconnect input power before inspecting or servicing machine. LES CHOCS ÉLECTRIQUES peuvent être mortels Do not operate with covers removed. DESCARGAS ELECTRICAS pueden matar Do not touch electrically live parts.

  • Page 13: Gun And Cable Installation

    INSTALLATION GUN AND CABLE INSTALLATION 2. Remove the cylinder cap. Inspect the cylinder valves and regulator for damaged threads, dirt, The Magnum 250L gun and cable provided with the dust, oil or grease. Remove dust and dirt with a POWER MIG ®...

  • Page 14: Coil Claw™ Installation

    INSTALLATION COIL CLAW™ INSTALLATION The Coil Claw™ and mounting screws are provided as an optional accessory for the POWER MIG ® 216. This user-install accessory provides cable management for the machine. WARNING Turn the welder power switch OFF before installing Coil Claw™. ------------------------------------------------------------------------ 1.
  • Page 15 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions .

  • Page 16: Operation

    OPERATION Read entire Operation section before operating the POWER MIG® 216. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. • Always wear insulating gloves.

  • Page 17: Product Description

    OPERATION PRODUCT DESCRIPTION DESCRIPTION OF CONTROLS The POWER MIG ® 216 is a complete semiautomatic See Figure B.1 DC voltage arc welding machine built to meet NEMA 1. Power ON/OFF Switch - Press the switch to "ON" specifications. It combines a tapped transformer volt- position to energize the POWER MIG 216.

  • Page 18: Wire Drive Roll

    OPERATION WIRE REEL LOADING - SPOOLS OR WIRE DRIVE ROLL COILS The drive rolls installed with the POWER MIG ® have two grooves, one for .035”(0.9mm) wire and the To Mount 10 to 44 Lb. (4.5-20 kg) Spools (12"/ 300 other for .045”(1.1mm) wire.

  • Page 19: To Start The Welder

    OPERATION TO START THE WELDER The pressure arm controls the amount of force the drive rolls exert on the wire. Proper adjustment of pres- Turn the “Power Switch” switch to “ON”. With the sure arm gives the best welding performance. For best desired voltage and wire speed selected, operate the results, set pressure arm to the suggested value.

  • Page 20: Making A Weld

    OPERATION 5. Loosen the socket head cap screw that holds the 3. Press the trigger to feed the wire electrode through connector bar against the gun adapter. the gun and cable. For solid wire, cut the electrode within approximately 3/8" (10 mm) of the end of the Important: Do not attempt to completely contact tip [3/4"...

  • Page 21: Avoiding Wire Feeding Problems

    OPERATION WIRE FEED OVERLOAD 9. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun PROTECTION trigger to release gas pressure, and turn OFF The POWER MIG ® 216 has solid state overload pro- POWER MIG ®...
  • Page 22 NOTES POWER MIG ®...
  • Page 23 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Drive Roll Kits .

  • Page 24: Optional Spool Guns And Adapters

    ACCESSORIES ALTERNATIVE MAGNUM GMAW DRIVE ROLL KITS GUN AND CABLE ASSEMBLIES Refer to Table C.1 for various drive roll kits that are available for the POWER MIG 216. The item in Bold ® The following Magnum 250L gun and cable assemblies is supplied standard with the POWER MIG ®...

  • Page 25: Making A Weld With The Spool Gun Adapter Kit And Spool Gun Installed

    ACCESSORIES MAKING A WELD WITH THE SPOOL GUN ADAPTER KIT AND SPOOL GUN INSTALLED CAUTION In either toggle switch position, closing either gun trigger will cause the electrode of both guns to be electrically “HOT”. Be sure unused gun is posi- tioned so electrode or tip will not contact metal case or other metal common to work.
  • Page 26 NOTES POWER MIG ®...
  • Page 27 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .

  • Page 28: General Maintenance

    MAINTENANCE SAFETY PRECAUTIONS 3. If using optional adjustable slip-on nozzles, See Table D.2 in this section. WARNING • Be sure the nozzle insulator is fully screwed onto the gun tube and does not block the gas holes in the diffuser. ELECTRIC SHOCK can kill.

  • Page 29: Liner Removal And Replace- Ment

    MAINTENANCE 8. Tighten the set screw in the side of the gas diffuser LINER REMOVAL AND REPLACE- against the cable liner using a 5/64" (2.0 mm) Allen MENT wrench. NOTE: Changing the liner for a different wire size FIGURE D.1 requires replacement of the gas diffuser per Table D.1 to properly secure the different liner.

  • Page 30: Gun Handle Disassem- Bly

    MAINTENANCE TABLE D.2 GUN HANDLE DISASSEM- ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES The internal parts of the gun handle may be English Metric inspected or serviced if necessary. Description Part No. Size Size The gun handle consists of two halves that CABLE LINER For 15' (4.5 m) or KP42-25-15...
  • Page 31 MAINTENANCE FIGURE D.2 – MAJOR COMPONENT LOCATIONS 1. Case Front Assembly 2. Case Back Assembly 3. Center Assembly 4. Wire Drive Assembly 5. Base & Power Component Assembly 6. Covers Assembly POWER MIG ®...
  • Page 32 NOTES POWER MIG ®...
  • Page 33 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 Input Line Voltage, Voltage Selector Switch, Main Transformer, Auxiliary Transformer And Center Panel Mounted Diode Bridge .

  • Page 34: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 - INPUT POWER CIRCUIT WIRE SPEED SOLENOID CONTROL WIRE RECTIFIER DRIVE DIODE LINE SWITCH MOTOR BRIDGE FAN MOTOR CONTROL BOARD TRANSFORMER OUTPUT BRIDGE THERMOSTAT THERMOSTAT TRANSFORMER GUN TRIGGER ASSEMBLY OUTPUT POSITIVE CHOKE TERMINAL RECONNECT PANEL OUTPUT CAPACITORS OUTPUT...
  • Page 35 THEORY OF OPERATION FIGURE E.3 - CONTROL CIRCUITS WIRE SPEED SOLENOID CONTROL WIRE RECTIFIER DRIVE DIODE LINE SWITCH MOTOR BRIDGE FAN MOTOR CONTROL BOARD TRANSFORMER OUTPUT BRIDGE THERMOSTAT THERMOSTAT TRANSFORMER GUN TRIGGER ASSEMBLY OUTPUT POSITIVE CHOKE TERMINAL RECONNECT PANEL OUTPUT CAPACITORS OUTPUT NEGATIVE...
  • Page 36 THEORY OF OPERATION FIGURE E.4 - OPERATIONAL CIRCUITS WIRE SPEED SOLENOID CONTROL WIRE RECTIFIER DRIVE DIODE LINE SWITCH MOTOR BRIDGE FAN MOTOR CONTROL BOARD TRANSFORMER OUTPUT BRIDGE THERMOSTAT THERMOSTAT TRANSFORMER GUN TRIGGER ASSEMBLY OUTPUT POSITIVE CHOKE TERMINAL RECONNECT PANEL OUTPUT CAPACITORS OUTPUT NEGATIVE...

  • Page 37: Protective Devices And Cir- Cuits

    THEORY OF OPERATION PROTECTIVE DEVICES AND CIR- CUITS THERMAL AND OVERLOAD PROTECTION The POWER MIG 216 has two built-in protective ther- ® mostats that respond to excessive temperatures. One is located on the main transformer. The other thermo- stat is located on the output rectifier heat sink assem- bly.
  • Page 38 NOTES POWER MIG ®...
  • Page 39 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .
  • Page 40 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 41: Troubleshooting And Repair

    Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.
  • Page 42 5. The control board may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER MIG...
  • Page 43 See Wiring Diagram. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER MIG ®...
  • Page 44 The wire feed functions nor- mally. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER MIG ®...
  • Page 45 Replace. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER MIG ®...
  • Page 46 Service Facility. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER MIG ®...
  • Page 47 Rectifier Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER MIG ®...
  • Page 48 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER MIG ®...

  • Page 49: Auxiliary Transformer Test

    AUXILIARY TRANSFORMER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 50 TROUBLESHOOTING AND REPAIR F-12 F-12 AUXILIARY TRANSFORMER TEST (continued) FIGURE F.1 – AUXILIARY TRANSFORMER AUXILIARY TRANSFORMER PROCEDURE 1. Remove input power to the POWER MIG ® 216. 2. Using a 3/8” Nutdriver, remove the case wrap- around cover. 3. Locate the Auxiliary Transformer. See Figure F.1.
  • Page 51 TROUBLESHOOTING AND REPAIR F-13 F-13 AUXILIARY TRANSFORMER TEST (continued) TABLE F.1 LEAD IDENTIFICATION NORMAL EXPECTED VOLTAGE X9 TO X10 32 VAC 5. Carefully apply the correct input voltage to the WARNING POWER MIG ® 216 and check for the correct secondary voltages.
  • Page 52 NOTES F-14 F-14 POWER MIG ®...
  • Page 53 CR1 AND CR2 RELAY TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 54 TROUBLESHOOTING AND REPAIR F-16 F-16 CR1 AND CR2 RELAY TEST (continued) FIGURE F.2 – RELAY TEST POINTS NORMALLY OPEN 12 VDC NORMALLY OPEN PROCEDURE 1. Using a 3/8” nutdriver, remove the left side of 6. Connect on terminals 6 and 8, and measure the case wraparound.

  • Page 55: Main Transformer Test

    MAIN TRANSFORMER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 56 TROUBLESHOOTING AND REPAIR F-18 F-18 MAIN TRANSFORMER TEST (continued) FIGURE F.3 – X1 AND X2 LOCATION X1 AND X2 TAP SELECTOR SWITCH PROCEDURE WARNING WARNING ELECTRIC SHOCK can kill THE ON/OFF POWER SWITCH will be “hot” during these tests. • Do not touch electrically live parts such as output terminals -------------------------------------------------------- or internal wiring.
  • Page 57 TROUBLESHOOTING AND REPAIR F-19 F-19 MAIN TRANSFORMER TEST (continued) TABLE F.2 – TEST POINTS INPUT VOLTAGE TAP SELECTOR SWITCH TEST POINTS EXPECTED VOLTAGE READING 230 VAC X1-X2 12.23 VAC 230 VAC X1-X2 14.26 VAC 230 VAC X1-X2 16.43 VAC 230 VAC X1-X2 18.69 VAC 230 VAC...
  • Page 58 NOTES F-20 F-20 POWER MIG ®...

  • Page 59: Output Rectifier Test

    OUTPUT RECTIFIER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 60 TROUBLESHOOTING AND REPAIR F-22 F-22 OUTPUT RECTIFIER TEST (continued) FIGURE F.4 – RECTIFIER TEST POINTS NEGATIVE LEAD PROCEDURE 1. Remove input power to the Power MIG ® 4. Test for “shorted” or “leaky” diodes by checking machine. from the anodes to the cathodes of the diode heatsink plates.

  • Page 61: Wire Drive Motor Test

    WIRE DRIVE MOTOR TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 62 TROUBLESHOOTING AND REPAIR F-24 F-24 WIRE DRIVE MOTOR TEST (continued) FIGURE F.5 – PLUG J4 Black White PROCEDURE NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS. Test for correct wire drive motor armature voltage. 1. Disconnect main input power to the machine. 2.
  • Page 63 TROUBLESHOOTING AND REPAIR F-25 F-25 WIRE DRIVE MOTOR TEST (continued) 5. Make the following voltage tests: WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • All input power must be elec- trically disconnected before proceeding.
  • Page 64 NOTES F-26 F-26 POWER MIG ®...

  • Page 65: Choke Test Procedure

    CHOKE TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 66 TROUBLESHOOTING AND REPAIR F-28 F-28 CHOKE TEST PROCEDURE (continued) FIGURE F.6 – CHOKE CHOKE PROCEDURE 1. Using a digital ohmmeter, make sure that the Choke windings are not grounded to the lami- nation (> 1megohm). No windings or terminal connections should look burned or over-heated.

  • Page 67: Typical Output Voltage Waveform - Machine Loaded

    TROUBLESHOOTING AND REPAIR F-29 F-29 TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED (MAX TAP “G”) 0 volts 10.0V MACHINE LOADED TO 200 AMPS AT 22 VDC This is a typical DC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 10 volts and that each horizontal division rep-...
  • Page 68 TROUBLESHOOTING AND REPAIR F-30 F-30 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP “G”) 0 volts 20.0V 1.0ms This is a typical DC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division rep- resents 1.0 milliseconds in time.

  • Page 69: Abnormal Output Voltage Waveform - Machine Loaded

    TROUBLESHOOTING AND REPAIR F-31 F-31 ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED (MAX TAP “G”) ONE OUTPUT DIODE NOT FUNCTIONING 0 volts 20.0V MACHINE LOADED TO 180 AMPS AT 16 VDC This is NOT a typical DC output volt- age waveform. One output diode is not functioning.
  • Page 70 TROUBLESHOOTING AND REPAIR F-32 F-32 ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING (MAX TAP “G”) 0 volts 20.0V This is NOT a typical DC output volt- age waveform. The output capacitors are not functioning. Note the lack of “filtering”...

  • Page 71: Output Diode Bridge Removal And Replacement Procedure

    OUTPUT DIODE BRIDGE REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 72 TROUBLESHOOTING AND REPAIR F-34 F-34 OUTPUT DIODE BRIDGE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.7 – OUTPUT DIODE BRIDGE LEADS DISCONNECT RECTIFIER 1104A AND 1104B THERMOSTAT REMOVAL PROCEDURE 1. Using a 3/8” nutdriver, remove both sides of the 5. Using a 3/8” nutdriver and a 3/8” wrench, locate case wraparound cover.
  • Page 73 TROUBLESHOOTING AND REPAIR F-35 F-35 OUTPUT DIODE BRIDGE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.8 – OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET Mounting Bracket Mounting Bolts 1/2" Rectifier Mounting Mounting Bolts Bracket REPLACEMENT PROCEDURE 1. Mount the new Rectifier to the mounting brack- 6.
  • Page 74 NOTES F-36 F-36 POWER MIG ®...

  • Page 75: Main Transformer Removal And Replacement Procedure

    MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 76 TROUBLESHOOTING AND REPAIR F-38 F-38 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.9 – MAIN TRANSFORMER LOCATION Main Transformer REMOVAL PROCEDURE 8. Feed leads H8 and H9 toward the inside of the 1. Using a 3/8” nutdriver, remove both sides of the machine.
  • Page 77 TROUBLESHOOTING AND REPAIR F-39 F-39 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.10 – VOLTAGE CONTROL SWITCH LEADS FIGURE F.11 – THERMOSTAT LEADS DISCONNECT THERMOSTAT LEADS POWER MIG ®...
  • Page 78 TROUBLESHOOTING AND REPAIR F-40 F-40 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.12 – REAR ACCESS PANEL REMOVE REAR ACCESS PANEL FIGURE F.13 – REAR ACCESS PANEL (CLOSE-UP) 208V POWER MIG ®...
  • Page 79 TROUBLESHOOTING AND REPAIR F-41 F-41 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.14 – MAIN TRANSFORMER MOUNTING NUTS REMOVE REMOVE REPLACEMENT PROCEDURE 1. Carefully maneuver the new Main Transformer 6. Apply a thin film of Penetrox A-13 to the rectifi- back into the machine and onto its mounting er bridge assembly and reconnect the two sec- studs.
  • Page 80 TROUBLESHOOTING AND REPAIR F-42 F-42 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.15 – TYPICAL LEAD MOUNTING HARDWARE CONFIGURATION PLAIN WASHER LOCK WASHER HEX NUT BOLT LEAD TERMINAL SWITCH CONTACT POWER MIG ®...

  • Page 81: Control Board Removal And Replacement Procedure

    CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 82 TROUBLESHOOTING AND REPAIR F-44 F-44 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.16 – CONTROL BOARD MOUNTING NUTS CONTROL BOARD HEX LOCK MOUNTING NUTS REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1. Remove power to the machine. 1. Mount the new board to the existing mounting studs.

  • Page 83: Wire Drive Assembly Removal And Replacement Procedure

    WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 84 TROUBLESHOOTING AND REPAIR F-46 F-46 WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1. Disconnect main input power to the machine. 1. Bolt the Wire Drive Assembly to the wire drive compartment. 2. Remove gun cable and remove the wire. 2.
  • Page 85 TROUBLESHOOTING AND REPAIR F-47 F-47 WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.17 – WIRE DRIVE ASSEMBLY REMOVAL 3H 3J 3J 3K 2. Gearbox Mounting Panel 8. Gun Adapter Assembly 3. Feedplate Assembly 9A. Feedplate Cover 3A. Connection Bar 9B.
  • Page 86 NOTES F-48 F-48 POWER MIG ®...

  • Page 87: Cr-1 And Cr-2 Relays Removal And Replacement Procedure

    CR-1 AND CR-2 RELAYS REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 88 TROUBLESHOOTING AND REPAIR F-50 F-50 CR-1 AND CR-2 RELAYS REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.18 – RELAY LOCATION RELAYS REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1. Remove power to the machine. 1. Mount the new Relays to the existing mounting studs. Install hex nuts along with the lock and 2.

  • Page 89: Fan Blade / Motor Removal And Replacement Procedure

    FAN BLADE / MOTOR REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 90 TROUBLESHOOTING AND REPAIR F-52 F-52 FAN BLADE / MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.19 – FAN MOUNTING BOLTS REAR Blade Motor Mounting Band 11/32" Mounting Nuts 5/16" Bolts REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1. Using a 3/8” nutdriver, remove case wrap- 1.

  • Page 91: Retest After Repair

    TROUBLESHOOTING AND REPAIR F-53 F-53 RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS Input Volts / Hertz Maximum Idle Amps Maximum Idle Watts 230 / 60 OPEN CIRCUIT VOLTAGE 36 VDC WIRE SPEED RANGE 50 - 700 IPM (1.27 - 17.8 m/minute) POWER MIG ®...
  • Page 92 NOTES F-54 F-54 POWER MIG ®...
  • Page 93 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (L15096) .
  • Page 94 ElECTriCal DiaGramS WiriNG DiaGram - (l15096) POWER MIG 216 (208/220/230V) CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P.C. BOARD) NOTES: N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS. N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY “POSITIVE”. TO CHANGE POLARITY, TURN...
  • Page 95 TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 CLEVELAND SCALE: CONTROL: EQUIPMENT TYPE: POWER MIG 216 UNLESS OTHERWISE SPECIFIED TOLERANCE: PAGE ___ OF ___ NONE ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm) DRAWN BY: jmilligan ON 3 PLACE DECIMALS IS ±...
  • Page 96 TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 CLEVELAND SCALE: CONTROL: EQUIPMENT TYPE: POWER MIG 216 UNLESS OTHERWISE SPECIFIED TOLERANCE: PAGE ___ OF ___ NONE ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm) DRAWN BY: ON 3 PLACE DECIMALS IS ±...
  • Page 97 ElECTriCal DiaGramS SChEmaTiC - CONTrOl PC bOarD (G4414-2) PG1 MOTOR DRIVE +15V +15V +25-75VDC CLUSTER 3 105A 3.32K FTP6 TOGGLE TRIGGER 47.5 TRIGGER INPUTS SWITCH 16 P1(2) 0.2A 150V 150V IN SPOOL +15V +15V GUN KIT 0.1W 1A/FR 0.5A SPOOL 400V TRIGGER HI-SIDE...
  • Page 98 ElECTriCal DiaGramS SChEmaTiC - CONTrOl PC bOarD (G4414-2) PG2 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWEr miG ®...
  • Page 99 ElECTriCal DiaGramS SChEmaTiC - CONTrOl PC bOarD (G4414-2) PG3 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWEr miG ®...

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