Lincoln Electric POWER MIG 180 DUAL Service Manual
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Lincoln Electric POWER MIG 180 DUAL Service Manual

Lincoln Electric POWER MIG 180 DUAL Service Manual

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POWER MIG
180 DUAL
®
For use with machines having Code Numbers:
11828
SERVICE MANUAL
SVM236-A
| Issue D ate 13-Jul
© 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 180 DUAL ® For use with machines having Code Numbers: 11828 SERVICE MANUAL SVM236-A | Issue D ate 13-Jul ©...

  • 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 dʼincendie 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 manufacturerʼs recommen- dations.
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-vi Installation .

  • Page 9: Table Of Contents

    TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .

  • Page 10: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 - GENERAL DESCRIPTION WIRE TRIGGER VOLTAGE SPEED RECEPTACLE CONTROL CONTROL CONTROL BOARD SOLENOID LINE CIRCUIT INPUT BREAKER SWITCH RECEPTACLE WIRE FEED MOTOR VOLTAGE FEEDBACK & MOTOR POWER MOTOR CHOKE MAIN OUTPUT MAIN TERMINALS TRANSFORMER BRIDGE GENERAL DESCRIPTION The Power Mig ®...

  • Page 11: Input Line Voltage, Fan Motor & Main Transformer

    THEORY OF OPERATION FIGURE E.3 - INPUT LINE VOLTAGE, FAN MOTOR & MAIN TRANSFORMER WIRE TRIGGER VOLTAGE SPEED RECEPTACLE CONTROL CONTROL CONTROL BOARD SOLENOID LINE CIRCUIT INPUT BREAKER SWITCH RECEPTACLE WIRE FEED MOTOR VOLTAGE FEEDBACK & MOTOR POWER MOTOR CHOKE MAIN OUTPUT MAIN...

  • Page 12: Output Control, Rectification & Voltage Feedback

    THEORY OF OPERATION FIGURE E.4 - OUTPUT CONTROL, RECTIFICATION & VOLTAGE FEEDBACK WIRE TRIGGER VOLTAGE SPEED RECEPTACLE CONTROL CONTROL CONTROL BOARD SOLENOID LINE CIRCUIT INPUT BREAKER SWITCH RECEPTACLE WIRE FEED MOTOR VOLTAGE FEEDBACK & MOTOR POWER MOTOR CHOKE MAIN OUTPUT MAIN TERMINALS TRANSFORMER...

  • Page 13: Trigger, Gas Solenoid And Wire Drive

    THEORY OF OPERATION FIGURE E.5 - TRIGGER, GAS SOLENOID AND WIRE DRIVE WIRE TRIGGER VOLTAGE SPEED RECEPTACLE CONTROL CONTROL CONTROL BOARD SOLENOID LINE CIRCUIT INPUT BREAKER SWITCH RECEPTACLE WIRE FEED MOTOR VOLTAGE FEEDBACK & MOTOR POWER MOTOR CHOKE MAIN OUTPUT MAIN TERMINALS TRANSFORMER...

  • Page 14: Scr Operation

    THEORY OF OPERATION FIGURE E.6 - SCR OPERATION INPUT CATHODE OUTPUT NOTE: AS THE GATE PULSE IS APPLIED ANODE LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED. GATE SCR OPERATION A silicon controlled rectifier (SCR) is a three terminal An SCR is fired by a short burst of current into the gate.

  • Page 15: Thermal Protection

    THEORY OF OPERATION THERMAL PROTECTION OUTPUT OVERLOAD The Power Mig 180 Dual Wire Welder are equipped ® The Power Mig 180 Dual Wire Welder has a rated out- ® with a circuit breaker which protects the machine from put duty cycle as defined in the Technical damage if maximum output is exceeded.
  • Page 16 NOTES POWER MIG ® 180 DUAL...
  • Page 17 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 18: How To Use Troubleshooting Guide

    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 19: Pc Board Troubleshooting Procedures

    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 20 7. The control P.C. 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 21 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 22 P.C. board may be faulty. 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 23 Replace. seals. 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 24 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 25 5. See Operation section for infor- mation. 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 26 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 27: Case Cover Removal And Replacement Procedure

    CASE COVER 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 28: Removal Procedure

    TROUBLESHOOTING AND REPAIR F-12 F-12 CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.1 – CASE REMOVAL CASE COVER SCREWS LONG SCREWS SIDE DOOR SCREWS REMOVAL PROCEDURE 3. Using a 5/16” nutdriver, remove the ten screws WARNING securing the case cover. Note the position of the two longer screws.

  • Page 29: Replacement Procedure

    TROUBLESHOOTING AND REPAIR F-13 F-13 CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully place the case cover into position on the machine. 2. Using a 5/16” nutdriver, attach the ten screws securing the case cover. Note the position of the two longer screws.
  • Page 30 NOTES F-14 F-14 POWER MIG ® 180 DUAL...

  • Page 31: Gas Solenoid Test

    GAS SOLENOID 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 32 TROUBLESHOOTING AND REPAIR F-16 F-16 GAS SOLENOID TEST (continued) FIGURE F.2 – GAS SOLENOID LOCATION & LEADS Gas Solenoid Leads PROCEDURE 3. Locate the gas solenoid and lead connections. WARNING Do not disconnect the leads. See Figure F.2. 4. Turn the machine on and pull the gun trigger to ELECTRIC SHOCK can kill.
  • Page 33 TROUBLESHOOTING AND REPAIR F-17 F-17 GAS SOLENOID TEST (continued) FIGURE F.3 – CONTROL BOARD LEAD LOCATIONS CONTROL BOARD 8. If voltage is correct at P3, the control board may be faulty. 9. If faulty, perform the Control P.C. Board Removal and Replacement Procedure. 10.
  • Page 34 TROUBLESHOOTING AND REPAIR F-18 F-18 GAS SOLENOID TEST (continued) FIGURE F.4 – PLUG P3 PIN LOCATIONS PIN 1 PIN 10 POWER MIG ® 180 DUAL...

  • Page 35: 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 36 TROUBLESHOOTING AND REPAIR F-20 F-20 WIRE DRIVE MOTOR TEST (continued) FIGURE F.5 – CONTROL BOARD AND J3 LOCATION CONTROL BOARD PROCEDURE 2. Perform the Case Cover Removal Procedure. WARNING 3. Locate plug P3 on the wiring harness. Plug P3 is inserted into J3 on the control board. See ELECTRIC SHOCK can kill.
  • Page 37 TROUBLESHOOTING AND REPAIR F-21 F-21 WIRE DRIVE MOTOR TEST (continued) FIGURE F.6 – PLUG P3 MOT- MOTA1 5. Make the following voltage tests: 7. If the leads and connections are good to the board, verify the correct supply voltage 9-33 a.
  • Page 38 TROUBLESHOOTING AND REPAIR F-22 F-22 WIRE DRIVE MOTOR TEST (continued) FIGURE F.7 – PLUG P3 PIN LOCATIONS PIN 1 PIN 10 POWER MIG ® 180 DUAL...

  • Page 39: Main Transformer Test 230 And 120 Volts

    MAIN TRANSFORMER TEST 230 AND 120 VOLTS 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 40 TROUBLESHOOTING AND REPAIR F-24 F-24 MAIN TRANSFORMER TEST 230 AND 120 VOLTS (continued) 120 VOLT TEST PROCEDURE SECONDARY TEST PROCEDURE NOTE: Secondary voltages will vary proportion- WARNING ately with primary input voltage. For this test, place voltage control potentiometer to ELECTRIC SHOCK can kill.
  • Page 41 TROUBLESHOOTING AND REPAIR F-25 F-25 MAIN TRANSFORMER TEST 230 AND 120 VOLTS (continued) 230 VOLT TEST PROCEDURE SECONDARY TEST PROCEDURE NOTE: Secondary voltages will vary proportion- WARNING ately with primary input voltage. For this test, place voltage control potentiometer to ELECTRIC SHOCK can kill.
  • Page 42 TROUBLESHOOTING AND REPAIR F-26 F-26 MAIN TRANSFORMER TEST 230 AND 120 VOLTS (continued) FIGURE F.8 – SECONDARY LEAD LOCATION SECONDARY LEAD (Secondary Lead on opposite side not shown) POWER MIG ® 180 DUAL...

  • Page 43: Fan Motor Test 230 And 120 Volt

    FAN MOTOR TEST 230 AND 120 VOLT 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 44 TROUBLESHOOTING AND REPAIR F-28 F-28 FAN MOTOR TEST 230 AND 120 VOLT (continued) FIGURE F.9 – PLUG P1 WHITE BLACK BLUE LATCH 208 OR 230 VAC 230 VOLT TEST PROCEDURE 4. Turn machine ON to conduct voltage test. WARNING NOTE: Turn the machine OFF between each test. ELECTRIC SHOCK can kill.
  • Page 45 TROUBLESHOOTING AND REPAIR F-29 F-29 FAN MOTOR TEST 230 AND 120 VOLT (continued) FIGURE F.10 – PLUG P1 120 VAC WHITE BLACK BLUE LATCH 120 VAC 120 VOLT TEST PROCEDURE 4. Turn machine ON to conduct voltage test. WARNING NOTE: Turn the machine OFF between each test. ELECTRIC SHOCK can kill.
  • Page 46 NOTES F-30 F-30 POWER MIG ® 180 DUAL...

  • Page 47: Input Cord Continuity Test 120 And 230 Volt

    INPUT CORD CONTINUITY TEST 120 AND 230 VOLT 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 48 TROUBLESHOOTING AND REPAIR F-32 F-32 INPUT CORD CONTINUITY TEST 120 AND 230 VOLT (continued) FIGURE F.11 – INPUT CORD CONNECTOR 230 VOLT LESS THAN 1 OHM 230 VOLT TEST PROCEDURE 1. Disconnect input power to the Power Mig ® WARNING Dual machine.
  • Page 49 TROUBLESHOOTING AND REPAIR F-33 F-33 INPUT CORD CONTINUITY TEST 120 AND 230 VOLT (continued) FIGURE F.12 – INPUT CORD CONNECTOR 120 VOLT LESS THAN 1 OHM 120 VOLT TEST PROCEDURE 1. Disconnect input power to the Power Mig ® WARNING Dual machine.

  • Page 50: Typical Output Voltage Waveform - Machine Loaded

    TROUBLESHOOTING AND REPAIR F-34 F-34 TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED 0 volts 10 Volts 20 ms This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 10 volts and that each horizontal division represents 20 milliseconds in time.

  • Page 51: Abnormal Open Circuit Voltage Waveform

    TROUBLESHOOTING AND REPAIR F-35 F-35 ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 0 volts 10 Volts 20 ms This is NOT the typical voltage wave- form. The output capacitor was dis- connected from the circuit. Note the increased ripple in the waveform. This condition simulates the faulty output filter capacitor.
  • Page 52 NOTES F-36 F-36 POWER MIG ® 180 DUAL...

  • Page 53: 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 54 TROUBLESHOOTING AND REPAIR F-38 F-38 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.13 – CONTROL BOARD LOCATION CONTROL BOARD REMOVAL PROCEDURE 4. Using a 5/64” allen key, loosen the set screws WARNING from the voltage and wire speed knobs. See Figure F.14.
  • Page 55 TROUBLESHOOTING AND REPAIR F-39 F-39 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.14 – SCREW AND NUT LOCATIONS HANDLE SCREW NAMEPLATE CONTROL KNOB 5/64” ALLEN PHILLIPS SET SCREW SCREW 9. Label and disconnect plugs P4, P7 and P9 from the control board.

  • Page 56: Replacement Procedure

    TROUBLESHOOTING AND REPAIR F-40 F-40 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.15 – CONTROL BOARD LEAD LOCATIONS PLUG P9 PLUG P7 TERMINAL 1 LEAD 1 H2 (COPPER WIRE) PLUG P4 LEAD 302 R121 R120 R107 R119 LEAD 6 R115 R112 R111...
  • Page 57 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 58: Power Module

    TROUBLESHOOTING AND REPAIR F-42 F-42 POWER MODULE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.16 – REAR PANEL CONNECTION GAS HOSE AND RECEPTACLE SOLENOID CONNECTION ASSEMBLY SMALL CIRCUIT SCREWS BREAKER REMOVAL PROCEDURE 4. Using a 3/8” nutdriver, disconnect the two WARNING ground leads attached to the rear panel.
  • Page 59 TROUBLESHOOTING AND REPAIR F-43 F-43 POWER MODULE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.17 – CASE BACK MOUNTING SCREWS HANDLE SCREW LOCKING TABS MOUNTING SCREWS 9. Using a 5/16” nutdriver, remove the four mount- 14. Label and disconnect the four leads (MOTB, ing screws securing the rear panel of the MOTA2, MOTA1 and 543A) from the switch.
  • Page 60 TROUBLESHOOTING AND REPAIR F-44 F-44 POWER MODULE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.18 – SQUARE FLANGE FEMALE RECEPTACLE LOCATION SQUARE FLANGE FEMALE RECEPTACLE MOUNTING SCREWS FIGURE F.19 – CENTER PANEL SCREWS CENTER PANEL CENTER PANEL SCREWS POWER MIG ® 180 DUAL...
  • Page 61 TROUBLESHOOTING AND REPAIR F-45 F-45 POWER MODULE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.20 – SWITCH LEAD CONNECTIONS MOTB 543A EMPTY EMPTY MOTA2 MOTA1 FIGURE F.21 – CENTER PANEL WING NUTS WING NUTS POWER MIG ® 180 DUAL...
  • Page 62 TROUBLESHOOTING AND REPAIR F-46 F-46 POWER MODULE REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully place the new power module assem- 9. Using a phillips screwdriver, attach the two pre- bly into the machine. viously removed screws securing the handle to the front and rear panels.

  • Page 63: Rectifier, Transformer, Choke Assembly & Capacitor Removal And Replacement Procedure

    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 64 TROUBLESHOOTING AND REPAIR F-48 F-48 RECTIFIER, TRANSFORMER, CHOKE ASSEMBLY & CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.22 – LOCKING TABS LOCKING TABS 3/8” BOLTED LEAD (opposite side not shown) SLOTS REMOVAL PROCEDURE 4. Perform Power Module Removal WARNING Procedure. 5.
  • Page 65 TROUBLESHOOTING AND REPAIR F-49 F-49 RECTIFIER, TRANSFORMER, CHOKE ASSEMBLY & CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.23 – DOW CORNING APPLICATION AREAS LOCK WASHER PLAIN WASHER LOCKING TAB INSERTS DOW CORNING 340 (apply to contact surfaces on both terminals) TRANSFORMER AND CHOKE 1.
  • Page 66 TROUBLESHOOTING AND REPAIR F-50 F-50 RECTIFIER, TRANSFORMER, CHOKE ASSEMBLY & CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.24 – TRANSFORMER / CHOKE REMOVAL Transformer FIGURE F.25 – DOW CORNING 340 APPLICATION DOW CORNING 340 (Apply to area, opposite side not shown) POWER MIG ®...
  • Page 67 TROUBLESHOOTING AND REPAIR F-51 F-51 RECTIFIER, TRANSFORMER, CHOKE ASSEMBLY & CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position the new transformer and 6. Secure the previously removed top chassis to choke assembly into the power module assem- the power module assembly.
  • Page 68 NOTES F-52 F-52 POWER MIG ® 180 DUAL...
  • Page 69 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 70: Wire Drive Motor

    TROUBLESHOOTING AND REPAIR F-54 F-54 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.26 – SQUARE FLANGE FEMALE RECEPTACLE LOCATION SQUARE FLANGE FEMALE RECEPTACLE MOUNTING SCREWS REMOVAL PROCEDURE 3. Using a phillips screwdriver, remove the two WARNING screws securing the square flange female receptacle to the front cover.
  • Page 71 TROUBLESHOOTING AND REPAIR F-55 F-55 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.27 – FRONT PANEL CONNECTIONS HANDLE SCREW NAMEPLATE CONTROL KNOB 5/64” ALLEN PHILLIPS SET SCREW SCREW 9. Using pliers, disconnect the gas hose from the wire drive motor. 10.
  • Page 72 TROUBLESHOOTING AND REPAIR F-56 F-56 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.28 – WIRE DRIVE MOTOR MOUNTING SCREWS MOUNTING SCREWS (3) REPLACEMENT PROCEDURE 1. Carefully position the new wire drive motor 7. Using a 1/2” nutdriver, attach the two nuts and assembly on to the center panel of the machine.
  • Page 73 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 74 TROUBLESHOOTING AND REPAIR F-58 F-58 FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.29 – LOCKING TABS AND FAN LOCKING TABS SLOTS REMOVAL PROCEDURE 4. Perform Power Module Removal WARNING Procedure. 5. With the power module removed from the ELECTRIC SHOCK can kill.
  • Page 75 TROUBLESHOOTING AND REPAIR F-59 F-59 FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position the new fan motor assembly 4. Perform the Power Module Replacement into place in the rear of the power module Procedure. assembly. Be sure that the rotation arrow is 5.
  • Page 76 NOTES F-60 F-60 POWER MIG ® 180 DUAL...

  • Page 77: Gas Solenoid Removal And Replacement Procedure

    GAS SOLENOID 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 78 TROUBLESHOOTING AND REPAIR F-62 F-62 GAS SOLENOID REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.30 – GAS SOLENOID LOCATION Gas Solenoid SOL Leads REMOVAL PROCEDURE WARNING 4. Label and disconnect both SOL leads from the gas solenoid. See Figure F.30. See Wiring Diagram.
  • Page 79 TROUBLESHOOTING AND REPAIR F-63 F-63 GAS SOLENOID REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.31 – GAS HOSE AND SOLENOID ASSEMBLY CONNECTION LOCATION GAS HOSE AND RECEPTACLE SOLENOID CONNECTION ASSEMBLY SMALL CIRCUIT SCREWS BREAKER REPLACEMENT PROCEDURE 1. Carefully position the new solenoid assembly into the machine.

  • Page 80: Retest After Repair

    TROUBLESHOOTING AND REPAIR F-64 F-64 RETEST AFTER REPAIR 230 VOLT INPUT IDLE AMPS & WATTS INPUT VOLTS / HERTZ MAXIMUM IDLE AMPS MAXIMUM IDLE WATTS 230/60 2.50 OPEN CIRCUIT VOLTAGE 13 - 34 VDC WIRE SPEED RANGE 50 - 500 in./min. (1.3 - 12.7 m/min) POWER MIG ®...
  • Page 81 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (M22576) .

  • Page 82: Electrical Diagrams

    ElECTriCal DiaGramS WiriNG DiaGram - COmplETE maChiNE (m22576) WIRING DIAGRAM WARNING Do not operate with covers removed. SPOOL GUN (OPTIONAL) Disconnect input power before servicing Do not touch electrically live parts BLACK Only qualified persons should install, use or service this machine. WORK HIGH VOLTAGE Install equipment in accordance with the U.S.

  • Page 83: Schematic - Complete Machine (M22578

    TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 SCALE: CONTROL: CLEVELAND EQUIPMENT TYPE: POWER MIG 180 DUAL COMMON UNLESS OTHERWISE SPECIFIED TOLERANCE: PAGE ___ OF ___ ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE ON 3 PLACE DECIMALS IS ±...

  • Page 84: Schematic - Control Pc Board (G4741-3N1

    ElECTriCal DiaGramS SChEmaTiC - CONTrOl pC bOarD (G4741-3N1) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. pOWEr miG ® 180 DUal...

  • Page 85: Pc Board Assembly - Control (L12230-3

    Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

  • Page 86: Wiring Diagram - Spot Timer Kit (S26766

    ElECTriCal DiaGramS WiriNG DiaGram - SpOT TimEr kiT (S26766) 543B 215B SPOT CONTROL 215B TIMER P.C. BOARD 203B 203B P.C BOARD 544B 543B CONTROL P.C. BOARD HARNESS 544B ELECTRICAL SYMBOLSPERE1537 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY &...

  • Page 87: Schematic - Spot Timer C Board (M20960-2F0

    ElECTriCal DiaGramS SChEmaTiC - SpOT TimEr pC bOarD (m20960-2F0) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. pOWEr miG ® 180 DUal...
  • Page 88 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

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