Troubleshooting - Lincoln Electric COBRAMATIC IM597 Operator's Manual

TROUBLE
No wire feed at torch, feeder
not operating, i.e., no slave
motor or brake soleniod.
Brake soleniod inoperative.
No wire feed at torch, feeder
operating properly.
Wire feeds, but welding wire
is not energized.
Wire feeds erratically.
Wire feeds one speed only
Wire walks out of drive rolls

TROUBLESHOOTING

CAUSE
F2 & F3 (MDA7 7A Slow Blow)
fuse in feeder blown.
F1 (4 amp) fuse in feeder blown.
Micro-switch defective/not being
activated. Broken electrical cable.
Relay K2 inoperative.
Loose J2, J3, P.C. board
connector
Soleniod defective.
Relay K2 inoperative.
Bad potentiometer.
Bad torch motor.
Broken electrical cable.
Bad speed control/PCB.
Loose or no cable connections.
Relay K2 not sending contactor
signal.
Contactor control cable loose or in
wrong position.
Welding power source not working
right.
Excessive spool drag pressure.
Dirty or worn conduit.
Incorrect pressure on drive rolls.
Idler roll stuck.
Wrong size contact tip.
Bad potentiometer.
Broken electrical cable in lead
assy.
Bad speed control.
Idler roll upside-down.
Rear wire guide missing.
K1587-1 Cobramatic® Owner's Manual - Page 17
REMEDY
Check AC circuit. Replace fuse
Check motor leads for shorts, then
replace fuse
Replace switch. Check switch for
operation. Check micro switch wires for
continuity.
Check/Replace relay K2.
Check J2, J3 connectors.
Replace soleniod.
Check for 42VAC across J4-1 and J4-2
Check relay K2 for AC not present.
Check potentiometer with meter.
Check/Replace motor.
Check motor and potentiometer wires
for continuity.
Check/Replace P.C. Board.
Check all power connections.
Check/Replace relay K2.
Check power supply owners manual for
location and type of contactor signal
required, i.e. closing contacts or AC.
Check power supply for proper
operation.
Decrease spool drag pressure inside
hub.
Blow out or replace conduit.
Adjust pressure at both feeder and
torch.
Check for lock washer under idler roll, or
replace if damaged or worn.
See contact tip table.
Check with meter.
Check potentiometer wires for continuity
or shorts.
Check/Replace P.C. Board.
Place groove in idler roll towards top.
Replace wire guide.