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MULTIPROCESS WIRE FEEDER WELDER
ROUTINE MAINTENANCE
WARNING
Before carrying out service, maintenance and/or
repair jobs, fully disconnect power to the machine.
Use Personal Protective Equipment (PPE),
including safety glasses, dust mask and gloves to
avoid injury. This also applies to persons who enter
the work area.
MOVING PARTS can injure.
• Do not operate with doors open or guards off.
• Stop engine before servicing.
• Keep away from moving parts.
Have quali ed personnel do all maintenance and
troubleshooting work.
GENERAL MAINTENANCE
In extremely dusty locations, dirt may clog the air passages
causing the welder to run hot. Blow dirt out of the welder with
low-pressure air at regular intervals to eliminate excessive dirt
and dust build-up on internal parts.
The fan motor has a sealed bearing, which requires no service
DRIVE ROLLS AND GUIDE PLATES
After every coil of wire, inspect the wire drive mechanism. Clean it
as necessary by blowing with low pressure compressed air. Do
not use solvents for cleaning the idle roll because it may wash the
lubricant out of the bearing. All drive rolls are stamped with the
wire sizes they will feed. If a wire size other than that stamped on
the roll is used, the drive roll must be changed.
GUN TUBES AND NOZZLES
1. Replace worn contact tips as required.
2. Remove spatter from inside of gas nozzle and from tip after
each 10 minutes of arc time or as required.
GUN CABLE CLEANING
To help prevent feeding problems, clean cable liner after using
approximately 30 pounds (13.6 kg) of electrode. Remove the cable
from the wire feeder and lay it out straight on the oor. Remove
the contact tip from the gun. Using an air hose and only partial
pressure, gently blow out the cable liner from the gas diffuser end.
Excessive pressure at the beginning of the cleaning procedure
may cause the dirt to form a plug.
Flex the cable over its entire length and again blow out the cable.
Repeat this procedure until no further dirt comes out. If this has been
done and feed problems are experienced, replace the liner.
If for any reason you do not understand the procedures or are unable to perform the maintenance or repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR
PERIODIC MAINTENANCE
LINER REMOVAL, INSTALLATION AND TRIMMING
INSTRUCTIONS FOR MAGNUM 100L
CAUTION
NOTE: The variation in cable lengths prevents interchanging
of liners between guns. Once a liner has been cut for a
particular gun, it should not be installed in another gun
unless it can meet the liner cutoff length requirement.
1. Remove the gas nozzle from the gun by unscrewing counter-
clockwise
2. Remove the contact tip from the gun by unscrewing counter-
clockwise
3. Remove the gas diffuser from the gun tube by unscrewing
counter clockwise.
4. Lay the gun and cable out straight on a at surface. Loosen
the set screw located in the brass connector that connects to
the wire feeder. See bottom image. Pull the liner out of the
cable.
5. Insert a new untrimmed liner into the connector end of the
cable. Be sure the liner bushing is stenciled appropriately for
the wire size being used.
6. Fully seat the liner
bushing into the
connector. Tighten
the set screw on the
brass cable
connector. At this
time, the gas
diffuser should not
be installed onto the
end of the gun tube.
7. With the gas nozzle
and diffuser
removed from the
gun tube, be sure
the cable is straight,
and then trim the
liner to the length
shown. Remove any
burrs from the end
of the liner.
8. Screw the gas
diffuser onto the end
of the gun tube and
securely tighten.
9. Replace the contact
tip and nozzle.
D-1
MAINTENANCE
FIGURE D.1
Contact Tip
Gas Diffuser
Gas Nozzle or
Gasless Nozzle
1-1/4" (31.8mm)
Liner Trim Length
Brass Cable Connector
Set Screw
Liner Assembly
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