Lincoln Electric SVM189-B service manual 11OPERATION, Connect Leads and Cables on the Machine

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B-11OPERATION

C. CONNECT LEADS AND CABLES ON THE MACHINE

B-11

FIGURE B.14

Section

Master

(See Figure B.14)

LOCATE COMPONENTS TO CONNECT TO THE FRONT OF MACHINE

1.Open the case side door.

2.Slide the connector end of the gun and cable

through the hole of the machine front and into the

gun connector bushing on the wire drive.

SLIDE

CONNECTOR

 

END HERE

3. Make sure the gun connector end is seated fully into

 

the wire drive and tighten the thumbscrew to secure

(4 PIN)

the gun.

LEAD CONNECTOR

 

CASE SIDE DOOR

OPEN LATCH DOOR

TERMINAL END (FITS ON STUD INSIDE SEE FIGURE BELOW)

WORK CLAMP

4. Plug the gun trigger lead connector into the 4 pin

 

ALL COMPONENTS SHOWN CONNECTED

 

GUN AND CABLE

(FRONT AND SIDE DOOR IS REMOVED

gun trigger receptacle on the machine front.

FOR CLARITY)

 

 

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5. Wire Drive Polarity. MIG welding requires Positive

(+) polarity. Connect the short power cable from the

wire drive to the positive (+) output terminal and

THUMB SCREW TO

WORK LEAD CONNECTION

TIGHTEN CONNECTOR

BUSHING

NEGATIVE "-"

OUTPUT TERMINAL

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tighten the thumbscrew.

6. Work Lead Connection. Slide the lugged end of the

work cable through the hole in the machine front and

place on the negative (-) output terminal and tight-

en thumbscrew.

D. LOAD WIRE SPOOL

(See Figure B.15)

1.Locate the green labeled 4"(102mm) diameter spool of .025”(0.6mm) L-56 solid MIG wire and place onto wire spool spindle. Orient the spool so that the wire feeds off the top of the spool.

2.Secure spool in place by tightening the wing nut against the against the spacer that holds the wire spool on the spindle.

3.Open the top drive roll pressure arm by rotating the tension adjustor arm down and pivoting the idle roll pressure arm up.

4.Remove the outer wire guide.

CONNECTOR

 

END ATTACH

 

 

SHORT POWER

(4 PIN)

CABLE POSITIVE "+"

OUTPUT TERMINAL

TRIGGER RECEPTACLE

 

PLUGGED IN

 

 

WORK CLAMP

FIGURE B.15

TOP DRIVE ROLL PRESSURE ARM

TENSION ADJUSTOR DOWN

WIRE SPOOL

.025" (0.6mm)

L

 

 

 

IG

-

 

 

M

 

5

6

 

 

 

D

 

 

 

S OLI

 

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4a. Slide gun out of drive slightly.

5. Remove the lower drive roll and inner wire guide.

INNER WIRE GUIDE REMOVED

6. Install the .025”-.035”(0.6mm-0.9mm) inner wire guide.

LOWER DRIVE ROLL REMOVED

7. Install the .025”(0.6mm) smooth grooved lower drive roll.

OUTER WIRE

GUIDE REMOVED

8. Carefully unwind and straighten the first six inches of welding wire from the spool. Do not let the end of the wire go to prevent the wire from unspooling.

COMPACT WIRE WELDERS

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Contents SVM189-B Safety Depends on YouCalifornia Proposition 65 Warnings SafetyElectric Shock can kill ARC Rays can burn Welding Cutting For ElectricallyIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications InstallationSelect Suitable Location Safety PrecautionsStacking TiltingIdentify and Locate Components Table of Contents Operation Section Product Description Product Capabilities OperationCommon Welding Abbreviations Wear eye, ear and body protec- tionControls and Settings See Figure B.1See Figure B.2 Drive Roll Tension Thumbscrew Turning See Figure B.3Number Part Number Wire Diameter Drive Roll Drive Roll Part Inner Wire GuideItems Needed for Flux Cored Welding Setting UP and Making a FLUX-CORED WeldLoad Wire Spool Connect Leads and Cables onMachine Figure B.9 025 MIG Conversion Kit K2526-1Shielding GAS Install Shielding GASConnect Leads and Cables on the Machine 11OPERATIONDo not Remove or Conceal Warning Labels 12OPERATIONFigure B.20 Compact Wire Welders Table of Contents Accessories Section K2525-1 Spot Timer Kit AccessoriesK2532-1 Magnum 100SG Spool Gun K2377-1 Small Canvas CoverK520-Utility Cart K2275-1 Welding Cart Unpacking the Spool GUN Technical Specifications Magnum 100SG Spool GUN K2532-1Locating Spool GUN Components Features Safety PrecautionsFigure C.3 Assembly of Items Inside the Magnum Spool GUNSafety Precautions Welding Machines Recommended Welding MachinesSpool GUN Spool GUN / Wire Drive Selector Switch Installation Disconnect input power from the machineOpen the Machine Electrical Connections 11.B. Connect P5 6-pin to harness J8 6-pin11.C. Connect harness P8 6-pin to board J5 6- pin 544A 543A If Machine does have Optional Spot Timer .A. thru 12.DRE-ASSEMBLE Machine AS Follows Mounting the SwitchDisconnect input power to the machine ACCESSORIESC-13Routine Welding Machine Preparation Preparing the Spool GUNFigure C.5 Loading Aluminum WireFigure C.11 Figure C.17 Connecting the GUN to the Welding MachineTable of Contents Maintenance Section Maintenance Maintenance Safety PrecautionsRoutine Maintenance GUN and Cable Maintenance Overload ProtectionFor Magnum 100L GUN Changing Liner GUN Handle PartsLiner trim length Major Component Locations Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 General Description Theory of OperationInput Line VOLTAGE, FAN Motor & Main Transformer Figure E.3 Input Power CircuitsFigure E.4 Output Circuits Output CONTROL, Rectification & Voltage FeedbackFigure E.5 TRIGGER, GAS Solenoid & Wire Drive TRIGGER, GAS Solenoid and Wire DriveFigure E.6 SCR Operation SCR OperationElectronic Wire Drive Motor Protection Compact Wire Welders Table of Contents Troubleshooting & Repair HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board Troubleshooting Procedures Wiring Diagram OUTPUT/FEEDING Problems Feeding Problems Welding Problems Maintenance Section Issues Maintenance Section Cone or gas diffuser Case Cover Removal and Replacement Procedure Test DescriptionMaterials Needed Figure F.1 Case Removal ProcedureGAS Solenoid Test GasSolenoid Leads Wire Drive Motor Test MOT-MOT+ Test ProcedureMain Transformer Test Secondary Test Procedure Secondary Lead Compact Wire Welders FAN Motor Test Figure F.5. Control Board Lead Locations Scope Settings Typical Output Voltage Waveform Machine LoadedVolts 10Volts 20ms Abnormal Open Circuit Voltage Waveform Control Board Removal and Replacement Procedure See Figure F.7 Nameplate Control Knob Compact Wire Welders Power Module Removal and Replacement Procedure Viewed from Rear of Machine Center Panel PolarityPanel CenterPanelScrews OutputStuds Compact Wire Welders Misc. Hand Tools Dow Corning Fine Steel Wool See Figure F.12 Dow Corning Figure F.12 DOW Corning Application Areas Transformer Compact Wire Welders Wire Drive Motor Removal and Replacement Procedure Lincolnelectric Phillips Mounting Screws Compact Wire Welders FAN Motor Assembly Removal and Replacement Procedure Viewed from Rear of Machine Center Panel CenterPanelScrews Locking Tabs Fan Wire Speed Range Troubleshooting & Repair Retest After Repair 125 AMP UnitsRetest After Repair 140 AMP Units Open Circuit VoltageTroubleshooting & Repair Retest After Repair 180 AMP Units Table of Contents Diagram Section COmpacT WirE WElDErS Wiring DiagramSpool GUN Interface Wiring Diagram Wiring Diagram Thermostat TMP FAN TS1 M20410-3 a COmpacT WirE WElDErSSchEmaTic cOmplETE machiNE m21240 C12 R1Feed R24
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