Lincoln Electric SVM189-B service manual Table of Contents Installation Section

Page 7

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A-1

TABLE OF CONTENTS - INSTALLATION SECTION

A-1

 

 

 

 

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Machines in This Manual

. . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . .A-1

Technical Specifications .

. . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . .A-2

Safety Precautions

. . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . .A-3

Location

. . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . .A-3

Component Identification

. .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . .A-4

 

 

MACHINES COVERED BY THIS MANUAL

 

 

 

 

 

 

 

CODE

 

K-NUMBER

PRODUCT NAME

 

 

11173

 

K2480-1

PRO-MIG 140T

 

 

 

 

 

 

 

 

11175

 

K2481-1

PRO-MIG 180T

 

 

 

 

 

 

 

 

11254

 

K2470-1

POWER MIG 140T *

 

 

 

 

 

 

 

 

11255

 

K2471-1

POWER-MIG 140C

 

 

 

 

 

 

 

 

11256

 

K2472-1

POWER MIG 180T *

 

 

 

 

 

 

 

 

11257

 

K2473-1

POWER MIG 180C

 

 

 

 

 

 

 

 

11300

 

K2479-1

PRO-CORE 125T

 

 

 

 

 

 

 

 

11302

 

K2513-1

WELD-PAK 125HD

 

 

 

 

 

 

 

 

11303

 

K2514-1

WELD-PAK 140HD

 

 

 

 

 

 

 

 

11304

 

K2515-1

WELD-PAK 180HD

 

 

 

 

 

 

 

 

11440

 

K2658-1

MIG-PAK 140

 

 

 

 

 

 

 

 

11441

 

K2659-1

MIG-PAK180

 

 

 

 

 

 

 

 

11442

 

K2661-1

POWER-MIG 180C

 

 

 

 

 

 

 

 

11444

 

K2668-1

POWER-MIG 180C

 

 

 

 

 

 

 

 

11501

 

K2688-1

SP140T

 

 

 

 

 

 

 

 

11502

 

K2689-1

SP180T

 

 

 

 

 

 

 

 

11503

 

K2696-1

EASY-CORE 125

 

 

 

 

 

 

 

 

11504

 

K2697-1

EASY-MIG 140

 

 

 

 

 

 

 

 

11505

 

K2698-1

EASY-MIG 180

 

 

 

 

 

 

 

 

11506

 

K2699-1

WORK-PAK 125

 

 

 

 

 

 

 

 

11646

 

K2481-1

PRO MIG 180

 

 

 

 

 

 

 

 

11647

 

K2515-1

WELD-PAK 180HD

 

 

 

 

 

 

 

 

11648

 

K2659-1

MIG PAK 180

 

 

 

 

 

 

 

 

11649

 

K2689-1

SP180T

 

 

 

 

 

 

 

 

11650

 

K2698-1

EASY-MIG180

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*Discontinued Models

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 For Electrically Welding CuttingIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications InstallationTilting Safety PrecautionsSelect Suitable Location StackingIdentify and Locate Components Table of Contents Operation Section Wear eye, ear and body protec- tion OperationProduct Description Product Capabilities Common Welding AbbreviationsSee Figure B.1 Controls and SettingsSee 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 WeldConnect Leads and Cables on Load Wire SpoolMachine 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 K2377-1 Small Canvas Cover AccessoriesK2525-1 Spot Timer Kit K2532-1 Magnum 100SG Spool GunK520-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 GUNRecommended Welding Machines Safety Precautions Welding MachinesSpool GUN Disconnect input power from the machine Spool GUN / Wire Drive Selector Switch InstallationOpen the Machine 11.B. Connect P5 6-pin to harness J8 6-pin Electrical Connections11.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 SwitchPreparing the Spool GUN ACCESSORIESC-13Disconnect input power to the machine Routine Welding Machine PreparationFigure C.5 Loading Aluminum WireFigure C.11 Figure C.17 Connecting the GUN to the Welding MachineTable of Contents Maintenance Section Maintenance Safety Precautions MaintenanceRoutine Maintenance Overload Protection GUN and Cable MaintenanceFor Magnum 100L GUN GUN Handle Parts Changing LinerLiner 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 Test Description Case Cover Removal and Replacement ProcedureMaterials 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 Typical Output Voltage Waveform Machine Loaded Scope SettingsVolts 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 Open Circuit Voltage Troubleshooting & Repair Retest After Repair 125 AMP UnitsWire Speed Range Retest After Repair 140 AMP UnitsTroubleshooting & 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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