Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
POWER MIG 200 Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. _____________________________________________...
Page 3 - ii; ELECTRIC SHOCK can kill.
POWER MIG 200 Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshiel...
Page 4 - iii
POWER MIG 200 Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National E...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
POWER MIG 200 Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les pr...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
v v POWER MIG 200 MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A ...
Page 7 - TABLE OF CONTENTS; Section A
TABLE OF CONTENTS - INSTALLATION SECTION - POWER MIG 200 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Safety Precautions . . ...
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS – POWER MIG 200
INSTALLATION A-2 POWER MIG 200 A-2 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 75°C Copper Wire 75°C Copper Wire Input Ampere in Conduit in Conduit Input Voltage/ F...
Page 9 - SAFETY PRECAUTIONS
INSTALLATION A-3 POWER MIG 200 A-3 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Read entire installation section before startinginstallation. SAFETY PRECAUTIONS ELEC...
Page 10 - FIGURE A.1 — Dual Voltage Machine Input Connections
INSTALLATION A-4 POWER MIG 200 A-4 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE A.1 — Dual Voltage Machine Input Connections 3. The 208/230 volt 60 Hz model P...
Page 11 - FIGURE A.2 — Triple Voltage Machine Input Connections; OUTPUT POLARITY CONNECTIONS
INSTALLATION A-5 POWER MIG 200 A-5 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE A.2 — Triple Voltage Machine Input Connections FIGURE A.3 — Receptacle Diagram...
Page 12 - GUN AND CABLE INSTALLATION
INSTALLATION A-6 POWER MIG 200 A-6 GUN AND CABLE INSTALLATION The Magnum 250L gun and cable provided with thePOWER MIG 200 is factory installed with a liner for.035-.045" (0.9-1.2 mm) electrode and an .035" (0.9mm) contact tip. Be sure that the contact tip, liner, anddrive rolls all match th...
Page 13 - Operation; Section B
TABLE OF CONTENTS - OPERATION SECTION - POWER MIG 200 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Product Description . ....
Page 14 - OPERATION
OPERATION B-2 B-2 POWER MIG 200 Read entire Operation section beforeoperating the POWER MIG 200. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wetclothing. Insulate yourself fromwork and ground. • Always wear dry insulating gloves. FUMES AND GASES can beda...
Page 16 - CAUTION
OPERATION B-4 B-4 POWER MIG 200 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC PROCEDURE FOR CHANGINGDRIVE AND IDLE ROLL SETS 1. Turn off the power source. 2. Release ...
Page 17 - FEEDING WIRE ELECTRODE
OPERATION B-5 B-5 POWER MIG 200 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FEEDING WIRE ELECTRODE When triggering, the electrode and drive mecha-nism are electrica...
Page 18 - FAN CONTROL; Steel Thickness Wire Feed Speed/Voltage Tap Settings; WireType
OPERATION B-6 B-6 POWER MIG 200 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observingthe foll...
Page 19 - Section C
TABLE OF CONTENTS - ACCESSORIES SECTION - POWER MIG 200 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 3/64” (1.2mm) Aluminum...
Page 20 - ACCESSORIES; DRIVE ROLL KITS
ACCESSORIES C-2 C-2 POWER MIG 200 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC DRIVE ROLL KITS Refer to Table C.1 for various drive roll kits that areavailable for t...
Page 22 - NOTES
NOTES C-4 C-4 POWER MIG 200 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC
Page 23 - Section D
TABLE OF CONTENTS - MAINTENANCE SECTION - POWER MIG 200 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2 General Maintenance . . ....
Page 24 - MAINTENANCE; • Have an electrician install and; GENERAL MAINTENANCE
MAINTENANCE D-2 D-2 POWER MIG 200 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Have an electrician install and service ...
Page 26 - GUN HANDLE DISASSEMBLY; ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS
MAINTENANCE D-4 D-4 POWER MIG 200 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC GUN HANDLE DISASSEMBLY The internal parts of the gun handle may beinspected or service...
Page 27 - Case Front Assembly
MAINTENANCE D-5 D-5 POWER MIG 200 6 2 3 4 5 1 1. Case Front Assembly 2. Rear Panel Assembly 3. Center Assembly 4. Wire Drive Assembly 5. Base & Power Component Assembly 6. Covers Assembly Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Maste...
Page 29 - Section E; FIGURE E.1 THEORY OF OPERATION BLOCK DIAGRAM
TABLE OF CONTENTS - THEORY OF OPERATION SECTION - POWER MIG 200 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2 Input Line Voltage ....
Page 30 - THEORY OF OPERATION
THEORY OF OPERATION E-2 E-2 POWER MIG 200 FIGURE E.2 – INPUT POWER CIRCUIT. INPUT LINE VOLTAGE, MAINTRANSFORMER, VOLTAGESELECTOR SWITCH ANDBAFFLE MOUNTED DIODEBRIDGE The single phase input power is connected tot h e P O W E R M I G 2 0 0 t h r o u g h a l i n e s w i t c hlocated on the front panel....
Page 33 - PROTECTIVE DEVICES AND CIRCUITS; THERMAL AND OVERLOAD PROTECTION
THEORY OF OPERATION E-5 E-5 POWER MIG 200 PROTECTIVE DEVICES AND CIRCUITS THERMAL AND OVERLOAD PROTECTION The POWER MIG 200 has two built-in protectivethermostats that respond to excessive temperatures.One is located on the main transformer. The otherthermostat is located on the output rectifier hea...
Page 35 - Section F
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR SECTION - POWER MIG 200 Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2 PC Board Troubleshooting Procedur...
Page 36 - TROUBLESHOOTING AND REPAIR
F-2 TROUBLESHOOTING AND REPAIR F-2 POWER MIG 200 If for any reason you do not understand the test procedures or are unable to perform thet e s t s / r e p a i r s s a f e l y, c o n t a c t t h e L i n c o l n E l e c t r i c S e r v i c e D e p a r t m e n t f o r t e c h n i c a ltroubleshooting a...
Page 37 - PC BOARD TROUBLESHOOTING PROCEDURES
F-3 TROUBLESHOOTING AND REPAIR F-3 POWER MIG 200 Sometimes machine failures appear to be dueto PC board failures. These problems cansometimes be traced to poor electrical con-nections. To avoid problems when trou-bleshooting and replacing PC boards, pleaseuse the following procedure: 1. Determine to...
Page 38 - OUTPUT PROBLEMS; Troubleshooting Guide –
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. Troubleshooting Guide – See Wiring D...
Page 41 - FUNCTION PROBLEMS
TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-7 F-7 POWER MIG 200 If for any reason you do not understand the test procedu...
Page 42 - WIRE FEEDING PROBLEMS
TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-8 F-8 POWER MIG 200 If for any reason you do not understand the test procedu...
Page 43 - WELDING PROBLEMS
TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-9 F-9 POWER MIG 200 If for any reason you do not understand the test procedu...
Page 45 - TEST DESCRIPTION; MATERIALS NEEDED; MAIN TRANSFORMER TEST; This procedure takes approximately 40 minutes to perform.
TROUBLESHOOTING AND REPAIR F-11 F-11 POWER MIG 200 TEST DESCRIPTION This test will determine if the correct voltages are being applied. a. Applied to the primary windings of the main transformers. b. Induced on the secondary and auxiliary windings of the main transformer. MATERIALS NEEDED 3/8” Nutdr...
Page 46 - TEST PROCEDURE; FIGURE F.1. – OUTPUT SELECTOR SWITCH TERMINALS
TEST PROCEDURE THE ON/OFF POWER SWITCH will be“hot” during these tests. NOTE: Secondary voltages will vary proportionately with the primary inputvoltage. 1. Disconnect the main input power supply to the machine. 2. Remove the case top and side panels with a 3/8” nutdriver. 3. Remove the tool tray wi...
Page 48 - INPUT VOLTAGE
TROUBLESHOOTING AND REPAIR F-14 F-14 POWER MIG 200 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INPUT VOLTAGE TEST POINTS EXPECTED VOLTAGE READING 11.9-13.0 VAC 14.1...
Page 49 - WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST; This procedure takes approximately 30 minutes to perform.
TROUBLESHOOTING AND REPAIR F-15 F-15 POWER MIG 200 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST WARNING This procedure takes approximately 30 minutes to perform. Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipmen...
Page 50 - NOTE: POLARITY MUST BE OBSERVED
TROUBLESHOOTING AND REPAIR F-16 F-16 POWER MIG 200 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) FIGURE F.4....
Page 53 - OUTPUT BRIDGE RECTIFIER TEST; This procedure takes approximately 20 minutes to perform.
TROUBLESHOOTING AND REPAIR F-19 F-19 POWER MIG 200 OUTPUT BRIDGE RECTIFIER TEST Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Service and repair should only be perfor...
Page 54 - Front; Negative Lead
TROUBLESHOOTING AND REPAIR F-20 F-20 POWER MIG 200 OUTPUT BRIDGE RECTIFIER TEST (continued) Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TEST PROCEDURE 1. Remove inp...
Page 55 - CONTACTOR TEST
TROUBLESHOOTING AND REPAIR F-21 F-21 POWER MIG 200 Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to the technician or machine operator and will invalidate your factorywarranty. For your s...
Page 56 - NOTE: When the contactor is not activated,; Figure F.7. Contactor Terminals and Leads
TROUBLESHOOTING AND REPAIR F-22 F-22 POWER MIG 200 TEST PROCEDURE 1. Remove the input power to the POWER MIG 200 machine. 2. Using the 5/16” Nutdriver, remove the tool tray. 3. Locate and remove leads 106B, 106C and 107A from the contactor coil terminals. See Figure F.7. See theWiring Diagram. 4. Us...
Page 57 - TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED; Volts; NOTE: Scope probes connected at; SCOPE SETTINGS
TROUBLESHOOTING AND REPAIR F-23 F-23 POWER MIG 200 TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED (MAX TAP “G”) 10.0 V 5 ms 0 Volts This is a typical DC output voltage wave-form generated from a properly operat-ing machine. Note that each verticaldivision represents 10 volts and thateach horizonta...
Page 58 - NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP “G”)
TROUBLESHOOTING AND REPAIR F-24 F-24 POWER MIG 200 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP “G”) 20.0 V 1.0 ms 0 Vo...
Page 59 - ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE
TROUBLESHOOTING AND REPAIR F-25 F-25 POWER MIG 200 ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED (MAX TAP “G”) ONE OUTPUT DIODE NOT FUNCTIONING 20.0 V 5 ms 0 Volts This is NOT a typical DC output voltagewaveform. One output diode is not func-tioning. Note the increased ripple con-tent. One diode...
Page 60 - ABNORMAL OPEN CIRCUIT VOLTAGE
TROUBLESHOOTING AND REPAIR F-26 F-26 POWER MIG 200 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING (...
Page 61 - CONTROL BOARD REPLACEMENT; DESCRIPTION
TROUBLESHOOTING AND REPAIR F-27 F-27 POWER MIG 200 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC This procedure takes approximately 20 minutes to perform. CONTROL BOA...
Page 62 - PROCEDURE
TROUBLESHOOTING AND REPAIR F-28 F-28 POWER MIG 200 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC CONTROL BOARD REPLACEMENT (continued) PROCEDURE 1. Remove power to th...
Page 63 - This procedure takes approximately 50 minutes to perform.; WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT
F-29 TROUBLESHOOTING AND REPAIR F-29 POWER MIG 200 This procedure takes approximately 50 minutes to perform. WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result ind...
Page 64 - WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued)
F-30 TROUBLESHOOTING AND REPAIR F-30 POWER MIG 200 PROCEDURE 1. Remove power to the machine. 2. Lift cover to gain access to the wire drive. See Figure F.9. 3. Using a pair of pliers, disconnect the gas hose from the bottom of the wire drive.See Figure F.10. 4. Using a 9/16” nut driver, remove the t...
Page 65 - Gas Hose
F-31 TROUBLESHOOTING AND REPAIR F-31 POWER MIG 200 WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued) FIGURE F.10. - WIRE DRIVE HOSE & LEAD LOCATION FIGURE F.11. - MOUNTING SCREW LOCATIONS Gas Hose 9/16" Bolt 5/16" SheetMetal Screws 5/16"Monuting Screws Retur n to Section TOC Retur n ...
Page 67 - OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT
F-33 TROUBLESHOOTING AND REPAIR F-33 POWER MIG 200 This procedure takes approximately 50 minutes to perform. OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result...
Page 68 - OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED)
F-34 TROUBLESHOOTING AND REPAIR F-34 POWER MIG 200 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED) PROCEDURE 1. Using a 3/8” nutdriver, remove the left side of the case wraparound cover. 2. Locate the output diode bridge rectifier. See Figure F.12. 3. Using a 1/2” nutdriver label and remove th...
Page 69 - FIGURE F.13. - OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET
F-35 TROUBLESHOOTING AND REPAIR F-35 POWER MIG 200 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED) 5/16" Mounting Bracket MountingBolts 1/2" RectifierMounting Bolts MountingBracket FIGURE F.13. - OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET Retur n to Section TOC Retur n to Section T...
Page 71 - OUTPUT CAPACITORS REPLACEMENT
F-37 TROUBLESHOOTING AND REPAIR F-37 POWER MIG 200 This procedure takes approximately 30 minutes to perform. OUTPUT CAPACITORS REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to...
Page 72 - OUTPUT CAPACITORS REPLACEMENT (Continued)
F-38 TROUBLESHOOTING AND REPAIR F-38 POWER MIG 200 OUTPUT CAPACITORS REPLACEMENT (Continued) PROCEDURE 1. Using a 3/8” nutdriver, remove the lower right side case wraparound cover. See Figure F.14. 2. Locate capacitor bank. See Figure F.14. 3. Label and remove the five leads connected to the capacit...
Page 75 - This procedure takes approximately 80 minutes to perform.; MAIN TRANSFORMER REPLACEMENT
F-41 TROUBLESHOOTING AND REPAIR F-41 POWER MIG 200 This procedure takes approximately 80 minutes to perform. MAIN TRANSFORMER REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to ...
Page 76 - Main Transformer
F-42 TROUBLESHOOTING AND REPAIR F-42 POWER MIG 200 MAIN TRANSFORMER REPLACEMENT (Continued) PROCEDURE 1. Using a 3/8” nutdriver, remove both sides of the case wraparound cover. 2. Using a 5/16” nutdriver, remove the tool tray. 3. Locate the main transformer. See Figure F.16. 4. Label and disconnect ...
Page 77 - REPLACEMENT
F-43 TROUBLESHOOTING AND REPAIR F-43 POWER MIG 200 MAIN TRANSFORMER REPLACEMENT (Continued) 15. Carefully maneuver the main transformer out the left side of the machine. NOTE: Two people may be needed to maneu- ver the main transformer out of themachine. REPLACEMENT 1. Carefully maneuver the new mai...
Page 81 - This procedure takes approximately 45 minutes to perform.; FAN BLADE/MOTOR REPLACEMENT
F-47 TROUBLESHOOTING AND REPAIR F-47 POWER MIG 200 This procedure takes approximately 45 minutes to perform. FAN BLADE/MOTOR REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to t...
Page 82 - REAR
F-48 TROUBLESHOOTING AND REPAIR F-48 POWER MIG 200 FAN BLADE/MOTOR REPLACEMENT (Continued) PROCEDURE 1. Using a 3/8” nutdriver, remove the lower right side of the case wraparound cover. 2. Perform the Output Capacitor Bank Removal Procedure. 3. Using a 5/16” nutdriver, remove the four fan mounting s...
Page 83 - OUTPUT CONTACTOR REPLACEMENT
F-49 TROUBLESHOOTING AND REPAIR F-49 POWER MIG 200 This procedure takes approximately 40 minutes to perform. OUTPUT CONTACTOR REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to ...
Page 86 - RETEST AFTER REPAIR; INPUT IDLE AMPS AND WATTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-52 TROUBLESHOOTING AND REPAIR F-52 POWER MIG 200 RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS OPEN CIRCUIT VOLTAGE WI...
Page 87 - ELECTRICAL DIAGRAMS
POWER MIG 200 G-1 ELECTRICAL DIAGRAMS G-1 TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 89 - SCHEMATIC - CONTROL PC BOARD
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-3 SCHEMATIC - CONTROL PC BOARD G-3 NOTE: This diagram is for reference only. It may not be accurat...
Page 90 - PC BOARD ASSEMBLY-CONTROL
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-vided for reference only....
Page 91 - SVM ERROR REPORTING FORM; Please give detailed description below:
SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as toadditional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col-umn troubleshoo...
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