Miller Electric S-21E User Manual

MiIIe~

November1996
Effective

With Serial

Form:

No.

TM-1571

JJ507797

TECHNICAL

Service

And

MANUAL

Parts

coverjml—SB-124

A

SERVICING

•

Have
qualified

practices.

U

For

help,
Service
414-735-4505

467

WARNING

canbehazardous.

all

service

procedures

persons

call

Factory

Department:

following

performed only

~U~r

Wire

standard

©

S-21E

Feed

Equipment

by

safety

FAX:

14-735-4136

1996

MILLER Electric

Mfg.

Co.

Use

MILLER

150

853)

Use

only genuine

parts.

L................J

Testing Booklet

when

servicing

MILLER

U

Or

write
MILLER
RO.

Box

Appleton,WI54912

this

unit.

replacement

to:

Electric

1079

PRINTEDINUSA

(Part

Mfg.

No.

Co.

USA

TABLEOFCONTENTS

OM-1571B—3/91

Section

SECTION

SECTION2-SHIPPING

No.

1-SAFETY

1-1.
1-2.

1-3.

General
Safety

Safety

PRECAUTIONS AND

Information And

Alert
Precautions

2-1. Preparation

Symbol And

AND

STORAGE

For

Reshipment

Safety

Signal

SIGNAL

Words

2-2. Storage

SECTION3—SPECIFICATIONS

3-1.

Description

SECTION4-INSTALLATIONORRELOCATION

4-1.
4-2.

4-3.
4-4. Shielding

4-5.
4-6.

4-7.
4-8.

4-9.
4-10.

Location

Drive

Roll

Installation

Welding Gun Connections

Gas

Installation

14-Pin

Welding
Welding

Adjust
Welding

Feeding Welding

Plug

Wire
Wire

The

Cable

Hub

Connection

Installation
Threading

Tension

Connection

Wire

WORDS

Page

No.

1
1

1

2
2

3

3
3

5
5

6
6

7
8

8
8

SECTION

5-OPERATOR

5-1.
5-2.

Power
Wire

Switch

Speed

CONTROLS

Control

SECTION6—SEQUENCEOFOPERATION

6-1.
6-2.

Gas

Metal Arc (GMAW)

Shutting

Down

And

Flux Cored

SECTION7-THEORYOFOPERATION

7-1.
Diagram

Diagram

Theory Of

7-1.

Block

7-2.

Block

Operation

Diagram
Diagram

For

Wire Feeder

For

SpotlBurnback

Arc

(FCAW) Welding

Time

Control

Option

9
9

9

10

10
11

12

Section

SECTION8-TROUBLESHOOTING

No.

Page

No.

8-1.
8-2.
8-3.

Diagram

8-4. Motor

Diagram

8-5.

Diagram

SECTION9-COMPONENT

Figure

SECTION

10-1.
10-2.

10-3.
10-4.
10-5.

SECTION

Testing
Circuit
Troubleshooting

Optional

9-1.

10—

Routine
Aligning

ReinstallationOfHub
Brush
Overload

11-ELECTRICAL

Instruments And Information

Board

Handling
8-1.
8-2.

8-3.

MAINTENANCE

Troubleshooting

Board

PCi

Troubleshooting

Board
SpotlBurnback

Troubleshooting

Board PC2

Component

Maintenance

Drive

Roll And

Inspection

Protection

Precautions

Circuit

Testing

Circuit

PCi

Board PC2 Testing

Circuit

IDENTIFICATION

Identification And

Wire

Assembly

And

Replacement

DIAGRAMS

Diagram For

Information

Diagram For

Diagram For

Guide

AND

LOCATION

Location

Wire Feeder
Motor Control

Information

Optional Spot/Burnback

14
14
14

16
17

18
20

22

24

25
26
26

27

27

Diagram
Diagram
Diagram

Diagram
Diagram

SECTION

Table 3-1.
Table 8-1.

Table
Table

11-1.
11-2.
11-3.

11-4.
11-5.

12—

PARTS

Specifications
Troubleshooting

10-1.

Maintenance

11-1.

ListOfCircuit Diagrams

Circuit
JJ507797

Wiring
JJ507797

Circuit
With Serial

Circuit

Effective

Circuit

Effective

Diagram For

Diagram

Diagram For
Diagram

With Serial

Diagram For

With Serial

LIST

LISTOFCHARTS AND

S-21EEffective

And Following

For

S-21EEffective

And Following

No.

Schedule

Motor Control

JJ507797 And Following

For

Optional

No.

JJ507797

Optional Spot/Burnback

No.

JK742029

And

Wiring

With Serial
With

Serial

Board

PCi

SpotlBurnback

Thru

JK742028

And Following

TABLES

Diagrams

No.

29

No.

29

Effective

30

Board PC2

31

Board PC2

32

3

15

25
28

SECTION

1-SAFETY

PRECAUTIONS

AND

SIGNAL WORDS

1-1.

This
specific
dures.Italso includes
vanttothese

tive toolinthe
ever,itdoes

training
arises

sented,orif
manual,
proceeding

1-2.
The

used
identify

tions.

A
A

A

IMPORTANT

GENERAL

manual

about

following safety alert

throughout

provides

operating,

procedures.

handsofa

not

nor

safety-conscious service

the

problems

contact

further.

SAFETY

WORDS

different

This safety alert
words

WARNING and

tionto

the

WARNING statements identify
practices which
ous personal injury

CAUTION

practices which
personal injuryordamagetothis

statements identify special

necessary

for

the

INFORMATION

testing, and

and

cannot

specific

arise

the

factory

ALERT

this

levels of

safety

statements identify procedures

most efficient

ment.

1-3.

SAFETY

PRECAUTIONS

AND SAFETY

theoryofoperation

troubleshooting

precautionary information

This

manual

trained

application

which

symbol

manual to

hazard

symbolisused

statements.

mustbefollowedtoavoid

mustbefollowedtoavoid

serviceperson.

take

the

work.Ifany

of procedures

are

not

Service Department

SYMBOL AND

and signal
call

and

CAUTIONtocall

or loss of

along

can

be an

placeofprevious

covered

SIGNAL

words

attention

special

with

the

procedures

life.

equipment.

instructions

operationofthis

with

proce-

rele-

effec

How-

doubt

pre

in this

before

are

to and

instruc

signal
atten

or

seri

or

minor

equip

•

Shut

down

unit

and

disconnect

when

servicing

cally

requiresanenergized

•

Do

not

leave

-

-

ARC

RAYS,

can

burn eyes

hearing.

•

Wear

FUMES
your

health.

•

Keep

•

Ventilate to

correct

AND

your

unless

live

SPARKS,

and

eye,

GASES can

the

unit

unattended.

AND HOT

skin; NOISE

ear,

and body

head outofthe

keep

from

breathing

input

procedure

unit.

SURFACES

can

damage

protection.

seriously

fumes.

fumes

power

specifi

harm

and

-

gases.

•Ifventilationisinadequate,
breathing

•

-

Read Material

and

materials

-

WELDING
wounds.

•

Do
any

-

HOT
cause

•

Watch

•

Haveafire
howtouse

•

Do

•

-

Allow

device.

Safety

manufacturer’s

used.

WIRE

not

point

gun towardany

conductive

METAL,

fire

and

for

surface,orother

SPATrER,

burns.

fire.

extinguisher

it.

not

use

near

flammable

work

and

Data

instructions

can

equipmenttocool

use

Sheets

cause

part of

AND

nearby

material.

approved

(MSDSs)

for

any

puncture

the

body,

personnel.

SLAG

and

can

know

before

handling.

MOVING

•

Keep

PARTS

away

can

from

cause

moving

serious

parts.

injury.

A

5-21E

W

ARNING: ELECTRIC

S

Do

not

touch

live

•

Protect
and

•

Insulate
rubber9loves

power is

yourself

clothing.

yourself

and

appliedtothe

SHOCK

electrical

with

dry

from

groundbyusing

insulating

unit.

can kill.

parts.

insulating

floormats

gloves

when

HOT

SURFACES

•

Allow

cooling

MAGNETIC
can

affect

pacemaker

•

Wearers

going near
mentorany

can

period

FIELDS

should

consult

the

servicingofarc

arc

welding

cause

before

FROM

HIGH CURRENTS

operation.

their

operations.

severe

burns.

servicing.

doctor

welding

TM-1571

before
equip

Page

1

-

SECTION2-SHIPPING

AND

STORAGE

PREPARATION

WARNING:

•

Do

not

A

•

Shut
source,
ing

touch

down wire

and

lockout/tagging

preparing unit

Lockout/tagging
sistofdisconnecting
for

welding

line

disconnect switch

ing

fuses

from

tagging circuit breaker or
device.

(—)

erators.

1.

Disconnect

feeder.

2.

Disconnect

3.

Disconnect and remove

devices.

4.

Disconnect

ble)

5.

Disconnect gun

6.

Secure

wire

7.

Tape

8.

Securely
around

if

available.

IMPORTANT:

Not

onlydocosts increase

more

subjecttolossordamage

9.

If

sending

factory
Department.

Stop

battery

hoses from

spoolorreel

cable

interconnecting
weld

shielding

welding

plastic

tie

sidesofunit.

Do

not

unittofactory,

Service

FOR

RESHIPMENT

ELECTRIC

live

disconnect

SHOCK

electrical

feeder

and

input

can

parts.

welding

power

procedures

for

shipping.

procedures

power

source

fuse

box,

engine, and

from

cable

gas

wire

feeder.

from

wire

wiretospool/reel,

from

around

and/or tape cardboard over

top

Use

ship without

dramatically

forwire

interconnecting

consistofpadlocking

in open

or shutting

other
disconnect

batteryonwelding

cord

from drive

any

remote

(and

feeder.

wire

feeder.

and

sidesofunit.

original

feedercon

position,

off

disconnecting

from

rearofwire

assembly.

controls

waterifapplica

and

shipping carton

a cardboard

but

cord,

the

withoutacarton.

ship

unitasdirected

DepartmentorTransportation

kill.

power

employ

before

and

remov-

and red­negative

gen

remove

top

and

carton.

unit

or

by

is

STORAGE

WARNING:

•

A

-

Do

•

Shut
source,

ing

ELECTRIC

not

touch

live

electrical

down

wire

feeder

and

disconnectinput power

lockout/tagging

procedures

SHOCK

parts.

and

can

kill.

welding

employ

before

power

-

storing

unit.

-

-

-

10.

11.

12.

13.

Lockout/tagging
sistofdisconnecting

for

welding

line

disconnect switch

ing

fuses

tagging circuit

device. Stop

(—)

battery

erators.

1.

Disconnect

feeder.

2.

Disconnect weld

3.

Disconnect and remove
devices.

4.

Disconnect
ble)

hoses

5.

Disconnect gun

6.

Secure
wire

spoolorreel

7.

Clean outside of

8.

Remove

9.

Using
Reinstall wrapper.

Selectastorage

unittowide

corrosive
Carry

Cover

power

from

cable

interconnecting

shielding

from

welding

wrapper.

dry

compressed

temperature

vapors.

unit

to storage

unit

with

procedures

source consistofpadlocking

fuse box,

breakerorother

engine, and

from

cable

gas

wire

feeder.

from

wire

wiretospool/reel,

from

unit.

location that

location.

plastic

forwirefeedercon

interconnecting

in open

or shutting

disconnect negative

batteryonwelding

cord

from drive

any

remote

(and

feeder.

wire

feeder.

air,

clean

least

variation,

or suitable

cord,

position,

off and

disconnecting

from

rearofwire

assembly.

controls

waterifapplica-

and remove

inside of

subjects

dust,

tarp.

and

remov-

red-

gen

unit.

the

dirt,

and

-

-

or

TM-1571

Page

2

5-21E

SECTION3-SPECIFICATIONS

Input

Power

Requirements

24

VAC

3.5

Amps

50/60

Hz

Electrode

Diameter

.O23thru

(0.6 thru

10-112
(267

Wire

Capacity

.045

in.

1.1

mm)

In.

mm)

Table 3-1.

Wire

Capacity

10to20

(4.5 to9kg)

8

in.

(203mm)

upto60

(27.2

Specifications

Spool

lb.

spools

lb.

kg)_coils

Electrode

(1.9-15.2

22-1(2

(572

Wire

Feed Speed

75-600 ipm

mom)

at24VA~

in.

mm)

Net

30

(13.6

Weight

lbs.

kg)

Ship

33

lbs.

(15 kg)

3-1. DESCRIPTION

This

unitisa

which
for

connection toaconstant

source

4-1.

The

service

components
high

levels of

extreme
A

proper installation

feederifthe

lengths
slotisprovided in
eyeonwelding
space

necessary

S-21E

semiautomatic

operates

througha14-pin

LOCATION

heat.

mustbeconsidered

shouldbemaintained

on 24

volts

(Figure 3-1)

life

and

efficiencyofthis unit

are

reduced

dust,

dirt, moisture,

site shouldbeselected

unitisto provide

the

baseofthe

power

connections

Figure

constant speed wire feeder
ac.

The

feederisdesigned

voltage (CV)

connector.If115

volts acisthe

3-1. Overall Dimensions

only

power supply
used

type

power

The
dirt.

SECTION4-INSTALLATION OR

4-2.

and

associated

when

they

are

subjected to

corrosive

dependable

when

installing

unittofit

sourcessoequipped. Suitable

around

and

for

maintenance

the

vapors, and

for

the

service.

the

over

the

unit

for

making

functions.

wire

Lead

unit.

lifting

A

A

power

available

to convert

case

canbetightly

for

adapter

the

powerto24

use

Model

latched to

RELOCATION

DRIVE

WARNING: ELECTRIC

•

•

Lockout/tagging
sistofdisconnecting

for

line
ing

tagging

device.

(—)

erators.

ROLL

INSTALLATION (Figure 4-1)

Do

not

touch

live

Shut

down

wire

source,
ing

and

disconnect

lockout/tagging

spectingorinstalling.

welding

disconnect switch

fuses

battery

power

from

circuit

Stop

cable

fuse

breakerorother

engine, and

SB-124

467

with

the

feeder,

PSA-2

volts

help

SHOCK

electrical

feeder and

input

procedures

procedures

source consistofpadlocking

box,

from

for

interconnecting

in open

or shutting

disconnect negative

batteryonwelding

the

optional

115/24 should

ac.

keep

out

dust

can kill.

parts.

welding

power

power

employ

beforein-

wire feeder

cord,

position,

remov-

off

and

disconnecting

TM-1571

Page

be

and

con

and

red-

gen

-

-

-

3

Wire

•

Spring

Hub

Pressure

(ShownInOpen

9

Roll

Assembly

PosItion)

Retaining

Ring

•

OPTIONAL

Itisnecessarytoinstall
tingupthis unit

IMPORTANT:

Base drive

and

the

also

recommendations:

The

dual-grooved drive
commodates
wire.

This

knurled
.030

in.

groove
wire.

The

sideofthe
feeder,
visible.

The50Series wire feeder
with

this feeder,

used,aknurled
.035

and

A

.023

drive

groove.

(0.6 and

for

feeding

wire

drive

the

wire

.045

(.089

W

ARNING:

Do

not
ment. The
cally

Use

size

roll.

size

drive

hot

roll

through

roll

has

the “V”

0.76

mm)

.035

and

for

each

When

stamp

but,

due to

roll is

and

ELECTRIC

store metallic

motor

whenever

gized.

TM-1571

Page

4

Ret.

50497

Figure

required

when

roll

provided

.045

both

groove

the

for

style

recommended

1.1

drive

changing

selectiononthe

with

in.

(0.6 through

a

“‘I”

groove

for

wire.

Use

.045

in.

(0.89

grooveisstampedonthe

drive

roll is

the

unused

drive

rolls

the flat

mm)

idler pressure

wire.

SHOCK

4-1.

rolls

when

wire

the

feederac-

and

feeding

the

“V”

and

installedinthe

groove

maybeused

when

can

objectsinthis

drive

assemblyiselectri

the

welding

circuitisener

Wire

set

sizes.

following

1.1

mm)

a

“‘I”

.023

and

knurled

1.1

mm)

will

be

roll

feeding

kill.

compart

Feeder

-

IMPORTANT:

can
verse

The

be

1.

2.

3.

4.

-

-

-

Components

Loose
createanelectrical

put
nents

metal

circuit and

resulting in

Both

be reversed

for

rollstoposition

dual-grooved

reversed,

a.
b.

c.
d.

but

Unlatch
Loosen

knob
Pivot

carrier.
For

and

pressure

free of

pressure

dual-grooved
Choose
Slide

drive
chosen
wire

size

after

installation.

Align

the

Insert

securing

the

groove

objects

path

any

metal

electric

typesof50

reuse

when

unused

drive

roll

pro

onlytofeed a

open

left

case

adjustment

pressure

proper

roll onto

for

the

drive

arm.

arm

away

roll

supplied

groove.

drive

toward

unused

roll

with

screws, and tighten.

GunlFeeder

connector

Securing

Ref.

in this

compartment

between

surfacesorcompo-

shock.

Series

they

the

style

become

groove(s)tofeed

vided

with

this

feedercan

different

inside of machine.

holes.

size

access

to expose

roll

groove

door.

knob,

with

feeder:

mounting hub with

willbevisible

Knob

SB-125

923

may

weld

out

drive

rolls

worn.Re-

wire.

wire.

and

pivot

drive

roll

The

5-21E

-

5.

For50Series

a.

Slide

b.

Align

c.

Insert

6.

For50Series

a.

Align holesonpair of split

b.

Insert

c.

Slide

d.

Align

e.

Insert

IMPORTANT:

the drive
set

becomes

7.

4-3.

A

roll

and

should

necessary,

Close

WELDING

And

WARNING:

•

Do

•

Shut

mounting

and

5-1)

source,
ing

ingonfeeder.

Lockout/tagging
sistofdisconnecting
for

welding

line

disconnect switch

ing

fuses

tagging circuit
device.

(—)

battery

erators.

IMPORTANT:

stallationofa
gas

line.

Remove snap-in

style

one-piece

drive

roll

onto

drive

drive

roll

with

holes.

securing

securing

drive
drive

securing

Horizontal

not

not

down

lockout/tagging

Stop

A

gun

screws, and tighten.

style

screw.

rolls

onto

rolls

with

screws, and tighten.

hub

require

secure

GUN

touch

readjustment.Ifreadjustment

see

Section 10-2.

left

CONNECTIONS

ELECTRIC

live

wire

and

disconnect

procedures

power

from

fuse box,

breakerorother

engine, and

cable

from

hole

ispro

requiring an

split

drive

holes.

alignmentofthe drive

with

case

electrical

feeder

procedures

interconnecting

source consistofpadlocking

videdinthe

blank

drive

rolls:

roll

drive

rolls:

drive

roll

the

wire

access

SHOCK

mounting

rolls.

mounting

guideisfactory

hub.

door.

(Figures

can kill.

parts.

and

welding

input

power

employ

before

for

wire feeder

cord,

in open

batteryonwelding

position,

or shutting

disconnecting

disconnect

remov-

off

and red-

negative

nameplate

opening

before

foranexternal

installation.

hub.

roll

on

4-1

power

work

con

and

gen

form-

B.

Connect

front

into

clockwise.

4-4.

A

A.

-

Chain

-

prevent
the

-

secure gas
B.

1.

-

IMPORTANT:

leaks.Donot

Gun

Trigger (Figure 5-1)

‘9=

TRIGGER

RECEPTACLE

gun

trigger plugtotrigger receptacleonthe

panelasfollows:

trigger

receptacle,

SHIELDING
4-2

And

4-3)

WARNING:

rupture
lossoflife;
serious

•

causing serious

injury

Keep

cylinders

electrical circuits.

•

Never

allow

cylinder.

•

Always fasten

gear

bracket,awall,orother

port.

Gas

Cylinder (Customer

the

cylindertoa

the

cylinder

valve.Ifoptional

cylinder

Regulator/Flowmeter

With

the

cylinder

cylinder
and

inder,
or
valve

open

dirt

cap,

valve

close

that

seat.

A

use

align

and

GAS

PRESSURIZED

FALLING

and

a welding

wall or

from

power

to running

stand

slightly.

valve.

may

have

gasket shouldbeinstalledtoprevent

lubricantsorsealing

keyways,

rotate

threaded

INSTALLATION

CYLINDERS can

personal

CYLINDERS

equipment

away

from
electrodetotouch

cylinder

falling

source

(Customer

securely

to one

This procedure

securelytorunning

Supplied)

other

stationary

over

running

gear

with

installed,

sideofcylinder

When

gas

accumulated

insert

gun

plug

collar

fully

(Figures

injury

and

can

cause

damage.

weldingorother

any

stationary

and

breaking

gear is

supplied

Supplied)

remove

flows

blows

support

used,

chain.

valve,

from

out

around

sup-

to

off

the

cyl

dust

the

agents.

-

A.

1.

2.

3.

4.

5.

S-21E

Gun

ConnectorToDrive

Unlatch and
Loosen

the

wire

Insert

holeinthe

Insert

with

the

as

possible

curing
Close and

open

gun/feeder

drive

housing.

gun/feeder connector

front

panel.

gun/feeder

outlet

wire

without touching,

knob.

secure

Assembly

left

case

access

connector securing

through

connector

guideasclosetothe

left

case

access

into
and

tighten

(Figure 4-1)

door.

drive

door.

knob

the

housing

drive

on

access

rolls

these-

2.

The

regulator/flowmeter

equipped withastem,

ket

for

use

type

cylinders.

3.

Install

gas

regulator/flowmeter onto

valve;
securelytogas

4.

A
the

keep

gaugeinvertical

shielding

wire

feeder.

5/8-18
gas
gas

right- hand

hosetothis

hosetothe

must

nut

connectors,

with

either

CO

2

cylindersorinert

the

faceofthe

position,

cylinder

gas fittingisprovidedonthe

Obtainasuitable

fitting.

fitting.

regulator/flowmeter.

and

valve.

Attach

Attach the

be

gas

regulator/flowmeter

tighten

one end of

other

TM-1571

properly

and

cylinder

stem

rear of

hose

end of

Page

gas

gas

nut

with

the
the

-

5

Flow

Adjustment

CO

2

Washer

CO2

Installation

Figure

CO2

cylinder

4-2. Typical

Argon

RegulatorlFlowmeter

Installation

Installation

Gas

cylinder

Valve

ArgonorArgon

Mix

cylinder

SB-109

492

4-5.

The
ing
wire

provides24voltacpower,
used

14-pin
insert

The
the

source
pins

PinA:Upto10

specttosocket
welding

PinB:24

tactor.
contact closure

PinG:24

welding

IMPORTANT:

not

14-PIN
4-4)

14-pin

cord,

feedertoa

withaconstant

receptacle.Tomake

plug,

pinsonplug

power

are

The

usedbythe

Shielding

valve

PLUG CONNECTION

plug

PLG1

providesajunction

welding

and

rotate

PLG

source

provides

designated as

power

volts ac

volts ac

power

and

six

amperesof24

G (circuit

source.

input

feeder

sends

from pin Atopin

circuit common;

source

The

remaining

feeder.

Gas

Fitting,

00,onthe

power

voltage

threaded

100

wire

functionstothe

follows:

common);

powertoenergize

back24volts ac by

chassis.

(Figures

end of

the

interconnect

point

for

connecting

source.

and

contactor

(CV)

connections,

are

definedinrelationtoboth

feeder.

volts

pinsinthe

This

control when

power

source
align

collar

fully

The

welding

wire

feeder.

ac,60Hz,

protected by

the

B.

also connected

receptacle are

Wire

Feed

connection

clockwise.

weld

meansofa

4-3

And

the

with

a

keyway,

power

The

withre-

fuse

in

con

to

-

Ref.

S-0004

Figure

4-6.

A

-

4-4. Front

WELDING

WARNING: ELECTRIC

•

Do

not

•

Shut
source,

ing

lockout/tagging

ViewOf14-Pin

Locations

WIRE

INSTALLATION

touch

live

down

wire

and

disconnect

electrical

feeder and

procedures

Plug

SHOCK

parts.

input

With

Pin

(Figure

can kill.

welding

4-5)

power

poweremploy

before

work

-

-

ingonfeeder.

A

Lockout/tagging
sistofdisconnecting

for

welding

line

disconnect

ing

fuses

tagging

device.

(—)

erators.

CAUTION: LOOSE
cause

•

Spooled wire
when

circuit

Stop

battery cable

Injury.

Keepafirm

tion,

removal,

loosened

procedures

power

source consistofpadlocking

switch

from

fuse

box,

breakerorother

engine, and

from batteryonwelding

holdonthe

and

hasatendencytounravel

from

forwire

interconnecting

in open

or shutting

disconnect

WELDING

wire

threading

the

spool.

feeder

cord,

position,

during

remov-

off and

disconnecting

negative

WIRE can

installa

operations.

rapidly

con

and

red-

gen

-

-

-

14-Pin

Plug

TM-1571

Page

Figure

6

4-3.

Rear

Weld

Cable

Connection

Opening

Panel

View

SA-125

924

IMPORTANT:

any

part of

If

it should become

the

hub

assembly

stallation instructioninSection

necessarytoreplace

see

hub

assembly

10-3.

rein

5-21E

-

A.

InstallationOfSpool-Type

1.

Remove

2.

Slide
bottomofthe

3.

Rotate
pininhub and

hub.

4.

Insert optional

5.

Reinstall retaining
hub.

B.

InstallationOfOptional

Type

Wire

1.

Remove
assembly

2.

Lay

3.

Remove

4.

Remove wire
reel.Besure

5.

Reinstall
reel.

6.

Slide
sembly

7.

Reinstall retaining

retaining

wire

spoolonhubsothat

spool.

wire

spool

seats

compression springifrequired.

(Figure 4-5)

retaining

from hub.

wire

reel

assembly

spanner

retainer,

that

wire

retainer and

wire

reel

assembly

until

hub

Wire

ring

from

hub.

until

hole

in spool

against back

ringtosecure

Wire

ring

and,ifapplicable,

flat

on a

nut

from

wire

and

install

wire

feeds

spanner

onto

guide

pin is

ring

onto

hub.

•Wlre

Retainer

(Figure 4-1)

wire

feeds

slides

flangeofthe

wire

spool

Reel

And

tableorfloor.

reel

assembly.

wire onto wire

off

bottomofreel.

nut

onto wire

hub,

and

rotateas-

seated in

reel.

off

wire

the

over

on

Reel-

reel

4-7.

A

A

WELDING

WARNING:
MOVING

•

Do

•

Keep

•

Do
feeder

The welding
withitare

WELDING
Wounds;

•

Do
do

•

Do
any

WIRE

ELECTRIC

PARTS

not

touch

clearofpinch

not

energize welding

until

instructedtodo

wire

energized

WIRE can

HOT

not

depress

so.

not

point

gun towardany

conductive

when threading

•

Allow

guntocool before

FLYING
injure personnel

•

Blow
pressed

move
cumulated.

CAUTION:
cause

•

Spooled wire
when

1.Install

DIRT

Point

gun

from

personnel

ing with

compressed

out the

air

when

any

metal

Injury.

Keepafirm
tion,

removal,

loosened

the

wireasinstructedinSection 4-6.

AND

liner onlyina

gun

LOOSE

hasatendencytounravel

THREADING

SHOCK

can

live

electrical

cause

injury.

parts.

points.

power

sourceorwirE

so.

and

all

metal

partsincontaci

while

welding.

cause puncture

SURFACES

gun

can

trigger

burn skin.

untll

part of

surface,orother
welding

wire.

touching.

METAL PARTICLES can

and

damage equipment.

safe direction

and

equipment when

air.

wire

9uide

liner

changing

chips

and

holdonthe wire

and

threading

from

the

wire.

dirt

that

WELDING

during

operations.

spool.

may

can

kill;

instructed

the

body

personne.

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clean~

with

com

This

willre-

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WIRE

can

installa

rapidly

tc

-

-

•

Spanner

Nut

•

OPTIONAL

Figure

S-21E

4-5.

Optional Wire

Reel

Installation

And

Reel-Type

SC-127

306

Wire

2.

Cut

off

any

portionofthe
whichisnot straight.Besure
free

from

rough

surfacestopermit

ing.

3.

Adjust

necessary.

4.

Loosen

drive

5.

Feed

the

mately4inches

6.

Close
sure
wireisin

aligned with
guideispart of

7.

Tighten
the
wire.Donot

hub

tension according to Section

the

pressure

housing,

the

drive

the

adjustment knob

proper

and

wire

through

rolls,

andoninto

(102

pressure

the

drive

the

gun).

the

pressure

clamping

overtighten. Further

free

endofthe

that

the

cut

proper

adjustment knobonthe

pivot

the

pressure

the

inlet

the

gun.

mm)ofwire

lever,

and

secure

making

roll

groove

inlet

and

outlet

adjustment knobtoobtain

pressureonthe

arm open.

wire

guide, past

Feed

into

the

with

sure

the

and

guides

adjustment

TM-1571

wire

end

is

feed

4-8

wire

approxi

gun.

pres

welding

properly

(outlet

welding

can

Page

-

if

-

-

7

be
operation.

4-8.

A

Check
the
sufficient

lash

sary,
support

4-9.

A

4-10.

A

ADJUST

CAUTION: LOOSE
:ause

Spooled

when

the

drive

when

loosen or

shaft

WELDING

WARNING: ELECTRIC

•

•

Lockout/tagging
sistofdisconnecting

for
line

ing
tagging
device.

(—)

erators.

1.

Unlatch and

2.

Route
openingonrearofunit

3.

Connect
drive
and

4.

Close and

FEEDING WELDING

WARNING: ELECTRIC
MOVING

•

•

•

The
withitare

made

Keepafirm
tion,

hub

roll.

tensiontokeep the

Do
Shut

source,
ing
ing

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Keep
Do

feeder

when

THE

Injury.

removal,

wire

loosened from

tensionbyslowly

The

wire

feeding

tighten

accordingly.

not

touch

down

lockout/tagging
weld

welding

disconnect switchinopen

fuses

from

circuit

Stop

battery

weld

end of

assembly.Besure

boltissecure.

secure

PARTS

not

touch

away

not

energize

until

welding

the

wire

HUB

TENSION

WELDING

holdonthe wire

and

threading

hasatendencytounravel

the

wire

should

the

CABLE

live

wire

and

disconnect

cable

power

fuse box,orshutting

breakerorother

engine,

cable

open

cable

cabletoterminalonbottom

live

from
instructedtodo

wire

energized

unwind

wire

stops.Ifadjustmentisneces

hex

nutonthe

CONNECTION

SHOCK

electrical

feeder and

procedures

connections.

procedures

interconnecting

source

and

from

batteryonwelding

left

case

through weld

(see

left

case

WIRE

can

cause

electrical

pinch

welding

and

all

while

feederisput

(Figure 4-1)

WIRE can

during

operations.

spool.

pulling

the

wire

freely,

taut and

consistofpadlocking

that

points.

metal

prevent

end of

can

parts.

welding

input

power

before

forwire

disconnect negative

access
Figures

access

SHOCK

powersourceorwirE

welding.

feedercon

position,

off

disconnecting

door.

cable

connection

4-1

terminalisclean

door.

Injury.

parts.

so.

partsincontaci

into

installa

rapidly

toward

but have

back

the

hub

kill.

power

employ

mak

cord,

and

remov

and

red-

gen

and

4-3).

can kill;

of

WELDING

HOT

•

Do
so.

•

Do
any

-

-

-

-

-

-

-

A

-

when threading

•

Allow

1.

Be

4-7.

2.

Be

of

this

3.

Cut
whichisnot straight.Ifnecessary,
to remove cast.Besure

from

4.

Lay

coilsinthe

5.

Energize the

6.

Place
position.

WARNING: ELECTRIC

GLED
ing Welding power

agetobe

pressed.

•

•Ifwire

•

7.

Press
ginningofthe Section).
pressureisproperly

If

wire

cordingtoSection

required,
correct
when
inch

8.

Shut
source.

WIRE

can

cause

SURFACES

not

depress

not

point

conductive

guntocool

sure

wireisinstalledasinstructedinSection

sure

gunisinstalled

manual

off

any

rough

gun

cable

the

WELDING

Do

not

pressed,

source,

Correctanyhub

liner

damage

tinue

welding.

the

gun

slippageisnoticed,

check

sizeorobstructions.

welding

(25

mm)

down

can

gun

gun

toward

surface,orother personnel

welding

before

and

the

portionofthe

surfacestopermit proper

assembly

cable/conduit).

welding

wire

feeder POWER switchinthe

WIRE can

presentoncaseifgun

touch

wire

and

wire does

stops

feeding,

and

determine

tension,

problems

trigger

adjustedtoprevent

4-8.Ifexcessive

gun

contact

wire extends

outofgun tip.

wire

feeder

puncture

burn skin.

trigger until

according

gun

that

out flat

power

source

feeder

(see

Wire feedsifdrive

instructedtodo

any

part of

wire.

touching.

to Section

Owner’s
free

source.

SHOCK

caseifgun

not

tum

the

jammed

before

WARNING blockatbe

adjust

tube

Release

approximately

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Manual.

end of

straighten

the

cut

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can kill;

touch

open-circuit

feed.

off

welding

cause.

tryingtocon-

hub

and gun

welding

endisfree

feeding.

straight

case

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tensionac­pressure

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the

body

4-3

the

wire
wire

(no

ON

TAN

caus-

volt

trigger

slippage.

the

trigger

power

roll

liner

for

trigger

one

power

is

is

is

-

-

-

TM-1571 Page

8

S-21E

SECTION5-OPERATOR

CONTROLS

Access

Gun/Feeder

Gun

Trigger

Receptacle

6-1.

A

GAS
CORED

WARNING: ELECTRIC
MOVING
EXPOSURETOENVIRONMENT
internal parts.

•

•

Warrantyisvoidifthe
with

removed.

ARC
can

•

FUMES

your

•

•Ifventilationisinadequate,

HOT
cause

•

•

•

MAGNETIC

can

•

5-21

E

Hole

For

Connector

Wire

Figure

Do
Keep

Wear

5-1.

Control

METAL

ARC

not

case

any

portionofthe

RAYS

damage hearing.

correct

AND

health.

ARC

(FCAW)

PARTS

touch

live

closed

can

eye,

GASES can

burn

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gases.

breathing

Watch
Keepafire

howtouse

Allow

device.

METAL,

fire

and

for

fire.

work

SPATrER,

burns.

extinguisher

it.

and

handling.

FIELDS

affect

pacemaker operation.

Wearers

going

welding

should

near

arc

operations.

Speed

Control

Panel

View

SECTION

(GMAW)

WELDING

can

cause

electrical

while operating.

wire

outer

eyes

ear,

and body

from

breathing

equipmenttocool

FROM

consult

welding

AND

SHOCK

serious

can

parts.

feederisoperated

enclosure open

and

skin; NOISE

seriously

use

AND

nearby

HIGH

CURRENTS

their

doctor

gouging,orspot

5-1.

The
the

5-2. WIRE SPEED

The

88-124

467

in

ing
feed

6—

SEQUENCEOFOPERATION

FLUX

can kill;

injury;

damage

POWER

POWER switch

wire

feeder.

WIRE

SPEED

inches per

the WIRE

speed.

minute

The

WELDING
Wounds.

•

Do
any

1.

Install

2.

Wear

dry

3.

Connect

SPEED

not

conductive

and

piece.

or

protection.

harm

4.

A

Rotate
(see

WIRE

Section

WARNING:

•

Do

not

•

Do

not

contact

fumes

and

The

welding

withitcarry

approved

SLAG

and

know

can

source

5.

Energize

6.

Place

the

7.

Turnonshielding

8.

Wear

welding

accordingtoANSI Z49.1.

before

before

9.

Hold
from
flows,

is

Section 4-7.

tip

workpiece,

gas

noticed,

SWITCH

(Figure 5-1)

POWER

functions as

CONTROL

the

ON/OFF switch

(Figure 5-1)

WIRE SPEED

ojo

control

scaleiscalibratedininches per

point

connect

insulating gloves

work

touch

touch welding

withitwhile

weld

contactorisenergized.

the

welding

POWER switchintheONposition

of gun

flows,
adjust drive

adjusts

within

the

control

WIRE can

gun

wire

clockwise

toward

surface,orother

unit

according

clamptoclean,

SPEED

controltodesired

5-2).

ELECTRIC

live

SHOCK

electrical

wireorany

welding.

wire

and all

metal

output when

power

gasatthe

helmet with

approximately

and

depress

and

wire

feeds.Ifwire

roll

pressure

the

wire

feed

speed

range.

increases

minute.

cause

any

part of

puncture

the

personnel.

to Section

and

clothing.

bare metalatwork-

position

can kill.

parts.

metal

partsincontact

the

welding

sourceorgenerator.

source,ifapplicable.

proper filter lens

1/2 in.

gun

(13

trigger.

Current

slippage

according

TM-1571

for

speed
Rotat

wire

body

4.

part

in

power

mm)

to

Page

9

-

WARNING: ELECTRIC

A

7-1.

IMPORTANT:

writteninsteps

grams

A.

TANGLED
causing
voltagetobe

pressed.

•

Do

pressed

•Ifwire
source,

•

Correctanyhub
liner

continue

THEORYOFOPERATION

7-1

and

Wire

Feeder

The

1.

2.

3.

4.

5.

6.

7.

8.

9.

14-pin

connecting cord
from

the

tactor
POWER switch51provides

volts ac
Circuit

for

the

Motor
drive

R32.

PCi

ing

power

CR1.

Gas

valve

weld

cycle.

Integrated
input
CapacitorClprovides

Voltage regulator

put

voltageto24

PCi

and

Trigger receptacle

put signaltothe

WELDING

welding

presentoncaseifgun

not

touch

and

stops

and

damage

welding.

The

following

which

match

7-2.

Without

plug PLG100onthe

welding

controltothe

input

powertothe

breaker

wire

Board

motorMlas

powertoa

CB1

feeder.

PCi

also

controls

source

051

rectifier

trigger

provides

SHOCK

WIRE can

power

wire
wire does

feeding,

determine

tension,jammed

problems

source

feeder

not

turn

the

caseifgun

feed.

off

welding

cause.
before

SECTION7-THEORYOFOPERATION

TheoryOfOperation

the

circled

Options

provides24volts ac

power

source

welding

provides

regulates
setbyWIRE

gas

contactor

shielding

SRi

converts

rectified35volts

filtering

VR1

reduces the35volts dcin-

volts dc

receptacle

RC101provides

motor

stop/start

numbersonDia-

(Diagram 7-1)

end of

and

power

on/oft

wire

feeder.

overload

the speedofwire

SPEED

valve

051

via

gas

the24volts ac

dc.

for

the35volts

for

control

RC1

01.
circuitry.

can kill;

touch

open-circuit

provides

source.

controlof24

control relay

the

case

trigger

wire,orgun

trying

the

input

protection

and

during

circuitry

triggerin-

trigger

power

inter

power

con-

control

weld-

the

dc.

is

is

to

is

on

6-2.

A

-

SHUTTING

1.

Stop

welding.

2.

Place

3.

Shut

down

4.

Turn

off

WARNING: HIGH

SHIELDING

•

Shut

10.

Motor
brake turnonramp,
trol relay circuitries.

11.

Control
welding

plug

PLG100.

12.

Brake

cal

path

13.

Turnonramp
control

14.

WIRE
the

comparator circuitrytocontrol the

15.

Feedback circuitry

with

a feedback

16.

Comparator circuitry compares feedback
to

R32

tion

circuitry

17.

Phase
ingofphase modulation.

18.

Unijuction
lation

19.

Pulse
lated

signaltothe

20.

Drive
phase
wire

drive

21.

Wire

drive

DOWN

POWER switchinthe

welding

shielding

off

gas

stop/start

relay

power

circuitry

for

motor

R32.

SPEED

control signal
reset

transistorsQ5and

transistorQicreates

from

the

transformerTitransfers
SCR’s

modulation

motor

motorMlfeeds

power

gasatsource,ifapplicable.

GAS

can

supply

circuitry

phase modulation,

CR1

controls

source

transistorQ7providesanelectri

current

provides

control

provides

signalofactual

and

accordingly.

charging of

gatesofSCRi

SCRi

and

signal

Mi.

OFF

sourceorgenerator.

CONCENTRATION

harm healthorkill.

when

provides

gas

contactor

during

powertoWIRE

R32

providesasignal
comparator circuitry

adjusts

capacitor ClO.

SCR2

and

the

position.

notinuse.

inputtothe

and

valve

051

through

braking.

wire

motor

voltage.

phase

Q6 reset the

the phase

the phase

and SCR2.

turnonfrom
supply

welding

power

wire.

OF

con-

and

the

14-pin

SPEED

to

speed.

signal

modula

tim

modu
modu

the

to

-

-

-

-

-

TM-1571

Page

10

S-21E

0

4-

0.

0

•1~

0

4-

1~

4)

4)

LI

-

4)

I

-

0

U

-

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I

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(U

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S-21E

-A

c~

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~(i)

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tb~.

~3O

c~o

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ZQ)

TM-1571

Page

11

B.

SpotlBurnback
7-2)

1.

Optional
controlofspot

back

2.

Burnback
of

the

onds.

Time

Spot/Burnback

weld

time.

potentiometer

burnback

time between

Control

time

and

R26 allows

Option (Diagram

Board PC2

provides

adjustmentofburn-

adjustment

0.02

and

0.25

sec-

3.

Spot

time potentiometer R25 allows

of

spot time
seconds
DIP

Switch

4.

Spot/Continuous
mal

untimed

cycle.

5.

Spot

time

short

range

(0.25to5

from

0.12to2.5

dependingonthe

secondsor0.25to5

settingofSpot

Sl.

switch

weld

DIP

switch51provides

S51

allows

cycleora timed

(0.12to2.5 seconds)orlong

seconds)

spot

time.

adjustment

Time

either a

spot

nor

weld

a selection

range

-

of

Diagram 7-2.

Block

Diagram

For

Spot/Burnback

Time

Control

Option

TM-1571

Page

12

S-21E

Notes

S-21E

TM-1571 Page 13

SECTION

8—

TROUBLESHOOTING

8-1.

The
testing
ohmmeter

greater

for

fied,
pedanceorgreater.

TESTING

TION

INSTRUMENTS

service proceduresinthis

instruments.

(DVM)

and

variable

useagood

diode
resistor

Useagood quality

with

one

megohm

check capability

testing). Ifanoscilloscopeisspeci

quality

If a

unit

circuit

with

coating,itwillbenecessary
needle probesinthe

Recoat
Digital

areasifnecessary

volt-ohmmeters
larity attention
meter

may

indicate

procedure specified

rect

polarity

appearsonthe

connectionstotest
8-2.

A

CIRCUIT

WARNING:

•

Do

not

•

Shut
source,

ing
inspecting,

test

areatoobtain

to retain

(DVM’s)donot

when making connections.

a—(negative)

a+(positive) voltage.Ifthe

display, reverse

points.

BOARD

touch live

down

and

HANDLING

ELECTRIC

electrical

wire

feeder

disconnect

lockout/tagging

maintaining,orservicing.

Lockout/tagging procedures
sistofdisconnecting
for

welding

line

disconnect switchinopen

ing

fuses
tagging
device.

(—)

battery

power

source

from

fuse box,orshutting

circuit

Stop

cable

breakerorother

engine,

from

erators.

A

MOVING

•

Keep

HOT

•

Allow

CAUTION:
(ESD)

•

Put
BEFORE

•

Transport

shielding

•

Perform

INCORRECT

plugs

•

Be

PARTS

away

from

SURFACES

cooling

can

on

period

ELECTROSTATIC

damage

properly

handling

circuit

carriersorpackages.

work

onlyata static-safe

INSTALLATIONormisaligned

can

damage

sure

that

plugs

can

moving

can

aligned.

EXCESSIVE
board.

•

Use

ment
board

TM-1571 Page

14

PRESSURE

only

minimal pressure and

when

plugs

disconnectingorconnecting

and

removingorinstalling

AND

INFORMA

manual

require

digital

input

impedance

(useananalog VOM

one

megohm

board

has

a protective

to remove

coatingoruse

proper

corrosion

protection.

require

However,

voltage

when

meter

PRECAUTIONS

SHOCK

can

parts.

and

welding

input

power

procedures

forwirefeedercon

interconnecting

cord,

consistofpadlocking

position,

off

disconnecting

and

disconnect

batteryonwelding

cause serious

parts.

cause

severe burns.

before servicing.

circuit

grounded

circuit

DISCHARGE

boards.

wrist

boards.

boardsinproper

work

circuit board.

are

properly

can

installed

break

gentle

-

proper

volt-

or

-

inputim-

contact.
leadpo-

the

the

test

incor

-

lead

kill.

power

employ

-

before

-

and

remov

and

-

red-

negative

gen

-

injury.

strap

static-

area.

and

circuit

move

-

board.

8-3.

A

TROUBLESHOOTING
gram

8-1)

WARNING:

•

Do

not

touch

•

Shut

down

source,
ing

and

lockout/tagging

inspecting,

Lockout/tagging procedures
sistofdisconnecting
for

welding

line

disconnect

ing

fuses

from
tagging
device.

(—)

circuit

Stop

battery

erators.

MOVING

•

Keep away

HOT

•

Allow

PARTS

SURFACES

cooling

Troubleshootingtobe
qualified

The

troubleshooting

of

the

troubles

circuit

normally

persons.

that

tiedtoground mustbeat

tial.

Use

the tableinconjunction

manual
in

ubleshooting
When replacing

replacement
ranty

Resistance
made

fore

IMPORTANT:

dures,
overheating

winding(s) failure
smoke,

are
ers,
rosion,
saves

IMPORTANT: Be

and
and

with

and

the exploded

the

Service

Parts Manual

procedures.

components,

parts.

repair by

with the

making

authorized

and

continuity

unit

resistance

Before beginning troubleshooting

visually

examine

and

failure.

are

and

smell.

relatively

incorrect

simple:

switch positions, loose

and

the

like.Acomplete,

considerable

secure according
switches

areinproper

troubleshooting.

ELECTRIC

live

electrical

wire

feeder

disconnect

(Table

SHOCK

8-1

And

can

parts.

and

welding

input

power

procedures

Dia

kill.

power

employ

before

maintaining,orservicing.

forwire

interconnecting

feeder

cord,

con-

and

power source consistofpadlocking

switchinopen

fuse box,orshutting

breakerorother

engine,

cable

from

from

can

moving

can

period

and

batteryonwelding

cause

cause

before servicing.

position,

off

remov

and

red-

disconnecting

disconnect negative

gen

serious

injury.

parts.

severe

performed

burns.

only

by

tableisdesignedtodiagnose some

can

developinthis

with the

views

use

MILLER parts

warranty

measurements

shut

down.

Isolate

and

continuity

wire

feeder.

ground

poten

diagramsinthis

and

component

values

while performing

only

genuine

are

required

service

MILLER

for

agency.

must

components

measurements.

Any

tro

war-

be

be-

proce

internalcomponents

Many

major problems,

usually

Fortunately

blown

apparentbydiscoloration,

most

fuses,

tripped

careful

time,

sure

money

that

and

all connections

to Section4and

positions

elect

before

for

signs
such

rical

pro

blems

circuit

break

connections,

inspection

cor

often

frustration.

are

correct

that

all

controls

proceeding

S-21E

of

as

-

-

-

-

-

-

-

-

-

Table 8-1.

Troubleshooting

TROUBLE

Wire

does not feed.

Wire feeds

Wire feeds

erratically. Pressureondrive

but thereisno

flow.

Wire

does not

is

pulled

but

continuestofeed

after

triggerisreleased.

Gun nozzle

The

gas

rattling
ble

erraticorslow

opening

valveinthe

loudly

speed.
Motor

runs

but

gized

with

Spot/Burnback

tion

installed.

feed

until

restricted. Weld

feeder

along

with possi-

wire

wireisnot

gas

trigger

feed

ener-

Op-

CAUSE REMEDY

Circuit

breaker

CB1.

Looseorimproperly

trigger

Welding

connection.

Gun

trigger. See

gun

shorted.

Motor

Ml.

Motor

Control

Board

poor connectionstoPCl.

ficient.
Drive

roll

wrong size

size

used.

Drive rolls
Dirt in
Motor

poor
Gas valve

Motor
poor

Welding
tween
and

worn.

drive

rolls.

Control

Board

connectionstoPCi.

GSl.

Control

Board

connectionstoPCl.

gunisshorted

one of

the

weld

cable.

spatterorforeign

accumulation.

is

Welding
tween

and

gunisshorted

one of

the

weld

cable.

Spot/Burnback

poor connectionstoPC2.

made gun

PCi

or

rollisinsuf-

for wire

PCl

or

PCl

or

be-

trigger leads

matter

be-

trigger leads

Board PC2

Check

pressure

tion
Check

gun

(see

10-5).

gun

4-3).

gun

Owner’s
Repairorreplace
Check

connections

motor brushes
if

necessary.

Check
Check

tion
Rotate

connections
PCi

8-4.

Replace

pressure adjustment
clockwisein1/4
stops

slipping

Changetocorrect
4-2).

Replace

drive rolls
Clean drive rolls
Check

Check
tion

Check
tions
Replace

tion

8-4.

(see

Check
Check

8-4.

connections
PCi

Replace

GS1

GSlifnecessary.

connections

PCl

Replace

Repairorreplace

Carefully

matter
nozzle

metal

remove

which

opening.

tool.

Repairorreplace

or

Check

connections

PC2

according

Replace

PC2ifnecessary.

liner,

hub

Section

trigger

tension,

4).

connection

and

Reset

(see

CBl

Manual.

welding

(see

gun.

for

continuitytoMl.

Section

for

10-4).

continuitytoPCl.

accordingtoDiagram

PClifnecessary.

knob

turn

increments

(see

Section

size drive

(see

(see

for

4-2).

roll

(see

Section

Section

4-2).

l0-lC).

continuitytoPCi.

accordingtoDiagram 8-2

PCiifnecessary.

for

proper

Diagram

coil

voltage

8-1).

Check

continuityofcoil.

for

continuitytoPCl.

accordingtoDiagram

PClifnecessary.
welding

any

may accumulate

Use

welding

to Diagram

gun.

weld spatterorforeign

around the

a hardwood

gun.

for

continuitytoPC2.

8-3

and Section 8-5.

drive

(see

Section

Replace

8-2

and

counter

until

the
Section

and

and

8-2

and

stick,

roll

Sec

Check

Ml

Sec

wire

Sec

connec

Sec

never

a

Check

5-21E

TM-i

571

Page

15

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TM-1571

)

Page 16

> >

CO

S-21E

8-4.

A

MOTOR BOARD
TION

(Figure

W

ARNING:

Do

not

•

Shut

ELECTRIC

touch

down

8-1

wire

sourceorstop
changing

meter

disconnectingorconnecting

A

MOVING

•

Keep

HOT

•

Allow

This
~

ized.

ollowing

form this

CAUTION:
(ESD)

•

Putonproperly

FORE

•
shielding

•

Perform

INCORRECT

plugs

•

Be

PARTS

away

from

SURFACES

cooling

procedure requires the

Only

qualified

standard

testing

ELECTROSTATIC

can

damage

handling

Transport

circuit

carriersorpackages.

work

INSTALLATIONormisaligned

can

damage

sure

that

aligned.

EXCESSIVE
board.

•

Use
ment

board

IMPORTANT:

the

continuityofleads between

where

checkisperformed.

the

connections

so

that

bad

connectionsorleads

the

problem.

PRESSURE

only

minimal pressure and

when

plugs

and

For all checks,besuretotest

and be

PCi

TESTING

And

Diagram 8-2)

SHOCK

live

electrical

feeder and

engine

before

leadconnections

can

cause

moving

can

period

parts.

cause

before servicing.

persons

safety practices

INFORMA

can

kill.

parts.

welding

power

making
and

before

any

leads.

serious

severe burns.

unittobe
familiar

injury.

ener

with

aretoper-

or

and

procedure.

DISCHARGE

circuit

grounded

circuit

boardsinproper

onlyata static-safe

circuit board.

plugs

boards.

are

properly

boards.

wrist

installed

can

break

gentle

strap

static-

work

area.

circuit

move

BE-

and

disconnectingorconnecting

removing

All

actual

checks

orin

the

stalling

board

and

and

the

board.

verify

area

shouldgothrough

terminal-to-terminal

and

corrosion

are

tests

not

-

A.

Preliminary

1.

Check
tacle

2.

Check

Checks

that

RC1onMotor

that

RC2onMotor

3.

Check

that

RC3onMotor

4.

Check

that

RC3onMotor

B.

Power

Supply

Input powerof24
pinsAandBof
present,

-

CBl
An

output

pin A
If

+24

Control
An

output voltageof+6.5 volts dc

check

for

proper operation

of receptacle

volts dc

Board

receptacle

POWER

voltage

are

PCl.

pin Cofreceptacle
with

gun

trigger

pressed.

at

pin C,

C.

Trigger

When

replace

the

gun

Motor

Circuit

triggerispressed, +19

presentatpin Bofreceptacle
common
dc

is
start/stop

ceptacle
control relay

-

D.

The0to

signal

wire
current

providing the

to

otherwise

when

the

gun

triggerisnot

then

suppliedtopin Aofreceptacle

control signal

RCltocontrol

CR1onPCi.

Wire

Feed Speed

+6.5 volts dc

shouldbepresentatpin Dofreceptacle

feed

speed

and

voltage

proper

wire

drive

motorMlthrough

(negative)ofreceptacle
present

Control

between pinsCandDof

Board

PCi.

jumper

volts ac

plug

PLGlissecureinrecep

Control

plug

PLG2issecureinreceptacle

Control

plug

PLG3issecureinreceptacle

Control

plug

PLG4issecureinreceptacle

Control

Circuit

Board

Board

Board

Board

PCl.

PCl.
PCl.

PCi.

shouldbepresent

RC4.If24

switch51and

volts ac

circuit

withanohmmeter.

of +24

volts dc

RC2

with

not

presentatpinA,replace

shouldbepresent at

respecttocircuit

shouldbepresent

RC2

with

respecttocircuit

If +6.5 volts dc

Control

Board

are

PCi.

volts dc

RC2

with

respecttocircuit

the

voltageatpinBshouldbe0 volts

pressed.

The

trigger

RCl

and

also suppliedtopinBofre-

gas

valve

GS1

and

Circuit

wire

feed

speed

command

command

feedback
voltage

signaliscomparedtothe

from

MotorMlthereby

outputof0

to +24

pinsD(positive)

RC4.If0

to +24

RC4,

volts dcisnot
replace

between

are

not

breaker

common.

Motor

at

common

not

present

should

be

signal

as a motor

contactor

input

RC2.

The

volts dc

and C

Motor

-

5-2iE TM-i57i

Page

17

A

WARNING:

can

•Donot

•

Shut
engine

tions

•

Have
standardsafetypractices

dures.

•

Follow
static-sensitive

ELECTRIC

cause serious

touch

down

before

and

only

standard ESD precautionstoprevent damaging

injury.

live

electrical

wire

feeder

makingorchanging

before

disconnectingorconnecting

qualified

parts

SHOCK

parts.

and

welding

persons

perform

during

can

kill;

power

meter

familiar

with

troubleshooting

testing.

MOVING

sourceorstop

lead

any

and

following

PARTS

connec

leads.

proce-

-

o

to

6.5

mm.tomax.ofWIRE

control

voltsdcinput

with

6.5

voltsdcoutput

~un

from
SPEED
trigger

Not used

+24

volts

dc

output

/

+19

volts

gun

option,

with

with

after spot timeortrigger

dc Input

triggerpreseed

+24

gun

trigger

option,0voltsdcinput

released

volts

with

without

dc input

pressed

.29.1

RI&M

mwus

~e~n

+24

voltsdcinput

with

gun

pressed

trigger

TM-i

571

Page

18

Diagram 8-2.

Troubleshooting Circuit

Diagram

For

Motor

Control

Board

PCi

S-2iE

IMPORTANT:

volt-ohmmeter
values.

For

are

AC,

with

shown
PLO4) unless

otherwise

specified.

For

DC,

the

(DVM)orequivalent

the

respecttocircuit

values are

values are

reading

RMS

readings.

common lead24(pinCof

otherwise indicated. The

based

on a

average

tolerances

.241.1

good

quality

(not

TheDCvoltages

RMS)

plug

are

±10%

unless

digital

24

voltsacinput

with

POWER

51

ON

24

switch

voltsacoutput

contactor

with

g

control

24

voltsacoutput

toasvalve

wit

gun

tr~ger

GSi

AC

circuit

common

S-2iE

+2W

DC

cirucit

common

TM-i57i

5D-124

Page

896

i9

Figure

8-1.

Motor Control Board

PCi

Component Locations

And

Information

Receptacle

RC3

Receptacle

RC4

SA-123

147-E

8-5.

A

A

TM-i57i

OPTIONAL SPOTIBURNBACK
TESTING
Figure

WARNING: ELECTRIC

•

Do

•

Shut
sourceorstop
changing
disconnectingorconnecting

MOVING

•

Keep

HOT

•

Allow

This

ized.

p

ollowing

form

CAUTION:
(ESD)

•

Putonproperly
FORE

•

Transport

shielding

•

Perform

INCORRECT

plugs

•

Be

INFORMATION

8-2)

not

touch

live

down wire

electrical

feeder

(Diagram

SHOCK

and

engine

meter

lead

connections

PARTS

away

SURFACES

cooling

can

from

period

cause

moving

can

parts.

cause

before servicing.

procedure requires the

Only

qualified

standard

this testing

ELECTROSTATIC DISCHARGE

can

damage

persons

safety practices

procedure.

circuit

grounded

handling circuit

circuit

boards.

boardsinproper

carriersorpackages.

work

onlyata static-safe

can

sure

INSTALLATION

damage

that

circuit board.

plugs

are

properly

parts.

welding

before

any

serious

severe

unittobe
familiar

boards.

wrist

or misaligned

aligned.

Page

20

BOARD

8-3

can

kill.

making
and

before

leads.

Injury.

burns.

with

aretoper-

strap

work

installed

PC2

And

power

or

ener

and

BE-

static-

area.

and

EXCESSIVE

board.

•

IMPORTANT:

the

continuityofleads between

where

checkisperformed.

the

connections

so

that

bad

the

problem.

A.

Power

Input

power
pinsAandB(DC
+35

-

volts dc

secureinreceptacle

plug

PLG1is

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A

trigger

at
mon

input

pin Dofreceptacle

when
shouldbepresent
+19

volts dc

pressed,

check

8-4.

C.

Motor

When

the

voltage

of +24

PRESSURE

Use

only
ment
board

minimal

when disconnectingorconnecting

plugs

pressure and

and

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the

All

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connectionsorleads

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of +35

Circuit

volts dc shouldbepresent between

circuit

are

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check

RClonBurnback

secureinreceptacle

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RCl

the

gun

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when

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are

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are still

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volts dc shouldbepresent

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gun

when

PCi

a motor

can

break

gentle

circuit

move

board.

and

verify

board

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the

area

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tests

corrosion

are

not

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plug

PLG51

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and

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not present,

check

to Section 8-4.

com

0 volts dc

triggerisreleased.

the

gun

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to Section

control

output

S-2iE

-

If

is

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ceptacle

motor

RC2

with

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and

0 volts dc shouldbepresent

triggerisreleased to

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place

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When the

present at

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gun

triggerispressed

pin Dofreceptacle

stop

when

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the

motor.If+24

the

gun

PC2.

RCl

common to

when

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start

the

the

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DIP

volts dc

with

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Si

are

circuit

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volts dc

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gerisreleased,

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teradelayof0to0.25
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gun

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of

-

-

Figure

8-2.

Optional SpotlBurnback

Board

PC2

Component Locations

And

Information

SA-125

969-C

S-2iE

TM-1571

Page

21

A

WARNING:

can

•Donot

•

Shutdown
engine

tions

•

Have

standardsafetypractices

dures.

•

Follow

static-sensitive

ELECTRIC

cause serious

touch

live

wire

before

and

only

makingorchanging

before

qualified

standard

Inlury.

electrical

feeder

disconnectingorconnecting

ESD

parts

SHOCK

persons

during

can kill;

MOVING

parts.

and

welding

power

meter

familiar

perform

precautionstoprevent damaging

testing.

with

troubleshooting

source

lead

any

and

following

PARTS

or stop

connec

leads.

proce

-

-

Spot time

potentiometer

R25

+35

TM-1571

volts

input

Page

UIN GND

dc

Circuit

common

Diagram 8-3.

22

TRIGGER

+19

voltsdcInput

gun

trIgger

with

pressed

Troubleshooting Circuit

Diagram

For

Optional

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Board

PC2

Not

used

S-21

/

E

IMPORTANT:

volt-ohmmeter
values.
shown are

PLG5I)unless
otherwise specified.

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(DVM) or equivalent

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AC,

the

with

respecttoDC

otherwise

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potentiometer

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values

R26

the

values

are

based

are

indicated. The

reading

RMS

readings.

circuit

common lead71(pinBof

on a

good

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with

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burnback

TM-1571

contactor

voltsdcoutput

voltsdoafter

trigger

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output

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time

80-125

23

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S-21E

SECTION

10—

MAINTENANCE

10-1.
IMPORTANT:

this
maintainedina

when
numberofprecautionary

A

*Frequencyofserviceisbasedonunits
hours
usage

A.

A

Every
insideofthe

and
cleaning

sent,

A

S-21E

ROUTINE MAINTENANCE

unit

for

legibility

necessary.

WARNING:

•

Do

not

•

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source,

ing
spectIng,

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consistofdisconnecting

and

for

locking
removing fuses
and

red-tagging

necting device.
negative

ing

generators.

•

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•

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not

maintenanceongun.

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fied

persons.

Table

Frequency*

Every

Month

Every6Months

per

week.

exceeds40hours

Internal

useaclean, dry

clean

B.

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Cleaning

ARNING:

tionatbeginning of

fore

proceeding.

month,

blow

wire

operation.Ifdustyordirty

the

ARNING:

tionatbeginning

fore

proceeding.

Every

six

months inspect

All

precautionary

clearly

touch

down

and

lockout/ta

welding

line

(—)

gun

depress

10-1.

Increase

feeder.

unit

and

readable

See

Service

labels.

ELECTRIC

live

electrical

wire

feeder and

disconnect

ggin9 procedures

maintaining,orservicing.

power

disconnect switchinopen

from

circuit

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battery

and

Units in

ments:
clean internal

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block,

and
drive rolls

Read

ourorvacuum

airstreamorvacuum

monthly.

cable

unittocool before

gun

Maintenance

heavy

Check labels,

all

Section

cables

frequencyofmaintenance

per

and

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Upkeep

Read

and

of entire

state

Parts

SHOCK

input

interconnecting

source

fuse box,orshutting

breakerorother

engine,

from batteryonweld-

trigger

performed

Maintenance

service

parts

labels

10-1).

(Section

(Section

week.

follow

entire

dust

the

follow

(Table

labels

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parts.

power

for wire

consistofpad

and

while

Schedule

and

(see

10-1

l0-lC).

safety

Section

and
outer

conditions

safety

Section

10-1)

the labels

and replaced

can

welding

beforein-

disconnect

touching.

performing

onlybyquali

environ

weld

drive

IMPORTANT

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B).

operated

dirt

enclosure,

suction

on

must

be

for

part

kill.

power

employ

feeder

cord,

position,

off

discon

cables,

rolls.

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40

if

informa

10-1be-

from

the

for

the

are

pre-

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10-1be-

Every

dustyordirty

monthly.

1.

2.

3.

-

4.

-

A

-

5.

-

6.

C.

A

Itisnecessary
ingofthe
installation

-

IMPORTANT:

can
the

1.

2.

-

3.

4.

six

months,

Inspection

Unlatch and
Inspect

parts;

Repairorreplace,asrequired,

ble;
cracked
bles

Remove
moisture

CAUTION:
CLES
equipment.

•

Point
from

ing

Blow out the
pressed

any metal
lated.

Close

CleaningOfDrive

WARNING:

tionatbeginning of
fore

MOVING

•

Keep

HIGH
damage to

•

Do
if
drive

wire

resultina

efficiencyofthe wire

Remove
each

Using
particlesinthe

Reinstall
Resume

inspect

conditions

gun

tighten,

give

particular

insulation

enter equipment.

grease

from

can

gun

personnel and

with

air

when

chips

and

secure

proceeding.

PARTS

away

ROTATIONAL

not

allow

compressed

roll

to remove

grooves

instructions).

Failuretoproperly

buildupofwire

the

drive

roll,

wire

drive rolls according

operation.

the

are

should

open

for

FLYING

compressed

Read

drive

assembly

three drive

brush,

consistofthe

left

case

broken

repair,

and

attentiontofrayed

and areas

and grime

electrical

DIRT

injure personnel

liner

onlyina

gun

wire

changing

and

dirt

left

case

Rolls

and

can

from

moving

rolls

drive

rollstorotateathigh

airisused

the

drive rolls

(see

Section

Useawire

feeding

and remove

remove

wire

grooves.

gun,

present,

areas,

parts

equipment

air.

guide

that

follow safety

entire

cause

SPEED

and

particles

roll

hoses, and

access

cracks,

replaceasrequired.

all

where

from

and

AND

safe direction away

wire.

may

access

Section

serious

parts.

injure

4-2
brush to

maintain

which

operation.

securing

drive

the

to Section 4-2.

cables.

inspect

METAL

liner

This

for

for

for

buildupofwire

the

unit

following:

door.

and

loose

hose

andca-

and

hose

andca-

components,

cable.

PARTI

and

damage

when

clean

with

com

will

remove

have

accumu

door.

informa

10-1be-

injury.

may

cause

personnel.

speed

cleaning

properclean

removal

clean

the drive

decreases

screws

rolls.

TM-1571

the

and

rolls.

rolls

from

Page

If

-

-

-

-

-

-

25

10-2.

A

The
feed

quire

roll and
mentisnecessary,

Behind

obtain

guide,
move

with

ALIGNING

(Figure

W

•

Lockout/tag
consistofdisconnecting

and

lockin9
removing

and

necting device.
negative
ing

MOVING

•

HOT

•

Maintenancetobe
persons.

drive

properly.

readjustment.Tocheck

wire

the drive

proper
rotate

drive

wire

Wire

10-1)

ARNING:

Do

not

touch

Shut

down wire

source,

employing

be

ore

workingonfeeder.

for

welding

line

fuses

red-tag9ing

(—)

generators.

PARTS

Keep

away

SURFACES

Allow

cooling

roll and

guide

Guide_-

wire

Alignmentisfactory set

guide positions

roll

alignmentofthe drive

drive

rollinor

(see

DRIVE

and

9ing procedures

disconnect switchinopen

battery

proceed

mounting

roll

out

ROLL

ELECTRIC

live

lockout/tagging

power

from

circuit

Stop

from

period

guide

mounting

until

Figure

SHOCK

electrical

feeder and

disconnect

interconnecting

source consistofpad

fuse

breakerorother

engine,

cable

from batteryonweld-

can

cause

moving

can

cause

before servicing.

performed

mustbealigned

alignment,
with

as follows:

hubisa

hub

grooveindrive

10-1).

AND

WIRE

can

parts.

welding

input

procedures

for wire

box,orshutting

and

serious

parts.

severe

onlybyqualified

and

should

compare

Figure

10-1.Ifalign

spring washer.

roll

with

securing bolt,

Welding Wire

GUIDE

kill.

power
power

feeder

cord,

-

position,

off

discon

disconnect

injury.

burns.

for wire

the

roll

lines

-

to

notre-

drive

-

To

wire

and

up

10-3.

A

Ifitshould

assembly,
the

REINSTALLATION

ure
WARNING: ELECTRIC

•

Do

•

Shut
source,

ing
ingonfeeder.

Lockout/tagging procedures
sistofdisconnecting

for

line
ing

tagging
device.

(—)

erators.

obtain

assembly.

1.

Slide the
shaftinorder

a.

Fiber

b.

Brake

c.

Hub

d.

Brake

e.

Fiber

f.

Keyed

g.

Spring

h.

Wire

i.

Wire

j.

Spanner

k.

Retaining

2.

Rotate

tated

hub.

3.

Install

OF HUB

10-2)

not

touch

live

electrical

down

wire

feeder and

and

disconnect

lockout/tagging

welding

disconnect

fuses

battery

become necessarytoreplace

power

from

circuit

Stop

cable

part and

following

Washer

Washer

Washer

Washer

Washer

Reel
Retainer

Nut

Ring

bolt into

only

untilaslight

retaining

engine,

given:

interconnecting

source consistofpadlocking

switchinopen

fuse box,orshutting

breakerorother

from

proceed

items

support

ringonhub.

ASSEMBLY

SHOCK

parts.

input

power

procedures

for wire

position,

and

disconnect negative

batteryonwelding

as follows

onto

the

shaft.

Bolt shouldbero

dragisfelt while

(Fig

can

kill.

welding

disconnecting

any

spool

power

employ

before

work

feeder

cord,

remov

off

and

partofthe

to reinstall

support

turning

con-

and
red

gen

-

-

-

-

-

-

-

CORRECT

ALIGNMENT

Drive

Roll

Washer

INCORRECT
ALIGNMENT

Secrurlng

Bolt

Figure

TM-1571 Page

A

10-1.

ReinstallationOfHub

26

Drive

Mounting

V

ViewIsfrom

of

feeder

down

with

roll

assembly

I

Assembly

Roll

Hub

top

looking
pressure

open

SA

145763

10-4.

A

1.

BRUSH

WARNING: ELECTRIC

•

•

Lockout/tagging procedures
sistofdisconnecting

for

line
ing

tagging

device.

(—)

erators.

Remove
drive

INSPECTION

Do

not

touch

live

Shut

down wire

source,
ing
ingonfeeder.

welding

fuses
battery

and

power

from

circuit

Stop

engine,

cable

two

brush caps

disconnect

switchinopen

fuse

breakerorother

lockout/tagging

disconnect

motor.

AND

SHOCK

electrical
feeder

procedures

interconnecting

source

from

consistofpadlocking

box,orshutting

and

batteryonwelding

locatedonend of

REPLACEMENT

can

kill.

parts.

and

welding

input

power

forwire

position,

disconnecting

disconnect negative

power

employ

before

work

feedercon

cord,

and

remov

off

and

red-

gen

S-21E

the

-

-

-

-

-

2.

Remove

3.

Examine
chippedorbrokenorif
of brush

4.

Install

brushes, and

10-5.

Circuit
circuits.

OVERLOAD PROTECTION

breaker

CBlislocated

brushes.

brushes. Replace

less

material

remains.

secure with

CBl

provides

towards

protectiontothe

the

brushesifthey

than

1/4

in.

(6.4

caps.

frontofthe

unit,

are

mm)

feeder

be-

hind

the

left

case access

loadorthe circuit

down

the

wire

feeder.IfCB1

and

manually

To

reset

1.

2.

3.

Unlatch and
Locate

Close

CBl,

reset the

proceed

CBl,

and

fail,

the

breaker.

as follows:

open

and

secure

door.Ifthe

breaker

opens,

left

case

reset

(see

left

case

motor

would

correct

access

Figure

access

should

trip

and

over

shut

the problem

door.

4-1).

door.

-

S-21E

TM-1571

Page

27

The

followingisa

1.

Know

2.

Use

3.

Call

listofall

unit

Model

Listtofind

the

Technical

Table

diagrams

and Serial or

diagram

number.

Publications

SECTION

11-1.

for

Style

11-ELECTRICAL DIAGRAMS

ListOfCircuit

models

covered by this

Diagrams

Number.

Departmentat414-735-4356.

And

Wiring Diagrams

manual.Toorder diagrams

needed, proceedasfollows:

Model

S-21E

Circuit

Circuit

Board

Board

•

Optional

PCl

PC2.

SerialOrStyle

JJ507797
JJ507797
JJ507797

JK742029

and
and
thru

and

Number

following
following
JK742028

following

Circuit

SB-124
SD-124

SC-122
SC-125

Diagram

895-B

896-A
194

971

Wiring

SB-l

24816-B

Diagram

SM-1571

Page

28

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SM-1571 Page

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I-

0)

C

0

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0’
N

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N

I’

6

z

I-

4)

U)

4-

4)
0

4)

w

N

C.)

a.

0

I-

(U
0

-

0
(U

.0

C

I

0

a.

U)

C
0

4-

0.

0

I..

0

IL

E

(U

L.

0)
(U

0

4-

I

(3

I..

0

C.)

E

(U

0)

(U

-

-

SM-1571

Page 32

MiIIeE

November1996
Effective With

Form: TM-1571

Serial

No.

JJ507797

SECTION

12-

PARTS

LIST

S-21E

S-21E

Wire

Feed Equipment

TM-1571

Page

33

CO

0

N

C—

Ci)

.0

E

4)

U’
U,

N

in

C%J

1~

4)

I

-

0)

IL

N
C,J

Ci)

E

a)

Ci)

a)

V

=

TM-i

571

Page34 S-21E

Item

No.

Dia.

Mkgs.

Part
No.

Description

Quantity

...

1
2

...

3

...

4

...

5

...

6
7

...

8

...

9

..10

11
12 124
13

..14

15
16

..17

127 232
151

828

112 031

111

523

114

415
092 237
089 477 SPRING,

085 244

089

562
010224 PIN,springcs.187x1.000
090416

817 HOUSING,

602 243

602213

601

966
604

538
124778

..18 124819...

18 130 365

..19

20
20

21
22 107
23

.24

25

..25

090440...
604

668

601

880

010

291
983

071

602

010494...
092

200

131

181

26
..27 134834...

..28....

GS1

109930...

010296...

010 869

112090...

..28....

29

- .

29 137

-

29

.30

-

.

30 152

31

-

32

33

34

35

36

-

.

37

37

38

.39

..40

41
..42

43

44 122
44 137

..45 122339...

S-21E

GS1

125785...

089

572

089 573

304

089 572

089573...

+122313...

725

134

464
090 439
126

873...

072 094
058 427

141

700

605

941
072 292
154 098

010 233 SPRING,
057

971
010191

058 628
058428

135

205

430...

461

Figure

...

12-1.

DRIVE

ASSEMBLY,

PIN,

cotter-hair

LEVER,

BEARING,
SCREW,
KNOB,

adjustment-tension

WASHER,

FASTENER,

PIN,

hinge

WASHER,
WASHER,

SCREW,

WASHER,

Main

Assembly

wire

(consisting

.042x.750

pressure-roll

ball

.315x.866

x

.275

phillips-flathd10-24x.625

cprsn

.770ODx

cupped

stl

1.000

.328IDx

wire

.812ODx

pinned

wire

drive

flat

stl std

.378

lockstlsplit.375

cap

stl

hexhd.375-16x1.250

flat

stl SAE

.312

of)

x

.715p1d

.125

KNOB

INSULATOR,

...

INSULATOR,

housing

housing-drive

drive

(PriortoKA759476)

(Eff

w/KA759476)

INSULATOR,coverhousing

...

NUT,

stl

slflkg

hex

med

fnsh

.500-20 (Prior

...

NUT,

stl

hex

jam

.500-13

...

WASHER,

...

BLANK,

...

LABEL,
BUSHING, snap-in

...

WIRE

...

WIREGUIDE&NUT,(Effw/JK702158)

PLATE,

flat-nylafil

snap-in

caution

GUIDE

identification

nyl

high frequency

&

NUT,

(Eff

w/JK7021

.625IDx

.SOOmtg

nyl

inlet

control panel

hole

1.375

IDx

(PriortoJK7021

1.250ODx
will

damage

l.7SOmtg

(orderbymodel

to JK7021

58)
.l2Sthk

etc

hole

58)

HOSE,SAE.l87lDx.4100D(orderbyft)

VALVE,24VAC2wayl/4lPSxl/8orf(PriortoJK6l7847)

FITTING,

...

FITTING,

FITTING,

hose

brselbml/4NPTx

pipe

brs bushing

pipe

brs

elb

1/8NPTx3/16

1/4

.625-l8RH

x

l/8NPT

(Prior

hose

(PriortoJK61

VALVE,24VAC2wayl/8orf(EffwIJK617847)

...

CATCH,

...

PLATE,

...

LATCH,

...

CATCH,
PLATE,

WRAPPER

...

WRAPPER

...

LABEL,

...

LABEL,

BUMPER,

...

HUB

link-lock

keeper

door

link-lock

keeper

(PriortoKA848999)

link-lock

(Eff

w/KA848999

(Eff

link-lock
(Priorto
(Eff

w/KC261

warning

warning

general

electric

polyurethane polymer

&

SPINDLE ASSEMBLY,
RING,
RING,
WASHER,
SHAFT,
SHAFT,

retaining-spool
retaining

spool
spool

flat

ext

stl
support
support

compression

WASHER,

flat

stl

(PriortoKA848999)

thru

w/KC261

810

(Effw/KC261810)

KC261810)

810)

precautionary

shock

can

.500

(consisting

.625

shaftx.OSOthk

.640IDx

1.000OD(Eff

(Prior

to KC237900)

(Eff

w/KC237900)

.970ODx

keyed

l.SOOdiax.l2Sthk

KC261

and

on)

kill

.120

809)

of)

(Eff

w/KC237900)

wire

WASHER,fbr.656lDx1.5000Dx.l2Sthk
WASHER,

brake
HUB,spool
NUT,

stl

...

BASE,

BASE,

FOOT,

slflkg hex

(Prior

to KA848999)

(Eff

w/KA848999)

rubber

reg

.625-11

1.2SOdiax1.125

high

(PriortoKA848999)

lip

58)

and

serial

number)

(PriortoJK617847)

to JK617847)

7847)

w/KC237900)

x 1.250

pld

TM-i

571

1

1

1

1
1

1

1
1

1

1

1

1
1
1

1
1
1
1

1

1
1

1
1

2

1
1
1
1

.

1

2ft

1

1

1
1

1

1

1
1
1
1
1
1
1

1

1
1

1
1
1
1
1

1

1

2
2

1
1
1
1

4

Page

35

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

..45
..46..

PLG100....

134306.

144310.

134732.
..47
..46..

PLG100....141

079739.

134731.
..47

..48
..49

143922.

007826.

605227.

120304.
..50

..51....

..52....

CBl
PCl

PLG1

115104.

123745.

123148.

115093.

113746.

PLG2
PLG3

115092
113

131

113

PLG4

115
113

..53
..54

..55

..56
..57

Ml

110375...

123810...

092865...

605308...

122741...

~136745
..58

..59....

..60
..60
..60

R32

079625...

073562...

124720...

137814...

153612...

.61
..62
..63
..64...

51

RC1Ol

....

097922...

111997...

048282...

079534...
..65
..66

..67
..68
..69
..70
..71
..71
..71
..71

..71
..72

057084...

058549...

605758...

079626...

000418...

602241...

124818...

•087130...

•053695...

•079726...

•079728...

124820...

•108008...

+When

*Recommended

•

BE

orderingacomponent originally

Spare

Parts.

OPTIONAL

SURETOPROVIDE MODEL

162.

746
054
746
094

746

Figure

FOOT,

12-1.

Main

Assembly

rubber1.2SOdiax1.375

CONNECTOR&PINS,

....

CONNECTOR,

....

CONNECTOR,

circ
circ

CONNECTOR&PINS,

CONNECTOR,

....

CONNECTOR,
CABLE,
NUT,
BLANK,

No.

nyl

snap-in

hex jam

CONNECTOR,
CIRCUIT
CIRCUIT

BREAKER,
CARD,

circ
circ

18/3c

(orderbyft)

.750,

nyl

.2SOmtg

clamp-cable

motor

CONNECTOR&SOCKETS,

....

CONNECTOR,

rect

CONNECTOR&SOCKETS,

CONNECTOR,

...

CONNECTOR&SOCKETS,

CONNECTOR,

...

CONNECTOR&SOCKETS,

CONNECTOR,

STAND-OFF,
STAND-OFF,

KEY,

.122x.123x.750
RING,
MOTOR,

retaining

gear 24VDC

rect
rect

rect

support
support

BRUSH&SPRING

WASHER, spring

stl

POTENTIOMETER,Cl/T

CASE

ASSEMBLY,

CASE

ASSEMBLY,

CASE

ASSEMBLY,

NAMEPLATE,
KNOB,

SWITCH,

pointer

rocker

(Prior
(Eff
(Eff

(orderbymodel

SPST

CONNECTOR&SOCKETS,

CONNECTOR,
BUSHING,
GUIDE,

wire-Inlet
SCREW,
SCREW,
SCREW,

WASHER,

ROLL,
ROLL,
ROLL,

ROLL,
ROLL,
HUB,

REEL, wire

drive-combination

drive-V-grooved .023 wire
drive-V-grooved .030 wire

drive-V-knurled
drive-V-knurled

mtg-roll

displaying a

AND

SERIAL

mach
mach
cap

circ

snap-in

1/16

stI

rdh

stl

filh

stl

hexhdslf

flat

stl

SAE

drive

(Fig

12-2)

precautionary

NUMBER

nyl

(Continued)

high

(Prior

to KB041147)

pin

push-in

clamp

(Eff

pin

push-in

clamp

(Eff

20-24ga

str

rlf

17-20

w/KB041147)

14-l8ga

str

rlf size 17-20

w/JK617847)

.500

manual

reset1P4A25OVAC

control

(Fig

12-3)

(consisting

skt

24-lBga

Molex

(consisting

skt

24-l8ga

Molex

(consisting

skt

24-l8ga

Molex

(consisting

skt

24-lega

Molex

122RPM (consisting

ASSEMBLY

.500

2W

10K

ohm

to KA848999)
w/KA848999
w/KC261810

1OA

25OVAC

and

thru
and

serial

(consisting

skt

push-in

.250ODx

14-lBga

.375mtg hole

10-32x1.000

10-32x.875

1kg

.250-20x.500

.250

large

.035

wire

.045

wire

label,

the

WHEN

ORDERING

(consisting

Amp213605-1

Amp 206322-2

(consisting

Amp

of)

213603-1

Amp 206070-3

of)

39-00-0038

of)

39-00-0038

of)

39-00-0038

of)

39-00-0038

of)

KC261

809)
on)
number)

of)

Amp

66358-6

label

should

alsobeordered.

REPLACEMENT

of)

4
1

14

1
1

14

1

llft

1

3

1
1
1

1

6

1

8

1
2
1

4
2
2

1
1

1

2
2

1
1
1
1
1
1

1
1

4

1
1

3
3
1
1
1
1
1
2
2
1
1

PARTS.

TM-1571 Page

36

S-21E

Item

No.

Part

No.

Description

Quantity

108 008

1

124904...NUT,spanner-spoolsupport

2 124

3

124 900..SUPPORT,

905..

1

Figure

RETAINER,

12-2.

spool

reel-spool

Reel,

-

Wire

(Optional)

support

1

1
1

2

3

BE

SURETOPROVIDE MODEL

AND

Figure

SERIAL

12-2.

NUMBER

Reel,

WHEN

Wire

ORDERING REPLACEMENT

Ref.

PARTS.

5C-127

305

S-21E

TM-1571

Page

37

SA-123 147-F

TM-1571

Page

38

Figure

12-3.

Motor

Control

Circuit

Card

PCi

S-21E

Dia.

Mkgs.

Part

No.

Description

Quantity

PCi

A1,2

Cl
C2

123

148

009159
039482
039481

C3,6,37,38,50

51,53-56,59

C4,5,8

C7,12

C9

....

ClO

Cli

C52

...

C60-62

CR1

D1,2,8,12

D3
D5

D6,7,9,10

Dli

....

122723

119198

000340

077206
031

693

035522

119197

053

991

099018
026202
087294
037250
028351
032210
092 648

Ji-lO

...

Q4,5,6

R3,5,7,8

...

R4,31

...

R6,22

R9,17,33

RiO
Ru

01
07

R2

092648
039355
037 200

121129
028284
093 037
044 789
072

559
000885
035829
035888

R12,14,24,26,40.072560

R13

Ri

5,35

....

R16

...

RiB

....

R19
R20

-

...

R21 039

-

...

R23

....

R25

....

R29

....

R30

-

...

R32

....

R34

R50,53,56

R51

,52,54,55

...

RC1

....

RC2

....

RC3

....

RC4

SCRi

,2

....

SRi

Ti

VR1

...

006424
035 828

052 143
093

041
093 030
052

139

106

108

437
030

105

084 205
030 098

072 677

108

436
605 919
605 918

114

654

113

749

117

038

113

748

080 508

121 131

111

910

091

256

Figure

...

IC,

...

CAPACITOR,

...

CAPACITOR,

...

CAPACITOR,
CAPACITOR, polye

...

CAPACITOR,

...

CAPACITOR, polye

...

CAPACITOR,

...

CAPACITOR,

CAPACITOR,

...

CAPACITOR,

...

RELAY,

DIODE,
DIODE,

DIODE,

...

DIODE, signal .020A 75V

12-3.

linear

358

end 24VDC

rect
fast

zener24V

Circuit

Card,

elctlt

iQOuf

elctlt

3.3uf

cer

mono

met

cer

disc

met

polye

film

polye

film

polye

met

cer

disc

SPDT5A1

1A400VSP

recovery3A400V

1W

DIODE,zenerlOVlW
RESISTOR,
RESISTOR,

...

TRANSISTOR,

...

TRANSISTOR,

...

TRANSISTOR,

...

RESISTOR,C.5W 27K

...

RESISTOR, ME .25W

...

RESISTOR, ME .25W
RESISTOR, ME

...

RESISTOR, ME .25W

...

RESISTOR, ME .25W

WWfxd
WW

fxd zero ohm
UJT15MA
NPN
NPN

.25W22.1K

zero ohm

200MA

iQA

RESISTOR,CE.25W

...

RESISTOR,ME.25W1Kohm

...

POTENTIOMETER, cermet
RESISTOR, ME .25W

...

RESISTOR, ME .25W

...

RESISTOR, ME

...

RESISTOR,ME.25W

...

RESISTOR,ME.25W

...

RESISTOR,CF.25W

...

RESISTOR,MF.25W

...

RESISTOR,C.5W 680

...

RESISTOR,ME.25W

...

RESISTOR,

...

RESISTOR,ME.25W

...

RESISTOR,ME.25W

...

RESISTOR,C.25W47ohm

...

RESISTOR,C.25W

...

CONNECTOR,

...

CONNECTOR,

...

CONNECTOR,

...

CONNECTOR,

...

THYRISTOR,

...

RECTIFIER,

...

TRANSFORMER,

...

IC,

linear 317L

.25W 150K

WW

fxd

5W1ohm

100
rect6pin2row
rect8pin2row
rect2pin2row
rect 4

SCR

8.5A

integ8A100V

pulse

Motor

Control

35VDC

50VDC

.luf

5OVDC

film .33uf 100V

.01uf5OVDC

film

.0047uf

.33uf1OOVDC
.047uf1OOV
film

.luf

100V

.OSuf

500VDC

20VAC

SP

(PriortoKC301174)
(Eff

40V

40V

100V

ohm

47.5K

ohm

lOOK

ohm

ohm

10K

ohm

1.5K ohm

2.2K

ohm

trmr

1/T

243

ohm

162K

ohm
ohm

15K

ohm

39.2K

ohm

470

ohm

4.75K

ohm

ohm

3.32K

ohm

33.2K

ohm

4.32K

ohm

ohm

rcpt
rcpt
rcpt

pin2row

rcpt

200V

(Fig

12-1

100V

w/KC301174)

.5W2Kohm

Molex

39-28-1063

Molex

39-28-1

Molex

39-28-1

Molex

39-28-1043

Item

083
023

52)

2

1
1

11

3
2

1
1

1
1

3
1

4

1
1

4

1
12
10

1

3

1

1

4
2
2
3

1

1

5

1

2

1

1

1

1

1

1

1

1

1

1

1

3
4

1

1

1

1

2

1

1

1

BE

SURETOPROVIDE

5-21E

MODEL AND

SERIAL

NUMBER

WHEN

ORDERING REPLACEMENT

PARTS.

TM-1571 Page

39

Dia.

Mkgs.

PC2

Al,2

Ci
C2
C3

C4,7-9,12,i3

...

C5,6

ClO

Cii

C14
CiS
CR1

Dl,7

D2

Part

No.

121

562

093

551

110

375

098

691

073 756

122

426

125

968

009159....

031

708
000 348
083

182
122

723
032 820
000 347
031

677
084

128

044

176
093

192
026 202
037386

0

Description

Kit,

Spot

Control

...

KNOB,

...

STAND-OFF

...

STAND-OFF, No 6-32x.500

...

STAND-OFF, No 6-32x.625

...

BRACKET,

...

CIRCUIT

....

....

....

....

....

....

....

....

....

....

....

....

pointer

mtg

CARD,

IC,

linear358
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,

CAPACITOR,
CAPACITOR,

RELAY,

end
DIODE, rectlA400V
DIODE,zenerllViWSP

(Field

SUPPORT,PCCardNo6

options

timer

elctlt
tantlm
cer

mono

cer

mono
tantlm
tantlm
tantlm

cer

mono

cer

disc

24VDC

Option)

Ig
Ig

(consisting

220uf

5OVDC

.47uf

35V
.iuf
.luf

2.2uf

35VDC

.33uf

35V

5.6uf

35VDC
.01uf5OVDC

.01uf1

DPDT

SP

of)

5OVDC
5OVDC

OOOVDC

screw

w/post

(Eff

w/JK742029)

(Eff

w/JK742029)

Quantity

2

1
1
1

1
1

2

1
1

1
6
2

1

1

1

1

1
2

1

0

4Q

RiB

R32

N

ci.

TM-1571 Page

40

Circuit

Card

Layout,

Timer

PC2

0

86-149

456

S-21E

Dia.

Mkgs.

Part

121

No.

562

Kit,

Spot

Control

Description

(Field

Option)

Quantity

(Continued)

D3-6

Ji-lo

Qi,2

....

R3,23

R4,8

R9,12,18

RiO,14
R13,22

...

R25,26

RC1
RC2

RC3
VRi

PLG1

PLG5i

....

PLG52
PLG65

RC65

Ri
R2

R5
R6
R7

Ru

RiS
R16

R19
R20
R21

Si

S51

028

351

092 648
037 200

108

436

035 828
039

335
044 789
035 830

108

434
003 272

108

437

000 885
039 329
035 827

117134

035 886
093 037

108

441

108

440

121

214

123

031

089 242
121

084

117114

091

256

115093

113746
105673
089

241

131

054

113746
123032

135635

114656
121

893

DIODE,
RESISTOR,

TRANSISTOR,

sig

200mA

WW

fxd

NPN

75V

RESISTOR,MF.25W
RESISTOR,MF.25W
RESISTOR,CF.25W
RESISTOR,MF.25W
RESISTOR,MF.25W

RESISTOR,MF.25W

RESISTOR,CF.25W1meg ohm
RESISTOR,MF.25W
RESISTOR,MF.25W
RESISTOR,CF.25W

....

RESISTOR,CF.25W

....

RESISTOR,MF.25W

....

RESISTOR,CF.25W

....

RESISTOR,MF.25W

....

RESISTOR,MF.25W

....

RESISTOR,MF.25W

....

POTENTIOMETER,Csltd
CONNECTOR,

...

CONNECTOR,

....

CONNECTOR,

rect6pin
rect4pin

rect2pin
SWITCH,DlPSPST5posn
IC,

linear 317L

...

CONNECTOR&SOCKETS,

....

CONNECTOR,

...

CONNECTOR,

...

CONNECTOR,

...

CONNECTOR&SOCKETS,

....

CONNECTOR,

...

CONNECTOR,

rect

rect
rect

rect

rect

skt
Gskt
4skt plug

skt
plug

CONNECTOR&PINS,

....

CONNECTOR,

...

SWITCH,

tgl

rect

pin

SPDT6Ai25VAC

SP

zero

ohm

200mA

4.32K
243

47K

lOOK

8.81K

3.01K

4.75K
10K

2.7K
10K

24.3K

22K

47.5K

18.2K
13K

rcpt
rcpt
rcpt

40V

ohm

ohm

ohm

ohm

ohm
ohm

ohm

ohm

ohm

ohm

ohm

ohm

ohm
ohm

ohm

sft

i/T1W1

Amp
Amp 640457-4
Amp

(consisting

24-i

8ga

plug

Amp

Amp

(consisting

24-i

8ga

keying

Amp

(consisting

24-i

8ga

meg ohm

640457-6

640389-2

of)

Molex

39-00-0038
640440-6
640440-4

of)

Molex

39-00-0038

641994-i

of)

Molex

39-00-0040

4

10

2

1

1
2
2

1

1

1
3

2

1
2

1

1

1

1

1
2

1

1

1

1

1

1

6

1

1

1

2

1

1

2

1

BE

SURE TO

5-21E

PROVIDE MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING REPLACEMENT

PARTS.

TM-1571

Page

41

Notes

Notes