Lincoln Electric SVM134-A service manual PRE-OPERATION Engine Service

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A-4

A-4

INSTALLATION

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STACKING

Classic I machines CANNOT be stacked.

TILTING

Place the machine on a secure, level surface whenev- er you use it or store it. Any surfaces you place it on other than the ground must be firm, non-skid, and structurally sound.

The gasoline engine is designed to run in a level posi- tion for best performance. If you do operate it at a slight angle, be sure to check the oil regularly and keep the oil level at the FULL mark as it would be in its normal level condition. Also, fuel capacity will be a little less at an angle.

LIFTING

The Classic I weighs 1370 lb./621 kg. A lift bail is provided for lifting with a hoist.

WARNING

WARNING

Keep hands away from the engine muffler or HOT engine parts.

Stop the engine when fueling.

Do not smoke when fueling.

Remove the fuel cap slowly to release pressure.

Do not overfill the fuel tank.

Wipe up spilled fuel and allow the fumes to clear before starting the engine.

Keep sparks and flame away from the fuel tank.

OIL

The Classic I is shipped with the engine filled with SAE 10W-30 oil. This should be fine for most ambient operating temperature condi-

tions. See the engine operation manual for specific recommendations. CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE. This is an added precau- tion. When full, the oil level should be up to but not over the FULL mark on the dipstick. If it is not full, add enough oil to fill it to the full mark. DO NOT overfill.

For more oil fill and service information, see the Maintenance section of this manual.

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FALLING EQUIPMENT can cause injury.

Do not lift this machine using lift bail if it is equipped with a heavy accessory such as a trailer.

Lift only with equipment of adequate lifting capacity. Be sure machine is stable when lifting.

FUEL

Fill the fuel tank with clean, gasoline only. The Classic I has a 15 gallon (57 liter) fuel tank with a top fill and fuel gauge mounted on the control panel. See the Operation and Maintenance sections of this manual

for more details about fuel.

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HIGH ALTITUDE OPERATION

It may be necessary to derate welder output at higher altitudes. Some engine adjustment may be required. Contact a Continental Service Representative.

PRE-OPERATION ENGINE SERVICE

Read and understand the information about the gaso- line engine in the Operation and Maintenance sec- tions of this manual before you operate the Classic I.

BATTERY CONNECTIONS

The Classic I is shipped with the negative battery cable

+ disconnected. Before you operate the

machine, make sure the IGNITION switch is in the OFF position and

attach the disconnected cable securely to the battery terminal. If the battery is discharged and won't start the engine, see the battery charging instructions in the Maintenance section.

CLASSIC I

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Contents Classic I TM Safety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications ClassicLocation and Ventilation Safety PrecautionsStoring PRE-OPERATION Engine Service Exhaust Spark Arrester Cooling SystemMuffler TrailersMachine Grounding Figure A.1 Ground Stud LocationWelding Cable Connections Auxiliary Power Receptacle PLUGS, and HAND-HELD EquipmentElectrical Output Connections Cable size for combined lengthClassic Table of Contents Operation Section Operation Safety InstructionsOperating Instructions Welder Operational Features and ControlsRecommended Applications GeneratorControls and Settings WELDER/GENERATOR ControlsControl of Welding Current Figure B.2 Current ControlsGasoline Engine Controls Return Section TOCBefore Starting the Engine Engine OperationStarting the Engine Cold Weather Starting Stopping the EngineBREAK-IN Period Welding Operation After you finish weldingAuxiliary Power Table B.1 Range Settings for Wire SIZE/SPEEDTable of Contents Accessories OPTIONS/ACCESSORIES Semiautomatic Welding AccessoriesConnection of the LN-25 to Connection of Lincoln Electric Wire FeedersWire Feed Module see Figure C.1 Classic I Across the ARC withClassic Table of Contents Maintenance Safety Precautions Routine and Periodic Maintenance Engine MaintenanceFigure D.1 OIL Drain and Refill MAX MIN Figure D.2A Engine Coolant Drain Plug Set the terminal gap with a feeler gauge or gapping After cleaning or when installing a new spark plugGap Specifications 0.032 inch .8 mm Tool. See Figure D.4Battery Maintenance Classic I charging system is NegativeWELDER/GENERATOR Maintenance Return to Section Return to Section TOCIdler Maintenance Figure D.5 Major Component Locations Classic Table of Contents Theory of Operation Section Theory of Operation BATTERY, STARTER, Engine Alternator and OIL Switch CircuitGeneral Description Excitation Flashing ENGINE, Main Generator Armature and Frame and DC ExciterMain SHUNT, Interpole and Series Coils Current Range Selector Fine Current AdjustmentEngine Idler Circuit DC Generator Machines Return to Section TOC Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures PC Board can be damaged by static electricityObserve Safety Guidelines Troubleshooting GuideDetailed in the beginning of this manual Shunt Field Winding Test Main Generator Throttle Adjustment Test Output Problems Function Problems Troubleshooting & Repair Engine Problems Welding Problems Test Description DC Exciter TestMaterials Needed Test Procedure DC Exciter TestFigure F.2 Exciter Cover Removal Small Flex Lead Solid Shunt Coil and Series Coil Resistance TestsIdler Solenoid Test Troubleshooting & Repair Main Generator Shunt Field Winding Test Main Generator Shunt Field Winding Test Figure F.6 Plug P10 PIN Assignments TAB Engine Throttle Adjustment Test Engine Throttle Adjustment Test Strobe Tach MethodEngine Throttle Adjustment Test Adjust High IdleAdjust Low Idle Flashing the Fields DescriptionProcedure Flashing the FieldsFigure F.11 Brush HOLDER/BATTERY Jumper Connections Normal Open Circuit Voltage Waveform 115VDC Supply Scope SettingsHigh Idle no Load Fine Current Control Rheostat AT Maximum Normal Open Circuit DC Weld Voltage Waveform Machine Loaded Selector Switch AT Maximum Typical DC Weld Voltage WaveformDC Exciter Armature and Field Coils Removal and Replacement Reassembly DC Exciter Armature Removal ProcedureDC Exciter Armature and Field Coils Field Coils Removal Procedure Perform the DC Exciter Armature Removal ProcedureMain Generator Frame Removal and Replacement Replacement Main Generator Frame Removal Bolt / NUTPerform the DC Exciter Armature Removal Figure F.16 Selector Switch Lead Removal Terminal LeadFigure F.18 Choke Control Cable Removal Loosen Here Main Generator Frame Removal Figure F.20 Front Panel Fastener Removal Troubleshooting & Repair Feet Remove Mounting NUTS, Washers BoltsPerform the DC Exciter Armature Reassembly Procedure Main Generator Armature Removal and Replacement Main Generator Armature Removal Armature is now free to be removed from the engineEngine Output DC Auxiliary Power Receptacle OutputRetest After Repair Welder DC OutputElectrical Diagrams Section Electrical Diagrams Wiring Diagram ClassicWire Feed Module Wiring Diagram Wiring Diagram Wire Feed ModuleSchematic Idler PC Board 16990 MPC Board Assembly Idler PC Board Idler