Lincoln Electric SVM134-A service manual Operation, Operating Instructions, Safety Instructions

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OPERATION

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OPERATING INSTRUCTIONS

Read and understand this entire section before operat- ing your Classic I.

SAFETY INSTRUCTIONS

WARNING

Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintenance instructions; and parts lists.

ELECTRIC SHOCK can kill.

Do not touch electrically live parts or electrodes with your skin or wet clothing.

Insulate yourself from the work and ground.

WARNING

ENGINE EXHAUST can kill.

Use in open, well ventilated areas or vent exhaust to the outside.

Do not stack anything on or near the engine.

MOVING PARTS can injure.

Do not operate this equipment with any of its doors open or guards off.

Stop the engine before servicing it.

Keep away from moving parts.

Only qualified personnel should install, use, or ser- vice this equipment.

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• Always wear dry insulating gloves.

FUMES AND GASES can be dan- gerous.

Keep your head out of fumes.

Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

Keep flammable material away.

Do not weld on containers that have held combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

GENERAL DESCRIPTION

The Classic I is a heavy duty engine driven DC arc welding power source capable of providing DC con- stant current output for stick welding or DC TIG weld- ing. The Classic I is wound with all copper coils for bet- ter arc stability and precise welding control. With the addition of the optional Wire Feed Module or CV adapter, the Classic I will provide constant voltage out- put for running the LN-25 wire feeder.

The Classic I has a current range of 40-300 DC amps. It provides 1.75 kw of 120V DC auxiliary power.

This unit uses the four cylinder Continental TM27 industrial, water-cooled gasoline engine.

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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 Cooling System MufflerExhaust Spark Arrester TrailersMachine Grounding Figure A.1 Ground Stud LocationAuxiliary Power Receptacle PLUGS, and HAND-HELD Equipment Electrical Output ConnectionsWelding Cable Connections Cable size for combined lengthClassic Table of Contents Operation Section Operation Safety InstructionsOperating Instructions Operational Features and Controls Recommended ApplicationsWelder 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 Lincoln Electric Wire Feeders Wire Feed Module see Figure C.1Connection of the LN-25 to 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 After cleaning or when installing a new spark plug Gap Specifications 0.032 inch .8 mmSet the terminal gap with a feeler gauge or gapping 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 engineDC Auxiliary Power Receptacle Output Retest After RepairEngine Output 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