Lincoln Electric SVM134-A Recommended Applications, Operational Features and Controls, Welder

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B-3

B-3

OPERATION

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RECOMMENDED APPLICATIONS

WELDER

The Classic I provides excellent constant current DC welding output for stick (SMAW) welding and for DC TIG welding. For more details on using the machine as a welder, see Welding Operation in the Operation section of this manual.

GENERATOR

The Classic I is also capable of providing 1.75 kw of 115V DC auxiliary power.

OPERATIONAL FEATURES AND CONTROLS

The Classic I was designed for simplicity. Therefore, it has very few operating controls. Two switches are used for welding operations:

•A five-position CURRENT RANGE SELECTOR switch selects current output ranges for constant cur- rent stick or TIG applications and constant voltage wire feed applications (with optional Wire Feed Module - see the Accessories section)

DESIGN FEATURES

•Constant current DC Stick welding (SMAW) process capability with output range from 40 - 300 DC amps.

•Work and Electrode welding cable mounting termi- nals.

•Separate ground stud for safe connection of case to earth ground.

•115 volt DC auxiliary power receptacle.

•Electric starting.

•Distributor type electronic ignition.

•Battery Charging Ammeter.

•Engine Hour Meter for determining periodic mainte- nance.

•Top-of-the-line 38 HP Continental gasoline engine.

•Top-mounted 15 gallon (57.0 litter) fuel tank with con- venient top fill.

•Automatic engine idler goes to low idle approximate- ly 15 seconds after welding for greater fuel economy; includes high idle switch.

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•A FINE CURRENT ADJUSTMENT control for fine adjustment of current from minimum to maximum within each range

Controls for the gasoline engine control include a two- position IGNITION ON/OFF toggle switch, a START pushbutton, and a two-position IDLER switch that selects engine speed for welding or auxiliary power applications. See Engine Operation in the Operation section of this manual for details about starting, run- ning, stopping, and breaking in the gasoline engine.

WELDING CAPABILITY

The Classic I is rated 200 amps, 40 volts constant cur- rent DC at 60% duty cycle based on a ten minute time period. Longer duty cycles at lower output currents are possible.

The current is continuously variable from 40 to 300 amps DC.

LIMITATIONS

The Classic I is not recommended for any processes besides those that are normally performed using DC stick welding (SMAW) and DC TIG welding. Specific limitations on using the Classic I for these processes are described in the Welding Operation section of this manual. Constant voltage welding is available with the optional Wire Feed Module.

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CLASSIC I

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Contents Classic I TM California Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Classic InstallationStoring Safety PrecautionsLocation and Ventilation PRE-OPERATION Engine Service Muffler Cooling SystemExhaust Spark Arrester TrailersFigure A.1 Ground Stud Location Machine GroundingElectrical Output Connections Auxiliary Power Receptacle PLUGS, and HAND-HELD EquipmentWelding Cable Connections Cable size for combined lengthClassic Table of Contents Operation Section Operating Instructions Safety InstructionsOperation Recommended Applications Operational Features and ControlsWelder GeneratorWELDER/GENERATOR Controls Controls and SettingsFigure B.2 Current Controls Control of Welding CurrentReturn Section TOC Gasoline Engine ControlsStarting the Engine Engine OperationBefore Starting the Engine BREAK-IN Period Stopping the EngineCold Weather Starting After you finish welding Welding OperationTable B.1 Range Settings for Wire SIZE/SPEED Auxiliary PowerTable of Contents Accessories Semiautomatic Welding Accessories OPTIONS/ACCESSORIESWire Feed Module see Figure C.1 Connection of Lincoln Electric Wire FeedersConnection of the LN-25 to Classic I Across the ARC withClassic Table of Contents Maintenance Engine Maintenance Safety Precautions Routine and Periodic MaintenanceFigure D.1 OIL Drain and Refill MAX MIN Figure D.2A Engine Coolant Drain Plug Gap Specifications 0.032 inch .8 mm After cleaning or when installing a new spark plugSet the terminal gap with a feeler gauge or gapping Tool. See Figure D.4Classic I charging system is Negative Battery MaintenanceReturn to Section Return to Section TOC WELDER/GENERATOR MaintenanceIdler Maintenance Figure D.5 Major Component Locations Classic Table of Contents Theory of Operation Section General Description BATTERY, STARTER, Engine Alternator and OIL Switch CircuitTheory of Operation Main SHUNT, Interpole and Series Coils ENGINE, Main Generator Armature and Frame and DC ExciterExcitation Flashing Engine Idler Circuit Fine Current AdjustmentCurrent Range Selector DC Generator Machines Return to Section TOC Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board can be damaged by static electricity PC Board Troubleshooting ProceduresDetailed in the beginning of this manual Troubleshooting GuideObserve Safety Guidelines Shunt Field Winding Test Main Generator Throttle Adjustment Test Output Problems Function Problems Troubleshooting & Repair Engine Problems Welding Problems Materials Needed DC Exciter TestTest Description DC Exciter Test Test ProcedureFigure F.2 Exciter Cover Removal Shunt Coil and Series Coil Resistance Tests Small Flex Lead SolidIdler 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 Strobe Tach Method Engine Throttle Adjustment TestAdjust High Idle Engine Throttle Adjustment TestAdjust Low Idle Description Flashing the FieldsFlashing the Fields ProcedureFigure F.11 Brush HOLDER/BATTERY Jumper Connections High Idle no Load Fine Current Control Rheostat AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115VDC Supply Normal Open Circuit DC Weld Voltage Waveform Typical DC Weld Voltage Waveform Machine Loaded Selector Switch AT MaximumDC Exciter Armature and Field Coils Removal and Replacement DC Exciter Armature and Field Coils DC Exciter Armature Removal ProcedureReassembly Perform the DC Exciter Armature Removal Procedure Field Coils Removal ProcedureMain Generator Frame Removal and Replacement Replacement Bolt / NUT Main Generator Frame RemovalPerform the DC Exciter Armature Removal Lead Figure F.16 Selector Switch Lead Removal TerminalFigure F.18 Choke Control Cable Removal Loosen Here Main Generator Frame Removal Figure F.20 Front Panel Fastener Removal Troubleshooting & Repair Remove Mounting NUTS, Washers Bolts FeetPerform the DC Exciter Armature Reassembly Procedure Main Generator Armature Removal and Replacement Armature is now free to be removed from the engine Main Generator Armature RemovalRetest After Repair DC Auxiliary Power Receptacle OutputEngine Output Welder DC OutputElectrical Diagrams Section Wiring Diagram Classic Electrical DiagramsWiring Diagram Wire Feed Module Wire Feed Module Wiring Diagram16990 M Schematic Idler PC BoardIdler PC Board Assembly Idler PC Board
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