Lincoln Electric SVM134-A service manual Welding Sparks can cause fire or explosion, Iii

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SAFETY

 

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WELDING SPARKS can cause fire or explosion.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot

materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

Away from areas where they may be struck or subjected to physical damage.

A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

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Mar ‘95

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