Lincoln Electric SVM134-A service manual Theory of Operation, General Description

Page 40

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E-2

E-2

THEORY OF OPERATION

FIGURE E.2 – BATTERY, STARTER, ENGINE ALTERNATOR AND OIL SWITCH CIRCUIT

 

 

 

 

 

 

 

SELECTOR

 

 

 

 

 

 

 

 

 

SWITCH

 

 

 

 

 

 

 

 

 

 

REED

 

 

 

IDLER

 

 

 

 

 

RELAY

NEGATIVE

 

 

BOARD

 

 

 

 

 

CR2

 

 

 

 

 

 

 

 

OUTPUT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TERMINAL

 

ENGINE

OIL

 

 

 

 

 

 

 

 

HOUR

PRESSURE

 

 

 

 

 

 

 

 

METER

LIGHT

 

 

 

 

 

 

 

 

 

 

IDLER

 

 

 

 

 

 

 

 

SOLENOID

 

 

 

 

 

 

 

 

OIL

 

 

GENERATOR

 

 

 

 

PRESSURE

 

 

 

FRAME

 

 

 

 

SWITCH

 

 

 

 

 

 

 

 

 

SERIES

 

 

 

RESIDUAL

 

 

 

 

 

COILS

 

 

 

 

 

 

 

 

 

 

 

MAGNETISM

 

 

FUEL

 

 

 

 

 

 

 

 

 

SHUTDOWN

 

 

 

 

 

 

SHUNT

 

 

 

 

 

 

BRUSHES &

COMMUTATOR

 

FIELD

 

SWITCH

 

ENGINE

MECHANICAL

GENERATOR

ARMATURE

EXCITER

115 VDC

 

 

 

 

 

 

 

 

DC

 

 

ENGINE

 

COUPLING

ARMATURE

 

 

SHAFT

ARMATURE

RECEPTACLE

IGNITION

IGNITION

 

 

 

ENGINE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ALTERNATOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SERIES

 

 

 

 

 

INTERPOLE

 

 

FIELD

 

 

 

 

 

 

 

 

 

 

 

 

 

COILS

 

 

 

 

 

 

STARTER

 

 

 

 

 

 

 

 

 

MOTOR

 

 

FIELD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SHUNT

 

 

 

 

 

 

 

 

 

WINDINGS

 

 

 

 

BATTERY

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GENERATOR

 

 

 

 

 

 

 

 

 

FIELD CONTROL

 

POSITIVE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT

 

 

 

 

 

 

 

 

 

TERMINAL

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GENERAL DESCRIPTION

The Classic I is a heavy duty, engine driven, DC arc welding power source capable of providing constant current output for stick welding or DC TIG welding. Also, a total of 1750 watts of auxiliary power is available at the 115VDC receptacle. The Classic I is manufac- tured with all copper windings.

BATTERY, STARTER, ENGINE ALTERNATOR AND OIL SWITCH CIRCUIT

The 12VDC battery powers the starter motor and, through the ignition switch, the engine ignition and fuel shutoff solenoid. The engine alternator supplies "charging" current for the battery circuit. If the oil pres- sure switch does not close, due to low oil pressure or inadequate oil supply, the oil pressure light will not glow, the hour meter will not operate and the engine alternator will not function.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

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