Lincoln Electric SVM134-A service manual Troubleshooting & Repair

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F-10	TROUBLESHOOTING & REPAIR					F-10
	TROUBLESHOOTING & REPAIR
Observe Safety Guidelines				TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

PROBLEMS		POSSIBLE AREAS OF		RECOMMENDED
(SYMPTOMS)		MISADJUSTMENT(S)		COURSE OF ACTION

			FUNCTION PROBLEMS
The engine will NOT go to high		1.	Check welding cables for loose	1. Check the reed switch (CR2) for
speed when a load is applied to the			or faulty connections.		proper operation. The	reed
welding output terminals.	The				switch should close when there
engine does go to high speed when					is current flow in the welding cir-
a load is applied to the DC auxiliary					cuit.
power receptacle.				2. Locate the red lead connected
				2. Locate the red lead connected
					to the idler PC board. While
					leaving the red lead connected,
					jumper the red lead to frame
					ground. If the engine goes to
					high speed, the fault is in the
					reed switch or associated leads.
					See the Wiring Diagram.
				3. If the engine does NOT go to
					high speed (in step 2), the idler
					PC board may be faulty.

The engine will NOT go to high		1.	Check the auxiliary power plug	1.	Check the black “B” leads con		-
speed when a load is applied to the			and associated leads for loose		nected to the idler PC board and
DC auxiliary receptacle.	The		or faulty connections.		associated connections.	See
engine does go to high speed when		2. The load may be too small. The			the Wiring Diagram.
a load is applied to the welding out-		2. The load may be too small. The
a load is applied to the welding out-			load must be above 150 watts.	2.	The idler PC board may be
put terminals.			load must be above 150 watts.	2.	The idler PC board may be
put terminals.					faulty.
					faulty.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353.

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 ClassicSafety Precautions Location and VentilationStoring 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 Safety Instructions OperationOperating 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 TOCEngine Operation Before Starting the EngineStarting the Engine Stopping the Engine Cold Weather StartingBREAK-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 BATTERY, STARTER, Engine Alternator and OIL Switch Circuit Theory of OperationGeneral Description ENGINE, Main Generator Armature and Frame and DC Exciter Excitation FlashingMain SHUNT, Interpole and Series Coils Fine Current Adjustment Current Range SelectorEngine 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 electricityTroubleshooting Guide Observe Safety GuidelinesDetailed 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 DC Exciter Test Test DescriptionMaterials 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 Scope Settings Normal Open Circuit Voltage Waveform 115VDC SupplyHigh 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 DC Exciter Armature Removal Procedure ReassemblyDC 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