Lincoln Electric SVM125-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 II.

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 II is a heavy duty engine driven DC arc welding power source capable of providing constant current output for stick welding or DC TIG welding. The Classic II is wound with all copper coils and is config- ured in a new shorter case with no exciter stickout and setup for one side service. With the addition of the optional Wire Feed Module, the Classic II will provide constant voltage output for running the LN-7 or LN-25.

This unit uses the Deutz F3L-1011F three-cylinder, industrial air cooled diesel engine.

CLASSIC II

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Contents Classic II 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 Muffler Undercarriages Spark ArresterElectrical Output Connections Welding Cable ConnectionsMachine Grounding Auxiliary Power RECEPTACLES, PLUGS, and HAND-HELD EquipmentCircuit Breakers Classic Table of Contents Operation Section Safety Instructions OperationOperating Instructions General DescriptionOperational Features and Controls Design FeaturesRecommended Applications WelderWelding Capability LimitationsControls and Settings WELDER/GENERATOR ControlsControl of Welding Current Figure B.2 Current ControlsDiesel Engine Controls Return toEngine Operation Before Starting the EngineStarting the Engine Check and fill the engine fuel tankCold Weather Starting Stopping the EngineBREAK-IN Period General Information Welding OperationIdler Operation After you finish welding Figure B.4 Welding Circuit Connections for Stick WeldingTable B.1 Range Settings for Wire SIZE/SPEED Auxiliary Power 13B-13Table B.2 Generator Power Applications Suggested Power Applications Running Watts Start-up WattsTable of Contents Accessories OPTIONS/ACCESSORIES Accessory Kit K703 Includes the followingTIG Welding Semiautomatic WeldingConnection of the LN-7 to Classic II Using K867 Universal Connection of Lincoln Electric Wire FeedersAdapter see Figure C.1 Adapter Work Electrode Cable To LN-7 Figure C.3 Classic II/LN-25 Connection Diagram With K444-2 Remote Control K487-25 Table of Contents Maintenance Routine and Periodic Maintenance Engine MaintenanceFigure D.1 OIL Drain and Refill Figure D.2 Tightening the Cooling Blower Belt Daily or Before Starting EngineFirst 50 Hours Every 50 HoursBattery Maintenance Checking Specific GravityWELDER/GENERATOR Maintenance Idler MaintenanceFigure D.3 Major Component Locations Table of Contents Theory of Operation Section ALTERNATOR, and Protection Theory of OperationCircuits Auxiliary and Field Feedback Coils Excitation FlashingInterpole and Series Coils Current Range Selector Fine Current AdjustmentEngine Idler Circuit DC Generator Machines Classic 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 Perform the Shunt Field Wind Troubleshooting & Repair Function Problems Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair Welding Problems Test Description Alternator Rotor TestMaterials Needed Test Procedure Alternator Rotor TestFigure F.2 Measuring Rotor Resistance Classic Figure F.3 Measuring Rotor Resistance to Ground Classic Shunt Field Winding Test Shunt Field Winding Test PIN TAB Idler Solenoid Test Idler Solenoid Test Engine Throttle Adjustment Test Engine Throttle Adjustment Test Frequency Counter Method Oscilloscope MethodAdjusting Screw Locking NUT Flashing the Fields DescriptionProcedure Do not remove brush holderNormal Open Circuit Voltage Waveform 115VAC 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 Position Typical DC Weld Output Voltage WaveformAlternator Rotor Removal Replacement Replacement Alternator Rotor RemovalFuel Tank Return Line Mounting Hardware Cable Retainer Bowl Negative Output Terminal Copper Strap on Rear Side Figure F.14 Alternator Cover Removal Figure F.15 Rotor Removal Replacement Alternator Stator Removal and Replacement Procedure Alternator Stator RemovalVAC Receptacle Circuit Breaker Field Bridge Rectifier Genernator Brush HOLDER/COIL Cables Drill Spot STATOR/ENDBRACKET Mounting Bolt Generator Frame Removal and Replacement Generator Frame Removal Figure F.21 Generator Lead and Cable ConnectionsRope Sling ENGINE/GENERATOR Mounting Holes Generator Armature Removal and Replacement Generator Armature Removal Blower Paddle PADDLE/ARMATURE Mounting BoltsAC Auxiliary Power Receptacle Output Retest After RepairEngine Output Welder DC OutputElectrical Diagrams Section Classic Electrical Diagrams Wiring Diagram CodeRemote Control Optional Remote Control Optional Wire Feed Module Optional Wire Feed Thermostat * Machine Must not be Running J3 Sensor Idler PC Board M13708 Schematic Idler PC Board M13708 Components Idler PC Board l9902 Schematic Idler PC Board l9902 Components

SVM125-A specifications

The Lincoln Electric SVM125-A is a versatile and highly efficient welding machine that has gained significant recognition in the welding industry. Designed for both professionals and enthusiasts, this machine combines advanced technology with user-friendly features to deliver outstanding performance in a range of welding applications.

One of the standout features of the SVM125-A is its Inverter Technology. This cutting-edge technology allows for lightweight and compact design, making the machine highly portable. The inverter technology also provides a steady arc, which is crucial for achieving clean, high-quality welds. With a duty cycle of 125 amps at a 60% duty cycle, this welding machine can handle a variety of materials and thicknesses, from thin sheet metal to heavier structural components.

The SVM125-A supports multiple welding processes, including MIG, stick, and TIG welding. This versatility makes it an ideal choice for diverse welding tasks, whether you're working in a fabrication shop, doing repair work, or engaged in hobbyist projects. The machine features easy switch functionality, allowing users to quickly shift between welding processes without complicated setup.

Another notable characteristic is the machine's user-friendly interface. The intuitive control panel includes clear indicators and knobs that allow for easy adjustments of voltage and wire feed speed. This design is especially helpful for novice welders, providing them with the confidence to make adjustments as needed and ensuring optimal weld quality.

Safety is also a priority with the SVM125-A. The machine is equipped with thermal overload protection, which automatically shuts it down in case of overheating, preventing damage to the unit and ensuring operator safety. Additionally, the machine features a robust construction that emphasizes durability, making it suitable for demanding work environments.

Portability is enhanced through its lightweight design, and the built-in carrying handle makes it easy to transport from one job site to another. The SVM125-A is also compatible with a variety of welding accessories, further increasing its adaptability and functionality.

In conclusion, the Lincoln Electric SVM125-A stands out as a well-rounded welding machine that integrates advanced technology with user-friendly features. Its versatility in welding processes, robust design, and emphasis on safety and usability make it a valuable tool for welders at all skill levels. Whether for professional use or personal projects, the SVM125-A is a reliable choice that delivers exceptional performance and quality.