Lincoln Electric SVM125-A service manual Troubleshooting & Repair

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F-9

 

 

 

F-9

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE

 

 

Observe Safety Guidelines

 

 

 

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 AC auxiliary

 

 

cuit.

power receptacles.

 

 

 

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.

 

 

 

 

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 leads associated with

speed when a load is applied to the

 

and associated leads for loose

the current transformer for loose

AC auxiliary receptacles.

The

 

or faulty connections.

or faulty connections. See the

engine does go to high speed when

2. The load may be too small. The

Wiring Diagram.

a load is applied to the welding out-

 

 

load must be above 150 watts.

2. Check the current transformer

put terminals.

 

 

 

 

 

for “opens” in the windings.

 

 

 

 

 

 

 

 

3. The Idler PC board may be

 

 

 

 

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 216-383-2531 or 1-800-833-9353.

CLASSIC II

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Contents Classic II 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 Spark Arrester Muffler UndercarriagesWelding Cable Connections Electrical Output ConnectionsCircuit Breakers Auxiliary Power RECEPTACLES, PLUGS, and HAND-HELD EquipmentMachine Grounding Classic Table of Contents Operation Section General Description Safety InstructionsOperation Operating InstructionsWelder Operational Features and ControlsDesign Features Recommended ApplicationsLimitations Welding CapabilityWELDER/GENERATOR Controls Controls and SettingsFigure B.2 Current Controls Control of Welding CurrentReturn to Diesel Engine ControlsCheck and fill the engine fuel tank Engine OperationBefore Starting the Engine Starting the EngineBREAK-IN Period Stopping the EngineCold Weather Starting Idler Operation Welding OperationGeneral Information Figure B.4 Welding Circuit Connections for Stick Welding After you finish weldingTable B.1 Range Settings for Wire SIZE/SPEED 13B-13 Auxiliary PowerSuggested Power Applications Running Watts Start-up Watts Table B.2 Generator Power ApplicationsTable of Contents Accessories Accessory Kit K703 Includes the following OPTIONS/ACCESSORIESSemiautomatic Welding TIG WeldingAdapter see Figure C.1 Connection of Lincoln Electric Wire FeedersConnection of the LN-7 to Classic II Using K867 Universal 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 Engine Maintenance Routine and Periodic MaintenanceFigure D.1 OIL Drain and Refill Figure D.2 Tightening the Cooling Blower Belt Every 50 Hours Daily or BeforeStarting Engine First 50 HoursChecking Specific Gravity Battery MaintenanceIdler Maintenance WELDER/GENERATOR MaintenanceFigure D.3 Major Component Locations Table of Contents Theory of Operation Section Circuits Theory of OperationALTERNATOR, and Protection Interpole and Series Coils Excitation FlashingAuxiliary and Field Feedback Coils Engine Idler Circuit Fine Current AdjustmentCurrent Range Selector DC Generator Machines Classic 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 Perform the Shunt Field Wind Troubleshooting & Repair Function Problems Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair Welding Problems Materials Needed Alternator Rotor TestTest Description Alternator Rotor Test Test ProcedureFigure 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 Oscilloscope Method Frequency Counter MethodAdjusting Screw Locking NUT Description Flashing the FieldsDo not remove brush holder ProcedureHigh Idle no Load Fine Current Control Rheostat AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115VAC Supply Normal Open Circuit DC Weld Voltage Waveform Typical DC Weld Output Voltage Waveform Machine Loaded Selector Switch AT Maximum PositionAlternator Rotor Removal Replacement Alternator Rotor Removal ReplacementFuel 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 Alternator Stator Removal ProcedureVAC Receptacle Circuit Breaker Field Bridge Rectifier Genernator Brush HOLDER/COIL Cables Drill Spot STATOR/ENDBRACKET Mounting Bolt Generator Frame Removal and Replacement Figure F.21 Generator Lead and Cable Connections Generator Frame RemovalRope Sling ENGINE/GENERATOR Mounting Holes Generator Armature Removal and Replacement Blower Paddle PADDLE/ARMATURE Mounting Bolts Generator Armature RemovalWelder DC Output AC Auxiliary Power Receptacle OutputRetest After Repair Engine OutputElectrical Diagrams Section Classic Wiring Diagram Code Electrical DiagramsRemote 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.