Lincoln Electric SVM125-A service manual

Contents

Main SVM125-A October 1996 Safety Depends on You CLASSIC II i i FOR ENGINE powered equipment. WARNING ELECTRIC AND MAGNETIC FIELDS may be dangerous ii ii ARC RAYS can burn. ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. iii WELDING SPARKS can cause fire or explosion. iv iv PRCAUTIONS DE SRET Mar. 93 PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR MASTER TABLE OF CONTENTS FOR ALL SECTIONS - INSTALLATION SECTION - TECHNICAL SPECIFICATIONS - CLASSIC II INPUT - DIESEL ENGINE Manufacturer Description Speed Displacement Ignition Capacities RATED OUTPUT - WELDER Duty Cycle Amps Volts at Rated Amperes OUTPUT - WELDER AND GENERATOR SAFETY PRECAUTIONS LOCATION AND VENTILATION STORING STACKING TILTING PRE-OPERATION ENGINE SERVICE OIL FUEL BATTERYCONNECTIONS MUFFLER SPARK ARRESTER UNDERCARRIAGES ELECTRICAL OUTPUT CONNECTIONS WELDING CABLE CONNECTIONS MACHINE GROUNDING AUXILIARY POWER RECEPTACLES, PLUGS, AND HAND-HELD EQUIPMENT CIRCUIT BREAKERS Page - OPERATION SECTION - OPERATING INSTRUCTIONS SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. FUMES AND GASES can be dan- gerous. WELDING SPARKS can cause fire or explosion. RECOMMENDED APPLICATIONS WELDER Welding GENERATOR OPERATIONAL FEATURES AND CONTROLS WELDING CAPABILITY LIMITATIONS WELDER/GENERATOR CONTROLS CONTROLS AND SETTINGS CONTROL OF WELDING CURRENT FINE CURRENT ADJUSTMENT CURRENT RANGE SELECTOR DIESEL ENGINE CONTROLS ENGINE OPERATION WARNING WARNING BEFORE STARTING THE ENGINE Figure D.1 STARTING THE ENGINE STOPPING THE ENGINE COLD WEATHER STARTING BREAK-IN PERIOD WELDING OPERATION GENERAL INFORMATION Installation IDLER OPERATION Technical Specifications TO USE THE CLASSIC II FOR DC CONSTANT CURRENT STICK OR TIG WELDING: TO USE THE CLASSIC II FOR DC WIRE FEED WELDING (CONSTANT VOLTAGE) WITH WIRE FEED MODULE: AUXILIARY POWER Generator Power Applications, Accessories Figure B.1. Page - ACCESSORIES - OPTIONS/ACCESSORIES TIG WELDING SEMIAUTOMATIC WELDING CONNECTION OF THE LN-7 TO THE CLASSIC II USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.1.) CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS CONNECTION OF THE LN-7 TO THE CLASSIC II USING K584 INPUT CABLE ASSEMBLY(SEE FIGURE C.2.) CONNECTION OF THE LN-25 TO THE CLASSIC II USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.3.) CONNECTION OF THE LN-25 TO THE CLASSIC II ACROSS THE ARC (SEE FIGURE C.4.) Page -MAINTENANCE- SAFETY PRECAUTIONS Exploded View and Parts List ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE WARNING CAUTION { Change the Oil Figure D.1 Page BATTERYMAINTENANCE WELDER/GENERATOR MAINTENANCE IDLER MAINTENANCE D-8 D-8 FIGURE D.3 - MAJOR COMPONENT LOCATIONS Section E-1 Section E-1 FIGURE E.1 CLASSIC II BLOCK LOGIC DIAGRAM ENGINE -THEORY OF OPERATION SECTION- NEGATIVE OUTPUT TERMINAL POSITIVE OUTPUT TERMINAL 115 & 230VAC RECEPTACLES CURRENT TRANSFORMER FIELD RECTIFIER GENERAL DESCRIPTION BATTERY, STARTER, ENGINE, ALTERNATOR, AND PROTECTION CIRCUITS ENGINE, GENERATOR ARMATURE AND FRAME, ALTERNATOR STATOR AND ROTOR EXCITATION (FLASHING) AUXILIARY AND FIELD FEEDBACK COILS INTERPOLE AND SERIES COILS ENGINE, GENERATOR ARMATURE AND FRAME, ALTERNATOR STA- TOR AND ROTOR (CONTINUED) CURRENT RANGE SELECTOR FINE CURRENT ADJUSTMENT ENGINE IDLER CIRCUIT DC GENERATOR MACHINES Page TROUBLESHOOTING & REPAIR SECTION HOW TO USE TROUBLESHOOTING GUIDE Electrical Diagrams Section Table of Contents PC BOARD TROUBLESHOOTING PROCEDURES Flashing the Fields Alternator Rotor Test. Shunt Field Winding Test. Shunt Field Wind- ing Test. Page Idler Solenoid Test Page Page ENGINE PROBLEMS WELDING PROBLEMS ALTERNATOR ROTOR TEST Page Page Page SHUNT FIELD WINDING TEST SHUNT FIELD WINDING TEST (continued) PLUG P10 Figure F.5. SHUNT FIELD WINDING TEST (continued) PIN 3 PIN 5 TAB IDLER SOLENOID TEST IDLER SOLENOID TEST (continued) LEADS #56, #57 ENGINE THROTTLE ADJUSTMENT TEST STROBE MARK Strobe Tach Method NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY) HIGH IDLE - NO LOAD Figure F.9. Page FLASHING THE FIELDS FLASHING THE FIELDS (continued) NEGATIVE(-) Troubleshooting Guide POSITIVE (+) 12 VOLT BATTERY NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) HIGH IDLE NO LOAD FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE NO LOAD FINE CURRENT CONTROL RHEOSTAT AND SELECTOR SWITCH AT MAXIMUM TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM MACHINE LOADED SELECTOR SWITCH AT MAXIMUM POSITION AND REPLACEMENT REMOVE FASTENERS BATTERY RETAINER FASTENERS TERMINAL CABLES See Figure F.11 for steps 7 - 10. Page NEGATIVEOUTPUT TERMINAL (COPPER STRAP ON REAR SIDE) See Figure F.13 for steps 16 - 17. Page Page Page ALTERNATOR STATOR REMOVALAND REPLACEMENT ALTERNATOR STATOR REMOVALAND REPLACEMENT (continued) COMMUTATOR WRAP-AROUND F.18. Figure F.17 ALTERNATOR Page GENERNATOR BRUSH HOLDER/COIL CABLES (4) DRILL SPOT STATOR/ENDBRACKET MOUNTING BOLT Alternator Rotor Removal and Replacement GENERATOR FRAME REMOVALAND REPLACEMENT GENERATOR FRAME REMOVAL SELECTOR SWITCH CABLES BLUE AND BROWN LEADS Alternator Stator Removal GENERATOR FRAME REMOVAL ENGINE/GENERATOR MOUNTING HOLES ROPE SLING See Figure 22 for steps 10 - 13. Alternator Stator Removal and Replacement Alternator Rotor Removal and Replacement GENERATOR ARMATURE REMOVALAND REPLACEMENT GENERATOR ARMATURE REMOVAL BLOWER PADDLE Generator Frame Removal Alternator Stator Removal BLOWER PADDLE/ARMATURE MOUNTING BOLTS(8) RETEST AFTER REPAIR Page Page G-2 () Wiring Diagram (Code 9805 ) * * +- () Wiring Diagram (Code 10000) * +- L () REMOTE CONTROL (OPTIONAL) * * WIRE FEED MODULE (OPTIONAL) () REMOTE CONTROL (OPTIONAL) * * WIRE FEED MODULE (OPTIONAL) * 1-19-96 Wiring Diagram (Code 10219 ) * * 1-19-96 L9919 CLEVELAND, OHIO U.S.A. Wiring Diagram (Code 10220) G-8 Idler PC Board (M13708) Schematic NONE R4 ENGINE WELDERS G-8 G-9 Idler PC Board (M13708) Components M13708 Q2 C6 G-9 G-10 Idler PC Board (l9902) Schematic L IDLER 12 SEC. TIMER 9901 G-10 G-11 Idler PC Board (l9902) Components L9902 R IDLER ENGINE SHUTDOWN G-11