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Lincoln Electric SVM134-A service manual Output Problems

Models: SVM134-A

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F-8			F-8
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

	OUTPUT PROBLEMS
The actual welding current is much	1. Check the main DC generator		1. The engine operating speed
greater than is indicated on the	brushes for good commutation		may be too high. If necessary
dials.	and alignment.	Contact the	perform the Engine Throttle
	Lincoln Electric	Service Dept.	Adjustment Test.
	1-800-833-9353 (WELD).		2. While the machine is loaded,
			2. While the machine is loaded,
			check the series coils for signs
			of “arcing.” This condition could
			point to shorted turns in the
			series coils.
			3. Perform the DC Exciter Test.

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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Lincoln Electric SVM134-A service manual Output Problems

Contents

Classic I TM Safety California Proposition 65 Warnings Electric Shock can kill Welding Sparks can cause fire or explosion Iii Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Classic Location and Ventilation Safety PrecautionsStoring PRE-OPERATION Engine Service Cooling System MufflerExhaust Spark Arrester Trailers Machine Grounding Figure A.1 Ground Stud Location Auxiliary Power Receptacle PLUGS, and HAND-HELD Equipment Electrical Output ConnectionsWelding Cable Connections Cable size for combined length Classic Table of Contents Operation Section Operation Safety InstructionsOperating Instructions Operational Features and Controls Recommended ApplicationsWelder Generator Controls and Settings WELDER/GENERATOR Controls Control of Welding Current Figure B.2 Current Controls Gasoline Engine Controls Return Section TOC Before Starting the Engine Engine OperationStarting the Engine Cold Weather Starting Stopping the EngineBREAK-IN Period Welding Operation After you finish welding Auxiliary Power Table B.1 Range Settings for Wire SIZE/SPEED Table of Contents Accessories OPTIONS/ACCESSORIES Semiautomatic Welding Accessories Connection of Lincoln Electric Wire Feeders Wire Feed Module see Figure C.1Connection of the LN-25 to Classic I Across the ARC with Classic Table of Contents Maintenance Safety Precautions Routine and Periodic Maintenance Engine Maintenance Figure 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.4 Battery Maintenance Classic I charging system is Negative WELDER/GENERATOR Maintenance Return to Section Return to Section TOC Idler 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 Guide PC Board Troubleshooting Procedures PC Board can be damaged by static electricity Observe 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 Test Figure F.2 Exciter Cover Removal Small Flex Lead Solid Shunt Coil and Series Coil Resistance Tests Idler 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 Method Engine Throttle Adjustment Test Adjust High Idle Adjust Low Idle Flashing the Fields Description Procedure Flashing the Fields Figure 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 Waveform DC 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 Procedure Main Generator Frame Removal and Replacement Replacement Main Generator Frame Removal Bolt / NUT Perform the DC Exciter Armature Removal Figure F.16 Selector Switch Lead Removal Terminal Lead Figure 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 Bolts Perform 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 engine DC Auxiliary Power Receptacle Output Retest After RepairEngine Output Welder DC Output Electrical Diagrams Section Electrical Diagrams Wiring Diagram Classic Wire Feed Module Wiring Diagram Wiring Diagram Wire Feed Module Schematic Idler PC Board 16990 M PC Board Assembly Idler PC Board Idler