Lincoln Electric SVM194-A service manual Schematic Complete Machine Codes 11243, 11244 L12265-1

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G-16

ELECTRICAL DIAGRAMS

G-16

SCHEMATIC - COMPLETE MACHINE - (CODES 11243, 11244) (L12265-1)

1-L12265

ENGINEERING CONTROLLED

CHANGE DETAIL: New

MANUFACTURER:

No

JUMPERPLUGISBEHINDLOWER

LOWERRIGHTOFCONTROLPANEL

K924-5 REMOTE CONTROL

RIGHTSIDEOFCONTROLPANEL

AMMETER SHOWS FULL

12 VOLT SUPPLY

11

87

1

RPM CONTROL POTENTIOMETER

GLOW PLUG

DISCHARGE WHILE PRESSING

94

20

10,000 +/- 1,000 OHMS MAX

ENGINE

GLOW PLUG SWITCH

(OPTIONAL)

RATED VOLTAGE: 12V

ENGINE CONTROL UNIT

(ECU)

2

86

2

TURN POT COUNTERCLOCKWISE TO

BUTTON

SPEED

93

17

REDUCE RESISTANCE AND SUBSEQUENTLY

53

RATED CURRENT: 22mA MAX

SENSOR

CCW

GLOW PLUGS

LOCATEDBEHINDUPPERPORTIONOFCONTROLPANEL

3

88

REDUCE RPM BY UP TO 150RPM

BACK, RIGHT

60A

3

BACK, LEFTSIDEOFENGINE

SIDEOFENGINE

RATED VOLTAGE: 12V

4

51C

TYPICAL CURRENT

RATED CURRENT: 4.5A(MAX.)-TERMINAL #15

ALTERNATOR

DRAW IS 40 AMPS

LEAKAGE CURRENT 10micro A (MAX.)-TERMINAL #16

40 AMP / 12 VOLT

26

64

L

REMOTE CONTROL PLUG

69

13

SENSOR OPERATION:

SENSES ALTERNATOR OUTPUT

IG

G

WATER

-4vF -> 18.80 kOHMS

FLASHES ALTERNATOR

B

104vF ->

1.14 kOHMS

TEMP.

212E

Y

212vF ->

.16 kOHMS

SENSOR

60

16

51B

-40 TO 40 AMPS

BACK, LEFT

IGNITION

AMMETER

51

BACK, BOTTOM

X

SIDEOFENGINE

SWITCH

-

RATED VOLTAGE: 12V

1

9

15

212D

51A

50

STARTER

+

OFMACHINE

SHOWN IN "OFF"

+

RATED CURRENT: 2A

57

34

10

17

SOLENOID

BATTERY

W

25+/-1.25 OHMS EACH

COIL RESISTENCE:

18

25

POSITION

2.8 +/- .28 OHMS AT 20vC

12 VOLT

BACK, LEFTSIDEOFENGINE

212A

STARTER

12.6 VOLTS MIN

26

34

ENERGIZED FOR RUN

DE-ENERGIZED FOR STOP

ACTUATOR

SUPPLY

28

44

43

S

I

50A

MOTOR

AT REST

14-14.5 VOLTS

ACTUATOR CONTROLS RPM

BACK, RIGHT

TEMPERATURE

CCW

W

G

G

WHILE RUNNING

MECHANICAL STOP WILL SHUT

SIDEOFENGINE

56

18

GAUGE

START

64+/-6.4 OHMS MAX

TEMPERATURE SWITCH / SENDER

DOWN THE ENGINE AT 115%

LOWERLEFTOF

BUTTON

OF RATED SPEED.

ENGINE

ECU CONNECTOR DETAIL

SWITCH CLOSES

SENDER OPERATION:

212B

CONTROLPANEL

RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY

PROTECTION

COLOR: RED

140vF -> 134+/-13.5 OHMS

OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED

LIGHT

61

9

AT 230v+/-6vF

62

194vF -> 51.2+/-4.3 OHMS

12 VOLT

SENDER IS APPROX.

WHEN THE IGNITION SWITCH IS "ON" AND THE ECU

RHEOSTAT

CENTEROF

THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING THE ENGINE

212vF -> 38.5+/-3 OHMS

NORMALLY OFF

500 OHMS AT 70vF

SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT

841A

CONTROLPANEL

PROTECTION LIGHT IN A CODED SEQUENCE, SEE CHART FOR FAULT

FRONT, LEFTSIDEOFENGINE

S

I

OIL PRESSURE

212C

DOWN DUE TO A FAULT (EVEN IF THAT CONDITION

+

CODES AND CORRECTIVE MEASURES. WHEN THE ENGINE IS SHUT

27

54

200

DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING

REMOTE CONTROL BOX

58

6

DOWN DUE TO A FAULT, THE IGNITION SWITCH WILL NEED TO BE

GAUGE

HOUR METER

WK

G

G

OUT OF FUEL), THE IGNITION SWITCH WILL NEED TO BE

TURNED OFF THEN BACK ON TO RESTART THE ENGINE.

LOWERLEFTOF

52A

CENTEROF

TURNED OFF THEN BACK ON TO RESTART THE ENGINE.

31

1

19

30

32

7

12

OIL PRESSURE SWITCH / SENDER

CONTROLPANEL

CONTROLPANEL

SWITCH CLOSES

SENDER OPERATION:

STARTER

THE P10 PLUG IS ONLY ON UNITS

CONNECT TO 70A

CONNECT TO

AT 6+/-2 PSI

0 PSI -> 10+/-5 OHMS

RELAY

WITHOUT THE WIRE FEED MODULE.

60F

60E

70BGROUND FOR

40PSI -> 105+/-5 OHMS

WIRE-TIEDTOHARNESS

THE WIRE FEED MODULE HAS A

GROUND FOR

1600RPM, LEAVE

80 PSI -> 187+/-5 OHMS

HARNESS THAT PLUGS DIRECTLY

800RPM

844A

UNCONNECTED

52B

BEHINDCONTROLPANEL

P10

INTO J5.

FOR 1800RPM

55

12 11 10 9 8

7 6 5

4 3

2

1

FLYBACK DIODE PREVENTS

841B

BOTHOPENLEADSAREWIRE-TIEDINSIDETHEHARNESSBEHINDCONTROLPANEL

J5

VOLTAGE SPIKES IN SHUNT FIELD

48

FROM DAMAGING LOCAL/REMOTE

400D

TOGGLE SWITCH WHEN SWITCHED

GND-B

400E

JUMPER PLUG IS FOR CONNECTION

+

610

WINDING SPEC: ALT-241-3A

+

TO WIRE FEED MODULE

20A

15A

610A

610

40.5 - 42.5 OHMS AT 25C

CB1

CB3

AC

AC

DIODE

N

U W

Y

JUMPERPLUGISWIRE-TIEDUP

EXCITER REVOLVING

IDLER SWITCH

11A

-

LOWER, RIGHTSIDEOFCONTROLPANEL

BEHINDLOCAL/ REMOTESWITCHON

SHOWN IN "AUTO

FIELD (ROTOR)

600C

21

-

600B

RIGHTSIDEOFMACHINE(ASVIEWED

IDLE" POSITION

400F

7A

SLIP RINGS

FUSE

600A

FROMCONTROLPANEL)

POSITIVE SLIP RING

HOT LINE

HOT LOAD

115 VOLT GFCI

IS NEAREST TO IRON

15A

215

EXCITER CIRCUIT

RHEOSTAT

N

U

W

Y

GND-S

LOWER,

LEAD 21A TO 21B

CCW

RECEPTACLE

64+/-6.4 OHMS MAX

RIGHTOF

WINDING SPEC: ALT-214-2B

WHITE LINE

WHITE LOAD

230 VOLT

602B

CONTROL 214

.488 OHMS MAX AT 25C

GND-T

GND-E

RECEPTACLE

PANEL

42

41

115 VOLT CIRCUIT

602A

JUMPERPLUGIS

841

844

6A

810

J8

CB4

LEAD 810 TO 820

15A

EXCITER STATOR

6

4 5

3

1

2

WIRE-TIEDUP

WINDING SPEC: ALT-214-2C

BEHINDLOCAL/

IN-LINE BOLTED CONNECTION

820

(ALTERNATOR)

.230 OHMS MAX AT 25C

P9

REMOTESWITCH

41

600

ONRIGHTSIDEOF

11C

BEHIND CONTROL PANEL

115 VOLT CIRCUIT

11B

602

42

G

MACHINE

LEAD 820 TO 830

Y

LOCATEDBEHINDUPPERLEFT

WITH AC AUXILIARY POWER,

GENERATOR LEAD BLOCK

WINDING SPEC: ALT-214-2D

X

ROUTING DIRECTIONS OF THESE

SHOWN AS VIEWED WITH

.424 OHMS MAX AT 25C

PORTIONOFCONTROLPANEL

LEADS DOES NOT MATTER

2 TURNS

ENGINE IN THIS DIRECTION

REMOTE

W

SENSOR GROUNDS LEAD

DIODE AND MOV ASSEMBLY

CURRENT SENSING PC BOARD

RECEPTACLE

ON SENSE OF WELD OR

SELECTOR SWITCH

SERIES FIELD

-

+

SHUNT

LOCAL / REMOTE

MOUNTEDTONEGATIVE

AUXILIARY LOAD

SCHEMATIC S25973

FIELD

SWITCH

4

90-MIN

SHOWN IN LOCAL

BRUSHHOLDER

3

DRIVER

130-80

+

-

FJW-5AP

THIS CIRCUIT USES THE

CIRCUITS

190-120

POSITION

12 VOLT SUPPLY

842

2

67B

COIL PAIR:

RESIDUAL MAGNETISM OF

240-160

25.2 - 26.7

THE GENERATOR TO FLASH

1

3 TURNS

220-MAX

INTERPOLE

OHMS EACH

THE EXCITE THE ROTOR

COILS

WHICH IN TURN PROVIDES

LIGHT CODE

FAILURE DETECTED

POSSIBLE CAUSE - CORRECTIVE MEASURE

THE EXCITATION FOR THE

GENERATOR

LONG 1, SHORT 1

RPM IS OVER 115% OF RATED RPM (2070 RPM)

ACTUATOR IS STUCK - REMOVE ACTUATOR AND VERIFY PLUNGER PULLS IN WHEN ENERGIZED

LOW OIL - CHECK OIL LEVEL ON DIPSTICK

WELDING

LONG 1, SHORT 2

LOW OIL PRESSURE DETECTED FOR 1 SECOND

FAULTY OIL PRESSURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS RUNNING

BRUSH POSITION SHOWN AS

LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED - CHECK

VIEWED FROM CONTROL PANEL

GENERATOR

"L" TERMINAL IS GROUNDED ON ALTERNATOR

BROKEN OR LOOSE BELT - INSPECT

67A

_

COMPONENT VALUE UNITS:

LONG 1, SHORT 3

LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE SHORTED TO GROUND - CHECK

+

FOR 1 SECOND

FAULTY ALTERNATOR - CHECK

CAPACITOR: MFD/VOLTS

LONG 1, SHORT 4

HIGH WATER TEMPERATURE DETECTED FOR 1

AMOUNT OR QUALITY OF COOLANT INCORRECT - CHECK

NEGATIVE OUTPUT

RESISTOR: OHMS/WATTS

SECOND

FAULTY WATER TEMPERATURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING

POSITIVE OUTPUT

LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED - CHECK

TERMINAL

TERMINAL

CONNECTOR PIN NUMBERS:

LONG 1, SHORT 5

NOT ENABLED FOR LINCOLN PRODUCTS

TYPICAL OCV (WARM MACHINE):

0 RPM IS DETECTED AND 12V IS DETECTED

FAULTY RPM SENSOR - CHECK FOR GOOD CONNECTION

LONG 2, SHORT 1

94-99.0 VOLTS AT MAX RHEOSTAT

LEAD COLOR CODE:

LABELS:

EX. 12 PIN CONNECTOR

FROM "L" TERMINAL ON ALTERNATOR

FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU

44-54.5 VOLTS AT MIN RHEOSTAT

B-BLACK OR GRAY

1 2

LONG 2, SHORT 2

CURRENT TO ACTUATOR IS OUT OF LIMIT

FAULTY ACTUATOR - CHECK FOR PROPER COIL RESISTANCE

UNDERLEFTDOOR

6

LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK

G-GREEN

COMMON

LONG 2, SHORT3

NOT ENABLED FOR LINCOLN PRODUCTS

R-RED OR PINK

LONG 2, SHORT4

-50C WATER TEMPERATURE DETECTED

FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE

U-BLUE

FRAME GROUND

7

12

LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN - CHECK FOR CONTINUITY

W-WHITE

EARTH GROUND

LATCH

LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED

FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE

Y-YELLOW

LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK

VIEW OF CONNECTOR ON PC BOARD

N-BROWN

LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN - CHECK FOR CONTINUITY

0 VOLTS DETECTED FROM "L" TERMINAL ON

LONG 2, SHORT 6

BROKEN OR LOOSE BELT - INSPECT

PROPRIETARY & CONFIDENTIAL:THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED

ALTERNATOR FOR 1 SECOND

FAULTY ALTERNATOR - CHECK

UNLESS OTHERWISE SPECIFIED TOLERANCE

TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

INCORRECT BATTERY - INSPECT

DESIGN INFORMATION

REFERENCE: EQUIPMENT TYPE:

CLASSIC 300D (KUBOTA V2203M)

1

1

LONG 2, SHORT 7

OVER 18 VOLTS DETECTED FROM ALTERNATOR

MANUFACTURING TOLERANCE PER E2056

FAULTY ALTERNATOR - CHECK

ON 2 PLACE DECIMALS IS ± .02

DRAWN BY:

Maglietta

L12265

PAGE ___ OF ___

LESS THAN 4 VOLTS TO RPM SENSOR AND/OR

ON 3 PLACE DECIMALS IS ± .002

SUBJECT:

MACHINE SCHEMATIC

DOCUMENT

DOCUMENT

LONG 2, SHORT 8

FAULTY ECU - CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU

ON ALL ANGLES IS ± .5 OF A DEGREE

ENGINEER:

N. TAYLOR

SCALE:

NUMBER:

REVISION:

ACTUATOR SENSED BY ECU

MATERIAL TOLERANCE (" t") TO AGREE

L12265-1

A

WITH PUBLISHED STANDARDS.

APPROVED:

NONE

MATERIAL

NA

APPROVAL

03/11/2005

PROJECT

CRM34902

DO NOT SCALE THIS DRAWING

DISPOSITION:

DATE:

NUMBER:

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

CLASSIC® 300D & 300G