Lincoln Electric SVM194-A service manual Schematic Complete Machine Codes 11411, 11412 L13096

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G-18

ELECTRICAL DIAGRAMS

G-18

SCHEMATIC - COMPLETE MACHINE - (CODES 11411, 11412) (L13096)

L13096

ENGINEERING CONTROLLED CHANGE DETAIL: New

MANUFACTURER: No

K924-5 REMOTE CONTROL

CENTER OF CONTROL PANEL

IDLER / ENGINE PROTECTION PC BOARD

THIS LEAD PROVIDES FLASH

BACK, LEFT SIDEOF ENGINE

AMMETER SHOWS FULL

12 VOLT - NORMALLY OFF

61

J1-4

FOR ALTERNATOR AND

65 AMP / 12 VOLT

SWITCH

(OPTIONAL)

PROTECTION

60C

SCHEMATIC G4828-1

SENSES ALTERNATOR OUTPUT

GLOW PLUG SWITCH

RED ENGINE

LOCATED BEHIND UPPER PORTION OF CONTROL PANEL

ALTERNATOR

GLOW PLUG

DISCHARGE WHILE PRESSING

LIGHT

ENGINE

J1-3

59

BACK, RIGHT SIDEOF ENGINE

D+

53

N.C.

SHUTDOWN

B+

B3

55

WHITE

PULL COIL

IDLE SOLENOID

RIGHT SIDEOF ENGINE

51C

TYPICAL CURRENT DRAW AND

REMOTE CONTROL PLUG

BYINJECTION PUMP

N.O.

J1-8

57

RED

HOLD COIL

RESISTANCE:

-40 TO 40 AMPS

G

INJECTION

GND-C

58

J1-9

FLYBACK

BLACK

HOLD COIL: 1A, 10-15 OHMS

AMMETER

+

-

PUMP

ENGINE

DIODES

212E

PULL COIL: 40A, LESS THAN .1 OHM

51

GLOW PLUGS

Y

SOLENOID

58H

RUNNING

J1-2

212C

56

51A

TYPICAL CURRENT

APPROXIMATE

10A

X

J1-1

212D

IGNITION

DRAW IS 40 +/- 3 AMPS

RESISTANCE: 3.3 OHMS

CB4

50A

SWITCH

W

25+/-1.25 OHMS EACH

TYPICAL CURRENT DRAW: 3.3A

LOWER LEFT OF

BACK, LEFT SIDEOF ENGINE

212A

SHOWN IN "OFF"

50

RIGHT SIDEOF ENGINE

CONTROL PANEL

J1-6

44

43

S

I

POSITION

BYOIL FILLER

W

G

G

TEMPERATURE

START

CCW

FUEL PUMP

SWITCH

BACK, BOTTOM

ENGINE

GAUGE

64+/-6.4 OHMS MAX

TEMPERATURE SWITCH / SENDER

APPROXIMATE

PROTECTION

LOWER LEFT OF

52

OF MACHINE

SWITCH CLOSES

SENDER OPERATION:

STARTER

RESISTANCE: 3-4 OHMS

CIRCUITS (SEE

212B CONTROL PANEL

+

AT 230v+/-6vF

140vF -> 134+/-13.5 OHMS

SOLENOID

BATTERY

TYPICAL CURRENT DRAW: 3A

BELOW FOR

194vF -> 51.2+/-4.3 OHMS

+

LOGIC)

RHEOSTAT

60

93

J1-10

212vF -> 38.5+/-3 OHMS

SENDER IS APPROX.

STARTER

12.6 VOLTS MIN

HOUR METER

BACK, TOPOF ENGINE

S

500 OHMS AT 70vF

MOTOR

AT REST

REMOTE CONTROL BOX

CENTER OF

J1-7

200

I

OIL PRESSURE

J1-5

54

14-14.5 VOLTS

UNUSED

WK

G

G

GAUGE

CONTROL PANEL

J2-1

LOWER LEFT OF

WHILE RUNNING

J2-2

CONTROL PANEL

B1

REVERSE VOLTAGE

OIL PRESSURE SWITCH / SENDER

60A

PROTECTION DIODE

IDLE

SWITCH CLOSES

SENDER OPERATION:

AT 6+/-2 PSI

0 PSI -> 10+/-5 OHMS

AUX LOAD SENSING

SOLENOID

B4

40PSI -> 105+/-5 OHMS

FLYBACK DIODE PREVENTS

CIRUITS

B5

UNUSED

80 PSI -> 187+/-5 OHMS

WELD LOAD SENSING

(SEE BELOW

VOLTAGE SPIKES IN SHUNT FIELD

THE P10 PLUG IS ONLY ON UNITS WITHOUT

B6

FOR LOGIC)

FROM DAMAGING LOCAL/REMOTE

J2-3 J2-4B2

ENGINE PROTECTION CIRCUIT LOGIC

THE WIRE FEED MODULE. THE WIRE FEED

P10

TOGGLE SWITCH WHEN SWITCHED

MODULE HAS A HARNESS THAT PLUGS

ON NEWER BOARDS,

12 11 10

9 8 7

6 5 4

3

2

1

1. UPON RECIEVING POWER FROM THE

DIRECTLY INTO J5.

844

GND-B

SHOWN IN "AUTO

J1 BECOMES J31, J2 BECOMES J32,

JUMPER PLUG IS FOR CONNECTION

IGNITION SWITCH, THE FUEL SOLENOID,

IDLE" POSITION

B5 AND B6 TERMINALS ARE DELETED.

J5

TO WIRE FEED MODULE

IDLER SWITCH

48

FUEL PUMP AND HOUR METER ARE

400D

JUMPER PLUG ISWIRE-TIED UP

ENERGIZED.

400E

BEHIND LOCAL / REMOTE SWITCH ON

15A

DC EXCITER

+

610

2. ENGINE PROTECTION IS BYPASSED

WINDING SPEC: ALT-241-3A

+

RIGHT SIDEOF MACHINE(ASVIEWED

FOR ONE MINUTE TO ALLOW OIL

20A

CB2

40.5 - 42.5 OHMS AT 25C

610A

610

U

FROM CONTROL PANEL)

PRESSURE BUILDUP. ENGINE MUST BE

CB1

EXCITER REVOLVING

AC

AC DIODE

N

W

Y

STARTED WITHIN ONE MINUTE OF

11A

7A

FIELD (ROTOR)

-

LOWER, RIGHT SIDEOF CONTROL PANEL

TURNING IGNITION SWITCH ON OR THE

600C

-

600B

FUEL SOLENOID, FUEL PUMP AND HOUR

400F 115 VOLT GFCI

SLIP RINGS

21

600A

TOP, RIGHT PORTION

METER WILL TURN OFF. AFTER ONE

6A

POSITIVE SLIP RING

FUSE

RECEPTACLE

MINUTE, THE IGNITION SWITCH MUST BE

IS NEAREST TO IRON

15A

EXCITER CIRCUIT

OF CONTROL PANEL

N

U

W

Y

810

215

CYCLED OFF AND BACK ON TO START

HOT LINE

HOT LOAD

LOWER,

CCW

RHEOSTAT

GND-E

LEAD 21A TO 21B

ENGINE.

230 VOLT

RIGHT OF

WINDING SPEC: ALT-214-2B

64+/-6.4 OHMS MAX

602B

WHITE LINE

WHITE LOAD

CONTROL 214

.488 OHMS MAX AT 25C

3. AFTER ENGINE STARTS, FLASHING

6A

RECEPTACLE

PANEL

602A

42

41

CURRENT IS SUPPLIED TO THE ENGINE

820

810

115 VOLT CIRCUIT

ALTERNATOR.

J8

GND-T

11C

LEAD 810 TO 820

EXCITER STATOR

6

4 5

3

1

2

4. AFTER ONE MINUTE, TIMER IS TIMED

GND-S

WINDING SPEC: ALT-214-2C

IN-LINE BOLTED CONNECTION

820

(ALTERNATOR)

.230 OHMS MAX AT 25C

P9

41

JUMPER PLUG IS

OUT. IF OIL PRESSURE IS LOW,

600

WIRE-TIED UPBEHIND

COOLANT TEMPERATURE IS HIGH OR

BEHIND CONTROL PANEL

115 VOLT CIRCUIT

42

G

ALTERNATOR IS NOT CHARGING, THE

11B

LEAD 820 TO 830

602

LOCAL / REMOTE

ENGINE WILL SHUT DOWN AND THE

844A

GENERATOR LEAD BLOCK

WINDING SPEC: ALT-214-2D

X

Y

SWITCH ON RIGHT

ENGINE PROTECTION LIGHT WILL COME

TOP, LEFT PORTION

SHOWN AS VIEWED WITH

.424 OHMS MAX AT 25C

SIDEOF MACHINE

ON.

ENGINE IN THIS DIRECTION

W

IDLE SOLENOID CIRUIT LOGIC

OF CONTROL PANEL

REMOTE

MOUNTED TO NEGATIVE

SELECTOR SWITCH

SERIES FIELD

SHUNT

RECEPTACLE

LOCAL / REMOTE

1. WHEN THE ENGINE IS RUNNING IN HIGH IDLE

-

+

BRUSH HOLDER

OR UNDER LOAD, THE SOLENOID IS NOT

90-MIN

FIELD

SWITCH

DIODE AND MOV ASSEMBLY

ENERGIZED.

2. IF NO AUXILIARY CURRENT DRAW OR WELD

130-80

+

-

FJW-5AP

SHOWN IN LOCAL

THIS CIRCUIT USES THE

190-120

POSITION

COIL PAIR:

RESIDUAL MAGNETISM OF

LOAD IS SENSED FOR 15 SECONDS AND THE

240-160

25.2 - 26.7

THE GENERATOR TO FLASH

IDLER SWITCH IS OPEN (AUTO), THE PULL AND

220-MAX

INTERPOLE

OHMS EACH

THE EXCITE THE ROTOR

HOLD COIL OF THE IDLER SOLENOID ARE

COILS

WHICH IN TURN PROVIDES

ENERGIZED. THE PULL COIL IS DE-ENERGIZED

THE EXCITATION FOR THE

AFTER HALF A SECOND.

GENERATOR

COMPONENT VALUE UNITS:

3. IF AN AUXILIARY CURRENT DRAW OR WELD

BACKOF OUTPUT STUD

WELDING

CAPACITOR: MFD/VOLTS

LOAD IS SENSED OR THE IDLER SWITCH IS CLOSED

BRUSH POSITION SHOWN AS

REED SWITCH

RESISTOR: OHMS/WATTS

(HIGH), THE IDLE SOLENOID IS DE-ENERGIZED.

VIEWED FROM CONTROL PANEL

GENERATOR

SWITCH CLOSES

_

CONNECTOR PIN NUMBERS:

WITH FLOW OF

+

WELDING CURRENT

EX. 12 PIN CONNECTOR

LEAD COLOR CODE:

LABELS:

GND-A

1 2

6

B-BLACK OR GRAY

NEGATIVE OUTPUT

POSITIVE OUTPUT

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

G-GREEN

COMMON

TERMINAL

TERMINAL

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

U-BLUE

FRAME GROUND

TYPICAL OCV (WARM MACHINE):

UNLESS OTHERWISE SPECIFIED TOLERANCE

DESIGN INFORMATION

REFERENCE: EQUIPMENT TYPE:

CLASSIC 300D PERKINS 404C-22

PAGE ___ OF ___

ON 2 PLACE DECIMALS IS ± .02

R-RED OR PINK

UNDER LEFT DOOR

MANUFACTURING TOLERANCE PER E2056

1

1

7

12

W-WHITE

94-99.0 VOLTS AT MAX RHEOSTAT

ON 3 PLACE DECIMALS IS ± .002

DRAWN BY:

Maglietta

L12561

SUBJECT:

MACHINE SCHEMATIC

DOCUMENT

DOCUMENT

LATCH

EARTH GROUND

44-54.5 VOLTS AT MIN RHEOSTAT

ON ALL ANGLES IS ± .5 OF A DEGREE

ENGINEER:

SCALE:

NUMBER:

REVISION:

Y-YELLOW

D. BENDER

VIEW OF CONNECTOR ON PC BOARD

MATERIAL TOLERANCE (" t") TO AGREE

DISPOSITION:

NA

DATE:

10/05/2006

NUMBER:

CRM37529

L13096

A

-BROWN

DO NOT SCALE THIS DRAWING

APPROVED:

NA

WITH PUBLISHED STANDARDS.

MATERIAL

APPROVAL

PROJECT

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

CLASSIC® 300D & 300G