Lincoln Electric SVM134-A Uživatelský manuál

CLASSIC ISVM134-AOctober, 2000For use with machine code numbers 10068 to 10069TMRETURN TO MAIN INDEXSERVICE MANUALSafety Depends on YouLincoln arc wel

STACKINGClassic I machines CANNOT be stacked.TILTINGPlace the machine on a secure, level surface whenev-er you use it or store it. Any surfaces you pl

COOLING SYSTEMThe cooling system has been filled at the factory with a50-50 mixture of ethylene glycol antifreeze and water.Check the radiator level a

MACHINE GROUNDINGAccording to the United States National ElectricalCode, the frame of this portable generator is notrequired to be grounded and is per

ELECTRICAL OUTPUT CONNECTIONSSee Figure A.2 for the location of the 115V DC voltreceptacle, weld output terminals, and ground stud.WELDING CABLE CONNE

NOTESA-8 A-8CLASSIC IReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC

Section B-1 Section B-1CLASSIC ITABLE OF CONTENTS- OPERATION SECTION -Operation...

OPERATING INSTRUCTIONSRead and understand this entire section before operat-ing your Classic I.SAFETY INSTRUCTIONSDo not attempt to use this equipment

RECOMMENDED APPLICATIONSWELDERThe Classic I provides excellent constant current DCwelding output for stick (SMAW) welding and for DCTIG welding. For m

OPERATIONB-4 B-4CLASSIC IFIGURE B.1 – OUTPUT CONTROLS1. CURRENT RANGE SELECTOR2. FINE CURRENT ADJUSTMENT3. 115 VOLT DC RECEPTACLE 4. WELD OUTPUT TERMI

CONTROL OF WELDING CURRENT• DO NOT turn the CURRENT RANGE SELECTORwhile welding because the current may arc betweenthe contacts and damage the switch

SAFETYi iCLASSIC IFOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires

GASOLINE ENGINE CONTROLSSee Figure B.3 for the location of the following features:1. IDLER CONTROL TOGGLE SWITCH: Adjusts therunning speed of the engi

ENGINE OPERATIONDO NOT RUN THE ENGINE AT EXCESSIVESPEEDS. The maximum allowable high idle speed forthe Classic I is 1550 RPM, no load. Do NOT increase

STOPPING THE ENGINE1. Remove all welding and generator power loadsand let the engine cool by running it for severalminutes at low idle.2. Place the IG

WELDING OPERATIONTO USE THE CLASSIC I FOR DCCONSTANT CURRENT STICK OR TIGWELDING:1. Remove the flange nuts from the weld output ter-minals and place t

OPERATIONB-10 B-10CLASSIC ITABLE B.1RANGE SETTINGS FOR WIRE SIZE/SPEEDDiameter (inches) Wire Speed Range Appropriate Current Range(inches/minute).035

TABLE OF CONTENTS- ACCESSORIES -Accessories...

OPTIONS/ACCESSORIESThe following options/accessories are available for yourClassic I from your local Lincoln Distributor.Trailer (K768) - For in-plant

The Lincoln Electric LN-25 wire feeder is recommend-ed for wire feed welding with the Classic I.CONNECTION OF THE LN-25 TO THECLASSIC I “ACROSS THE AR

NOTESC-4 C-4CLASSIC IReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC

Section D-1 Section D-1CLASSIC ITABLE OF CONTENTS-MAINTENANCE-Maintenance ...

SAFETYii iiCLASSIC IARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc

SAFETY PRECAUTIONS• Have qualified personnel do all maintenance andtroubleshooting work.• Turn the engine off before working inside themachine.• Re

CHANGE THE OIL: Change the oil, while the engineis still warm, as follows:1 . Drain the oil from the drain plug located on theengine bottom, as shown

FUEL FILTER: Inspect the in-line fuel filter daily. Whennecessary remove the sediment bowl from beneath thegas tank and clean out any accumulated dirt

FAN BELT: Fan belts tend to loosen after the first 50hours of operation. If the fan belt is loose, the enginecan overheat and the battery can lose it

BATTERY MAINTENANCEGASES FROM BATTERY can explode.• Keep sparks, flame, and cigarettes awayfrom battery.BATTERY ACID can burn eyes and skin.• Wear g

WELDER/GENERATOR MAINTENANCESTORAGE: Store the Classic I in clean, dry, protectedareas.CLEANING: Blow out the generator and controls peri-odically wit

CURRENT RANGE SELECTOR CONTACTS: Thecontacts should not be greased. To keep the contactsclean, rotate the current control handle through itsentire ran

MAINTENANCED-9 D-9CLASSIC IFIGURE D.5 - MAJOR COMPONENT LOCATIONS111298151416137653421101. RIGHT CASE SIDE (DOOR)2. BASE (WITH BATTERY)3. EXCITER BRUS

NOTESD-10 D-10CLASSIC IReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TO

Section E-1 Section E-1CLASSIC ITheory of Operation ...

CLASSIC IFOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. In

GENERAL DESCRIPTIONThe Classic I is a heavy duty, engine driven, DC arcwelding power source capable of providing constantcurrent output for stick weld

ENGINE, MAIN GENERATOR ARMATURE AND FRAME AND DCEXCITEREXCITATION (FLASHING)The main generator armature and the exciter arma-ture are mechanically cou

ENGINE, MAIN GENERATOR ARMATURE AND FRAME AND DCEXCITER (CONTINUED)CURRENT RANGE SELECTORThe selector switch acts as a course current adjust-ment by a

DC GENERATOR MACHINESThe armature winding of a DC generator is located onthe rotating member. Current is conducted from it bymeans of carbon brushes.

NOTESE-6 E-6CLASSIC IReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC

Section F-1 Section F-1CLASSIC ITroubleshooting & Repair Section...S

HOW TO USE TROUBLESHOOTING GUIDEService and repair should be performed by only Lincoln Electric Factory Trained Personnel.Unauthorized repairs perform

ELECTRIC SHOCK can kill.Have an electrician install and servicethis equipment. Turn the machine OFFbefore working on equipment. Do nottouch electrical

TROUBLESHOOTING & REPAIRF-4 F-4CLASSIC IObserve Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manual.CAUTIONIf for any

TROUBLESHOOTING & REPAIRF-5 F-5CLASSIC ITROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf for any

SAFETYiv ivCLASSIC IPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques

TROUBLESHOOTING & REPAIRF-6 F-6CLASSIC IObserve Safety GuidelinesTROUBLESHOOTING GUIDEdetailed in the beginning of this manual.CAUTIONIf for any r

TROUBLESHOOTING & REPAIRF-7 F-7CLASSIC ITROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf for any

TROUBLESHOOTING & REPAIRF-8 F-8CLASSIC IObserve Safety GuidelinesTROUBLESHOOTING GUIDEdetailed in the beginning of this manual.CAUTIONIf for any r

TROUBLESHOOTING & REPAIRF-9 F-9CLASSIC ITROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf for any

TROUBLESHOOTING & REPAIRF-10 F-10CLASSIC IObserve Safety GuidelinesTROUBLESHOOTING GUIDEdetailed in the beginning of this manual.CAUTIONIf for any

TROUBLESHOOTING & REPAIRF-11 F-11CLASSIC ITROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf for an

F-12 F-12CLASSIC ITROUBLESHOOTING & REPAIRTROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf for an

TROUBLESHOOTING & REPAIRF-13 F-13CLASSIC IDC EXCITER TESTWARNINGService and repair should be performed by only Lincoln Electric factory trained pe

TROUBLESHOOTING & REPAIRF-14 F-14CLASSIC ISERIES COIL CONNECTION POINT (NEGATIVE)POSITIVEFIGURE F.1 – 120VDC RECEPTACLEDC EXCITER TEST (continued)

TROUBLESHOOTING & REPAIRF-15 F-15CLASSIC IDC EXCITER TEST (continued)EXITER COVERWARRANTYCHECK VOLTAGE AT BRUSH HOLDERS HERE(RIGHT SIDE IS +)+FIGU

MASTER TABLE OF CONTENTS FOR ALL SECTIONSv vCLASSIC IPageSafety...

TROUBLESHOOTING & REPAIRF-16 F-16CLASSIC IWHITE FLEX LEADSMALLFLEX LEADSOLID LEADWARRANTYFIGURE F.3 – BRUSH HOLDER LEADSShunt Coil and Series Coil

TROUBLESHOOTING & REPAIRF-17 F-17CLASSIC IWARNINGIDLER SOLENOID TESTService and repair should be performed by only Lincoln Electric factory traine

TROUBLESHOOTING & REPAIRF-18 F-18CLASSIC IIDLER SOLENOID TEST (continued)FIGURE F.4 – IDLER SOLENOID CONNECTIONSQUICK CONNECT LEADSTEST PROCEDURE1

TROUBLESHOOTING & REPAIRF-19 F-19CLASSIC IWARNINGMAIN GENERATOR SHUNT FIELD WINDING TESTService and repair should be performed by only Lincoln Ele

TROUBLESHOOTING & REPAIRF-20 F-20CLASSIC IMAIN GENERATOR SHUNT FIELD WINDING TEST (continued)FIGURE F.5 – PLUG P10 LOCATIONPLUG P10TEST PROCEDURE1

TROUBLESHOOTING & REPAIRF-21 F-21CLASSIC IMAIN GENERATOR SHUNT FIELD WINDING TEST (continued)FIGURE F.6 – PLUG P10 PIN ASSIGNMENTSPIN 3PIN 5TAB5.

TROUBLESHOOTING & REPAIRF-22 F-22CLASSIC IWARNINGENGINE THROTTLE ADJUSTMENT TESTService and repair should be performed by only Lincoln Electric fa

TROUBLESHOOTING & REPAIRF-23 F-23CLASSIC IENGINE THROTTLE ADJUSTMENT TEST (continued)FIGURE F.7 – BLOWER PADDLE MARK LOCATIONBLOWERPADDLE MARKTEST

TROUBLESHOOTING & REPAIRF-24 F-24CLASSIC IENGINE THROTTLE ADJUSTMENT TEST (continued)Adjust High Idlea. Make sure there is no load on the machine.

TROUBLESHOOTING & REPAIRF-25 F-25CLASSIC IENGINE THROTTLE ADJUSTMENT TEST (continued)FIGURE F.9 – LOW IDLE ADJUSTMENTSPEEDADJUSTMENTSCREWLOCKINGNU

TABLE OF CONTENTS- INSTALLATION SECTION -Section A-1 Section A-1CLASSIC IInstallationTechnical Specifications ...

TROUBLESHOOTING & REPAIRF-26 F-26CLASSIC IWARNINGFLASHING THE FIELDSService and repair should be performed by only Lincoln Electric factory traine

TROUBLESHOOTING & REPAIRF-27 F-27CLASSIC IFLASHING THE FIELDS (continued)FIGURE F.10 – EXCITER COVER REMOVALEXITER COVER PROCEDURE1. Turn the engi

TROUBLESHOOTING & REPAIRF-28 F-28CLASSIC IFLASHING THE FIELDS (continued)FIGURE F.11 - BRUSH HOLDER/BATTERY JUMPER CONNECTIONS+RAISEEXCITERBRUSH O

TROUBLESHOOTING & REPAIRF-29 F-29CLASSIC IThis is the typical auxiliary outputvoltage generated from a properlyoperating machine. Note that eachve

TROUBLESHOOTING & REPAIRF-30 F-30CLASSIC IThis is the typical DC welding outputvoltage generated from a properlyoperating machine. Note that eachv

TROUBLESHOOTING & REPAIRF-31 F-31CLASSIC IThis is the typical DC welding outputvoltage generated from a properlyoperating machine. Note that eachv

TROUBLESHOOTING & REPAIRF-32 F-32CLASSIC IWARNINGDC EXCITER ARMATURE AND FIELD COILS REMOVAL AND REPLACEMENTService and repair should be performed

TROUBLESHOOTING & REPAIRF-33 F-33CLASSIC IDC EXCITER ARMATURE AND FIELD COILS REMOVAL AND REPLACEMENT (continued)FIGURE F.12 – EXCITER COVER REMOV

TROUBLESHOOTING & REPAIRF-34 F-34CLASSIC IDC EXCITER ARMATURE AND FIELD COILS REMOVAL AND REPLACEMENT (continued)Field Coils Removal Procedure1. P

TROUBLESHOOTING & REPAIRF-35 F-35CLASSIC IWARNINGMAIN GENERATOR FRAME REMOVAL AND REPLACEMENTService and repair should be performed by only Lincol

INSTALLATIONA-2 A-2CLASSIC ITECHNICAL SPECIFICATIONS - CLASSIC IINPUT - DIESEL ENGINEManufacturer Description Speed Displacement Ignition Capacities C

TROUBLESHOOTING & REPAIRF-36 F-36CLASSIC IMAIN GENERATOR FRAME REMOVALAND REPLACEMENT (continued)FIGURE F.13 – BATTERY PANEL REMOVALNEGATIVEBATTER

TROUBLESHOOTING & REPAIRF-37 F-37CLASSIC IMAIN GENERATOR FRAME REMOVALAND REPLACEMENT (continued)FIGURE F.14 – TOP AND DOORS ASSEMBLY DETAILSBOLT

TROUBLESHOOTING & REPAIRF-38 F-38CLASSIC IMAIN GENERATOR FRAME REMOVALAND REPLACEMENT (continued)FIGURE F.15 – FUEL TANK MOUNTING DETAILSBOLTS / N

TROUBLESHOOTING & REPAIRF-39 F-39CLASSIC IFIGURE F.16 – SELECTOR SWITCH LEAD REMOVALSELECTORSWITCH TERMINALLEAD (5)ACBDE9. Using the 1/2” wrench,

TROUBLESHOOTING & REPAIRF-40 F-40CLASSIC IFIGURE F.18 – CHOKE CONTROL CABLE REMOVALLOOSENHERECHOKE CABLE12. Using the slot head screw driver, remo

TROUBLESHOOTING & REPAIRF-41 F-41CLASSIC IFIGURE F.19 – FRONT PANEL WIRING CONNECTIONSACBDE15. SHUNT LEADS QUICK DISCONNECT13. RED LEAD TO

TROUBLESHOOTING & REPAIRF-42 F-42CLASSIC IFIGURE F.20 – FRONT PANEL FASTENER REMOVALBOLTS / NUTS / WASHERS (2)BASE MOUNTING BOLTS (4)MIDDLE SCREW

TROUBLESHOOTING & REPAIRF-43 F-43CLASSIC IFIGURE F.21 – BRUSH BRACKET WRAP-AROUND COVERBRUSH BRACKETWRAP- AROUND COVERREMOVE (2) NUTS, WASHERS, AN

TROUBLESHOOTING & REPAIRF-44 F-44CLASSIC IFIGURE F.23 – MAIN GENERATOR FEET MOUNTING MAIN GENERATORREMOVE MOUNTING NUTS, WASHERS, AND BOLTS FEET

TROUBLESHOOTING & REPAIRF-45 F-45CLASSIC I33. Using the rope sling and pry bars, carefullylift and “wiggle” the generator frame awayfrom the engin

Read this entire installation section before youstart installation.SAFETY PRECAUTIONSDo not attempt to use this equipment until you havethoroughly rea

TROUBLESHOOTING & REPAIRF-46 F-46CLASSIC IWARNINGMAIN GENERATOR ARMATUREREMOVAL AND REPLACEMENTService and repair should be performed by only Linc

TROUBLESHOOTING & REPAIRF-47 F-47CLASSIC IMAIN GENERATOR ARMATURE REMOVALAND REPLACEMENT (continued)FIGURE F.25 – MAIN GENERATOR ARMATURE MOUNTING

TROUBLESHOOTING & REPAIRF-48 F-48CLASSIC IRETEST AFTER REPAIRRetest a machine:• If it is rejected under test for any reason that requires you to

ELECTRICAL DIAGRAMSG-1 G-1CLASSIC IReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCElectrical Diagrams Section ...

ELECTRICAL DIAGRAMSG-2G-2Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

ELECTRICAL DIAGRAMSG-3CLASSIC IWIRING DIAGRAM - WIRE FEED MODULE3-18-94 L9259 AMPHENOL 1ADF510602610A503A609501CONTACTORCONTACTOR+++6226666

ELECTRICAL DIAGRAMSG-4CLASSIC ISCHEMATIC - IDLER PC BOARDEARTH GROUND CONNECTIONMVOLTAGE NETFRAME CONNECTION8R-20NO.10COMMON CONNECTIONTO SOLENOIDLAST

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa