Lincoln Electric SVM125-A - Manual

Lincoln Electric SVM125-A

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Table of Contents:

  • Page 2 – SAFETY; CLASSIC II; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
  • Page 3 – ii; ELECTRIC SHOCK can kill.
  • Page 4 – iii
  • Page 5 – iv; PRÉCAUTIONS DE SÛRETÉ
  • Page 6 – MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
  • Page 7 – TABLE OF CONTENTS; Tilting
  • Page 8 – INSTALLATION; TECHNICAL SPECIFICATIONS - CLASSIC II
  • Page 9 – SAFETY PRECAUTIONS; LOCATION AND VENTILATION; STORING; Maintenance section of
  • Page 10 – PRE-OPERATION ENGINE SERVICE; Operation and Maintenance sections of
  • Page 11 – Design capacity of the undercarriage vs. the weight; CAUTION
  • Page 12 – WELDING CABLE CONNECTIONS; • Loose connections will cause the output terminals to; FIGURE A.1 - CLASSIC II OUTPUT CONNECTIONS
  • Page 13 – MACHINE GROUNDING; Accessories section of this manual for details.; for the GFCI Receptacle kit.; CIRCUIT BREAKERS; may tend to trip at lower loads than it would normally.
  • Page 14 – NOTES
  • Page 15 – Operation
  • Page 16 – GENERAL DESCRIPTION; OPERATION
  • Page 17 – RECOMMENDED APPLICATIONS; WELDER; Welding; GENERATOR; Engine Operation in the Operation; DESIGN FEATURES
  • Page 18 – • The Classic II is not recommended for any process-
  • Page 19 – WELDER/GENERATOR CONTROLS; Control of Welding Current for; CONTROLS AND SETTINGS
  • Page 20 – CONTROL OF WELDING CURRENT; FIGURE B.2 – CURRENT CONTROLS
  • Page 21 – DIESEL ENGINE CONTROLS
  • Page 22 – ENGINE OPERATION; BEFORE STARTING THE ENGINE; Check and fill the engine oil level:; Maintenance section of this manual.; Check and fill the engine fuel tank:; Remove the fuel tank cap.; STARTING THE ENGINE
  • Page 23 – STOPPING THE ENGINE; Place the IGNITION switch in the OFF position.; COLD WEATHER STARTING; If the engine is frequently started below 10
  • Page 24 – WELDING OPERATION; GENERAL INFORMATION; Technical; engine high speed is controlled by the governor.
  • Page 26 – Select the appropriate electrode.; Engine Operation in; this section of the manual.; Control of Welding Current in this; section of the manual.
  • Page 27 – AUXILIARY POWER; Generator Power; To use the generator as an auxiliary power supply:
  • Page 29 – Accessories
  • Page 30 – ACCESSORIES
  • Page 32 – and duty cycle of application.; NOTE: Figure C.1 shows the electrode connected; Connect the K867 Universal Adapter to the K291 or; NOTE: For remote control, a K775 remote control is; CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS; CLASSIC II/LN-7 WITH K867 ADAPTER CONNECTION DIAGRAM
  • Page 33 – Connect the electrode cable from the LN-7 to the; NOTE: Welding cable must be sized for current and; duty cycle of application.; NOTE: Figure C.2 shows the electrode connected for; Connect the input cable from the K584-XX Input; CLASSIC II/LN-7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM
  • Page 34 – Connect the electrode cable from the LN-25 to the; NOTE: Figure C.3 shows the electrode connected for; Connect the K867 Universal adapter to the K432-L
  • Page 35 – Connect the electrode cable from the LN-25 to the; NOTE: Welding cable must be sized for current
  • Page 37 – Maintenance
  • Page 38 – ENGINE MAINTENANCE; MAINTENANCE
  • Page 39 – Change the Oil section,
  • Page 40 – TIGHTENING THE FAN BELT:
  • Page 41 – • Check fuel lines and clamps.
  • Page 42 – BATTERY MAINTENANCE; CLEANING THE BATTERY
  • Page 43 – COMMUTATOR AND BRUSHES:; The generator; IDLER MAINTENANCE
  • Page 45 – FIGURE E.1 – CLASSIC II BLOCK LOGIC DIAGRAM
  • Page 46 – THEORY OF OPERATION
  • Page 49 – DC GENERATOR MACHINES
  • Page 52 – HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; The; Electrical Diagrams Section Table of
  • Page 53 – PC BOARD TROUBLESHOOTING PROCEDURES
  • Page 54 – TROUBLESHOOTING GUIDE; OUTPUT PROBLEMS
  • Page 55 – Observe Safety Guidelines; Check the welding cables for; Shunt Field; Check the continuity of the
  • Page 56 – detailed in the beginning of this manual.; The armature commutator may
  • Page 57 – Check the AC auxiliary output
  • Page 58 – FUNCTION PROBLEMS; Idler Solenoid
  • Page 60 – Check the welding cables and
  • Page 61 – ENGINE PROBLEMS
  • Page 62 – WELDING PROBLEMS
  • Page 63 – ALTERNATOR ROTOR TEST; TEST DESCRIPTION
  • Page 64 – FIGURE F.1 – ALTERNATOR COVER REMOVAL; TEST PROCEDURE; ful to clear the leads.
  • Page 65 – Working from the left side of the machine,
  • Page 67 – SHUNT FIELD WINDING TEST
  • Page 68 – FIGURE F.4 – PLUG P10 LOCATIONS
  • Page 69 – FIGURE F.5 – SHUNT LEAD RESISTANCE CHECK; TAB
  • Page 70 – IDLER SOLENOID TEST
  • Page 72 – ENGINE THROTTLE ADJUSTMENT TEST
  • Page 73 – STROBE; Strobe Tach Method; Turn the engine welder OFF.
  • Page 74 – Frequency Counter Method
  • Page 75 – COLLAR
  • Page 76 – FLASHING THE FIELDS; DESCRIPTION
  • Page 77 – PROCEDURE; Turn engine welder OFF.; DO NOT remove brush holder.; Replace the exciter cover.; Troubleshooting Guide located in this
  • Page 78 – SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY); HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM; volts
  • Page 79 – NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM; HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AND SELECTOR
  • Page 80 – TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM; MACHINE LOADED – SELECTOR SWITCH AT MAXIMUM POSITION; MACHINE LOADED TO 250 AMPS AT 40 VDC
  • Page 82 – ALTERNATOR ROTOR REMOVAL; FIGURE F.11 – CASE FRONT REMOVAL PREPARATION; There are latches on both sides.
  • Page 83 – FIGURE F.12 – FUEL TANK REMOVAL; Turn off the fuel at the fuel bowl and remove
  • Page 84 – FIGURE F.13 – OUTPUT TERMINAL STRAP AND CASE FRONT REMOVAL; Carefully lift the case front assembly up from
  • Page 85 – FIGURE F.14 – ALTERNATOR COVER REMOVAL; on the left side of the alternator cover.
  • Page 86 – FIGURE F.15 – ROTOR REMOVAL; NUT; Bend the flat washer away from the rotor
  • Page 87 – Replacement
  • Page 88 – ALTERNATOR STATOR REMOVAL AND REPLACEMENT
  • Page 89 – ALTERNATOR STATOR REMOVAL AND; FIGURE F.16 – COMMUTATOR WRAP-AROUND REMOVAL; Alternator Rotor Removal
  • Page 90 – ALTERNATOR STATOR REMOVAL; CIRCUIT BREAKER
  • Page 91 – FIGURE F.19 - GENERATOR BRUSH HOLDER CABLE REMOVAL; GENERNATOR
  • Page 94 – GENERATOR FRAME REMOVAL; FIGURE F.21 – GENERATOR LEAD AND CABLE CONNECTIONS; SELECTOR; Disconnect the blue and the brown wires at
  • Page 95 – FIGURE F.22 – FRAME MOUNTING DETAILS
  • Page 97 – GENERATOR ARMATURE REMOVAL; FIGURE F.23 – BLOWER PADDLE REMOVAL; BLOWER PADDLE; Make sure the engine is supported with the
  • Page 98 – RETEST AFTER REPAIR; ENGINE OUTPUT
  • Page 99 – ELECTRICAL DIAGRAMS
  • Page 101 – R E M O T E C O N T R O L ( O P T I O N A L )
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SVM125-A

October 1996

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation .
. . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.

SERVICE MANUAL

World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

Sales and Service through subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100

For use with machine code numbers 9805 to 10220

CLASSIC II

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RETURN TO MAIN INDEX

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Summary

Page 2 - SAFETY; CLASSIC II; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY i i CLASSIC II FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. _____________________________________...

Page 3 - ii; ELECTRIC SHOCK can kill.

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY ii ii CLASSIC II ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield a...

Page 4 - iii

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC CLASSIC II FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Elec...

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