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Lincoln Electric SVM187-A Manual Do Utilizador

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ELECTRICAL DIAGRAMS
G-7
SAE-400 SEVERE DUTY
®
SCHEMATIC - COMPLETE MACHINE - CODE 10856 (G5351)
EN
-1
70
S
O
L
ID
E
D
G
E
G5351
SAE-400
MACHINE SCHEMATIC
NONE
-
DO NOT SCALE THIS DRAWING
EQUIPM
ENT TYPE:
SUBJECT:
SCALE:
NA
CRM38346
1
PAGE ___ OF ___
1
ENGINEERING CONTROLLED
MANUFACTURER:
Yes
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PRO
PRIETARY & CONFIDENTIAL:
t
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
ON A
LL ANGLES IS ± .5 OF A DEGREE
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
UNLESS OTHERWISE SPECIFIED TOLERANCE:
MANUFACTURING TOLERANCE PER E2056
Revised
CHANGE DETAIL:
REFERENCE:
MATERIAL
DISPOSITION:
APPROVAL
DATE:
PROJECT
NUMBER:
DOCUMENT
NUMBER:
DOCUMENT
REVISION:
IF PRINTED
@ A1 SIZE
UNITS:
INCH
1/1/2000
FEI
D. BENDER
-
DRAWN BY:
ENGINEER:
CLEVELAND
APPROVED:
CONTROL:
B
G535
1
LEAD COLOR CODE:
B-BLACK OR GRAY
G-GREEN
O-ORANGE
R-RED OR PINK
U-BLUE
W-WHITE
Y-YELLOW
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
VIEW OF CONNECTOR ON PC BOARD
1 2
6
7
12
LATCH
EX. 12PIN CONNECTOR
LABELS
:
COMMON
FRAME
GROUND
EARTH
GROUND
AUXILIARY
WINDINGS
12 VOLT
BATTERY
START BUTTON
SWITCH
ENGINE
STARTER
+
CURRENT
SENSE
TOROID
+10V
+10v
-
+
30 SEC TIMER
(LOCKS OUT ENGINE
SENSORS AND TIMES ALT
FLASH AT POWER-UP)
Vbatt
Vbatt
LAMP
DRIVE CKT
+12v
RECTI-
FIER
+10v
12 SEC
TIMER
OVERCURRENT
PROT. CKT
POWER
SUPPLY
+10v
Vbatt
+
+
-
AMMETER
B
B
B
235
B
233
THERMOSTART
IGNITER
THERMOSTART
ALTERNATOR
INPUTS
OUTPUTS
B
IGNITION
SWITCH
B
236
B
220
IDLER
SWITCH
5
A
G
LOWER PANEL
GND SCREW
B
237
B
W
W
223
B
B
221
R
LOWER PANEL
GND SCREW
U
222
B
225
B
234
U
226
R
ENGINE FAULT LAMP
5C
G
LOWER PANEL
GND SCREW
B
B
G
G
HOUR
METER
+
_
B
U
5C
B
B
G
G
OIL PRESS
SWITCH
TEMP
SWITCH
2 CR REED
RELAY
B
IDLER
SOLENOID
(SHOWN IN
AUTO IDLE
POSITION)
U
5C
B
B
G
G
B
FUEL INJ PUMP
PRI
SEC
ENGINE TEMP
SWITCH
B
229
G
5
B
LOWER PANEL
GND SCREW
J1-
7
J1-
6
J2-
3
J2-
4
R
J1-
1
J1-
5
J1-
2
J1-1
0
J1-
3
J1-
7
J1-
6
J2-
3
J2-
4
R
J1-
1
J1-
5
J1-
2
J1-
3
TO EXC TERMINAL
ON ENGINE ALT
W
224
FROM
PC BD
J1-3
W
224
B
242
R
240
LOWER PANEL
GND SCREW
FROM
HOUR MTR +
TERMINAL
RELAY
TO PC BD
R-TERMINAL
COMPRESSOR
ENABLE
SWITCH
G
B
241
LOWER PANEL
GND SCREW
G
Y
B
239
G
FROMAM-
METER +
POST
B
10A
FUSE
B
243
PRESSURE
SWITCH
B
85
30
87a
87
86
WELD'N AIR - AIR COMPRESSOR CIRCUIT
COMPRESSOR
CLUTCH
J1-1
0
B
ALTERNATOR
ROTOR
R
W
238
B
201
B
EXCITER
WI
NDING
15A
15A
20A
20A
B
B
B
B
B
W
B
R
W
B
B
TO PCB
J2
CURRENT
SENSE
TOROID
G
G
G
UPPER PANEL
GND SCREW
UPPER PANEL
GND SCREW
UPPER PANEL
GND SCREW
UPPER PANEL
GND SCREW
B
R
POLARITY
SWITCH
1
4
2
3
U
Y
R
600A
P8-2
600
Y-TERMINAL
R
Y
U
W-TERMINA
L
W
W
W
42
P8-3
42
A
W
602
P8-4
602
A
U
602
B
W
W
203
X-TERMINAL
X
B
n.c.
G
G
LO
CAL/
REMOTE
SWITCH
(SHOWN IN
LOCAL
POSITION)
OPTIONAL REMOTE
CONTROL BOX
TO D1
AC POSTS
TO D1
AC POST
D1
D2
-
-
+
+
SHUNT
FIELD
SERIES FIELD
BRUSH POSITION SHOWN AS
VIEWED FROMCONTROL PANEL
WELDING
GENERATOR
A
1
2
E
F
N
N
S
S
N
S
N
S
EL
ECTROD
E
WOR
K
2 CR
REED RELAY
TO PC BD
R-T
ERMINAL
N
U
B
R
POLARITY
SWITCH
U
Y
D2
ALTERNATOR
ROTOR
R
B
201
B
UPPER PANEL
GND SCREW
D1
W
610
610
600
POWER
SUPPLY
+15VDC
608
J1-8
EXC. OVER-
VOLTAGE
PROTECTION
605
J1-7
J1-3
J1-4
600
606
J2-3
510
500
J2-2
2 AMP
PWM
J1-1
667
+140VDC
25V
+15VDC
1/8 AMP
J1-5
J1-6
J1-9
J1-2
77
76
75
521
+140VDC
+15VDC
J2-1
J2-5
J2-6
501
503
509
INPUTS
OUTPUTS
no
vv
c
v
no
no
no
510
613
n.c.
S1
A
602
CR1 CONTACTOR
DRIVE CIRCUIT
SHUNT FIELD
DRIVE CIRCUIT
10
K
HOUR
METER
+ _
G
5
B
LOWER PANEL
GND SCREW
W
238
612
611
POSITIVE
VV
NEG.
C
V
NEG.
vv
c
v
567
vv
c
v
GENERATOR
666
622
R1
25,000
uf
 75v
x
4
C1
C2
C3
C4
621
CR1
COIL
CR1
CONTACTS
vv
c
v
GENERATOR
SHUNT FIELD
30OHMS
100W
602
J1-8
J1-7
J1-3
J1-4
J2-3
J2-2
J1-1
J1-5
J1-6
J1-9
J1-2
J2-1
J2-5
J2-6
TO PC BD
J1-10
229
203
600
A
S1D
S1B
S1C
CV VOLTAGE
CONTROL POT
500 OHMS
50W
500 OHMS
50W
S2
SAE400 INTERFACE WITH
OPTIONAL CV ADAPTER
IDLER/ENGINE SHUTDOWN
CIRCUIT
AUXILIARY POWER
CIRCUIT
ROTOR FIELDAND
FLASH CIRCUIT
WELDCIRCUIT
REMOTE RECEPTACLE
  AND PLUG
IDLE DRIVE
CIRCUIT
FUEL SOLENOID
DRIVE CIRCUIT
ENGINE PROTECTION
SENSE CIRCUIT
WELD& AUX CURRENT
SENSE CIRCUIT
+
-
+
-
+
-
BOARD
POWER
AUXILIARY
CURRENT
SENSE INPUT
WELD
CURRENT
SENSE INPUT
BOARD
POWER
CR1 CONTACTOR
DRIVE INPUT
CR1 CONTACTOR
DRIVE RETURN
ARC VOLTAGE
FEEDBACK
WELDCOMMON
POWER OUTPUT
TO SHUNT
FIELD
CV SWITCH FOR
SHUNT FIELD
FLYWHEEL
DIODE
IDLER/ENGINE
SHUTDOWN PCB
(S
CHEM. # L11006-2C1)
CV ADAPTER
CONTROL PCB
(S
CHEM. # L6922)
+
-
GENERATO
R
LE
AD
BLOCK
N
N
ARMATURE
&
BRUSHES
-
-
+
+
1
5
10
6
J
1
1
2
3
4
J
2
IDLER/ENGINE SHUTDOWN PCB
1
2
3
4
5
6
1
2
3
4
5
6
J
2
7
8
9
J
1
CV ADAPTER
CONTROL PCB
TO D1
AC POST
R
n.c.
n.c.
POLES
max
cw
64ohms +/-
6.4
150 W
max
cc
w
64ohms +/- 6.4
150 W
25OHM
50W
x3
120 OHMS
2.5W
35A
800V
100 OHMS
50W
R3
1A
1000V
max
cc
w
JOB
SELECTOR
  R
HEOSTAT
VARIABLE
REACTOR
CODE MACHINE DESPCRIPTION
10601
SAE400 PERKINS 1004.42 DIESEL
10602
SAE400 WELD -N- AIR PERKINS 1004.42 DIESEL
10856
SAE400 SEVERE DUTY
10884
SAE400 PERKINS (DOMESTIC)
10885
SAE400 WELD -N- AIR PERKINS (CANADIAN)
AUXILIARY OUTPUT
OCV
115/230 VAC + 10% @ 1800RPM
MAX LOAD
3KW @ 100% D.C.
PULL TO LOWIDLE
HI IDLE =1800RPM
LOW IDLE =1100RPM
SWITCH OPENS @ 15+/-3 PSI
8.8 OHMS +/- .88 @25C
TRIP POINT SET AT 220F +/- 4%
55AMP MAX DRAW
COMPRESSOR OUTPUT
DELIVERY
35CFM @ 100PSI @ 60% D.C.@ 1400RPM
MAX PRESSURE
150 PSI (11 GALLON TANK)
OPERATING PRESSURE LOADS @ 90 PSI
UNLOADS @ 130 PSI
120 OHMS
2.5W
1A
1000V
*10vdc =normal operation
*0vdc =shutdown
*10vdc =normal operation
*0vdc =shutdown
*10vdc =noweld current
*0vdc =weld current, pick up
to hi idle
rst
out
t
reset
reset
hi
reset
 lo
t
reset
reset
 hi
reset
 lo
P-CHNL
N-CHNL
10.5-12.5vdc
FLYWHEEL
DIODE
35A
800V
35A
800V
35A
800V
74hz
CENTER OFF =NO WELD OUTPUT
1
4
2
3
(NO AFFECT W/CV
ADAPTER HOOKED UP)
micro switch located
in temp guage
located behind
lower control
panel
located behind
lower control
panel
12.8ms
5.2ms
0v
50-250v
MAX POT/NO LOAD
0v
50-250v
12.8ms
.5ms
MIN POT/NO LOAD
VOLTAGE WAVEFORM : J2-6 to J2-1 INCV MODE
360-440 OHMS
@ 25C
23-24vdc
 in CV
*SEE WAVEFORM
(J2-6 to J2-1)
140vdc
(J2-3 to J1-4)
*140vdc
(J1-8 to J1-4)
*8.6-42vdc
(J1-1 to J1-2)
*12.9vdc
(J1-5 to J1-2)
*3.1vdc
(J1-9 to J1-2)
* NOTE : measurement made in CV mode.
*0vdc
(J2-2 to J1-4)
140vdc (w/ rheo-
stat at max)
140vdc
38.2-40.6 ohms
@ 25C
41.5 ohms +/- 1.0
@ 25C
MIN rheo=54vdc
MAX rheo=140vdc
MIN rheo=86vac
MAX rheo=0vac
4 ohms
24ohms
*11-13vdc
*12-14vdc
*11-13vdc
*12-14vdc
*NOTE : measurement made with respect to frameground.
1.0-2.0 ohms
B
+
ENGINE BLOCK
FRAME
FRAME
located behind
work stud
located behind
control panel
located engine right side
(viewfrom control panel end)
located engine starter side
at air intake manifold
located engine right side
(viewfrom control panel end)
located generator
end of machine
located engine left side
(viewed from control panel end)
located engine left side
(viewed from control panel end)
located behind upper
control panel on
reactor box
located behind upper
control panel on
reactor box
alternator &rotor located at
end of generator
diodes located behind
upper control panel
located behind upper
control panel on
reactor box
located behind upper
control panel on reactor box
located behind
work stud
CVadapter box located on left fuel tank
rail (viewed from control panel end)
NOTE!! : WHEN INSTALLING CV ADAPTER,
"ELECTRODE" STUDBECOMES VV
 "NEGATIVE"
STUD,& "TO WORK" STUDBECOMES
"POSITIVE"
STUD.
positive stud located on right fuel tank
rail (viewed from control panel end)
located behind lower
control panel
WINDING SPEC'S & RESISTANCES
 EXCITER
WINDING
SPEC
RESISTANCE
POWER
ALT-214-3C .230 OHMS @ 25C
QUADRATURE
ALT-214-3B .560 OHMS @ 25C
AUXILIARY (TAIL) ALT-214-3D .424 OHMS @ 25C
ROTOR (4-POLE) ALT-214-3A 41.4+/-1.0 OHMS @ 25C
DIAGRAM
M14262
 GENERATOR
INTERPOLE
S12261-25 N/A
SHUNT FIELD
FKL-5AJ
19.1-20.3 OHMS @ 25C
SERIES FIELD
FKL-420-U N/A
ARMATURE
FKL-37.4M N/A
DIAGRAM
M5570
ALTERNATOR
B
B
OIL PRESS
SWITCH
TEMP
SWITCH
W
224
FROM
PC BD
J1-3
SWITCH OPENS @ 15+/-3 PSI
TRIP POINT SET AT 220F +/- 4%
55AMP MAX DRAW
*10vdc =normal operation
*0vdc =shutdown
*10vdc =normal operation
*0vdc =shutdown
mounted on engine block
belowfuel pump
micro switch located
in temp guage
B
+
located engine right side
(viewfrom control panel end)
U
R
ENGINE FAULT LAMP
5C
G
LOWER PANEL
GND SCREW
B
B
G
G
U
5C
B
B
G
G
227
U
5C
B
B
G
G
B
FUEL INJ PUMP
PRI
SEC
ENGINE TEMP
SWITCH
TO EXC TERMINAL
ON ENGINE ALT
W
224
ENGINE ALT
FLASH & SENSE
4 ohms
24ohms
*11-13vdc
*11.5-12.9vdc
*12-14vdc
*NOTE : measurement made with respect to frameground.
located engine left side
(viewed from control panel end)
+10V
+10v
-
+
30 SEC TIMER
(LOCKS OUT ENGINE
SENSORS AND TIMES ALT
FLASH AT POWER-UP)
Vbatt
LAMP
DRIVE CKT
+12v
J1-
7
J1-
6
J1-1
0
J1-
3
J1-
7
J1-
6
J1-4
J1-9
J1-
3
J1-1
0
FUEL SOLENOID
DRIVE CIRCUIT
ENGINE PROTECTION
SENSE CIRCUIT
t
reset
reset
hi
reset
 lo
P-CHNL
HOUR
METER
+
_
B
229
G
5
B
LOWER PANEL
GND SCREW
*11-13vdc
*11.5-12.9vdc
ENGINE ALT
FLASH & SENSE
CURRENT
SENSE
TOROID
+
-
AMMETER
B
IGNITION
SWITCH
B
236
IDLER
SWITCH
5
A
G
LOWER PANEL
GND SCREW
W
W
R
LOWER PANEL
GND SCREW
U
222
B
B
234
B
2 CR REED
RELAY
B
IDLER
SOLENOID
(SHOWN IN
AUTO IDLE
POSITION)
B
AUXILIARY
CURRENT
SENSE INPUT
WELD
CURRENT
SENSE INPUT
PULL TO LOWIDLE
HI IDLE =1800RPM
LOW IDLE =1100RPM
8.8 OHMS +/- .88 @25C
*10vdc =noweld current
*0vdc =weld current, pick up
to hi idle
10.5-12.5vdc
FLYWHEEL
DIODE
located behind
work stud
located behind
control panel
located engine left side
(viewed from control panel end)
RECTI-
FIER
+10v
12 SEC
TIMER
OVERCURRENT
PROT. CKT
J2-
3
J2-
4
R
J1-
2
J2-
3
J2-
4
R
J1-
2
J1-8
IDLE DRIVE
CIRCUIT
WELD& AUX CURRENT
SENSE CIRCUIT
rst
out
reset
reset
 hi
reset
 lo
N-CHNL
J1-
5
POWER
SUPPLY
+10v
Vbatt
J1-
1
J1-
1
POWER
SUPPLY
+10v
Vbatt
J1-
1
J1-
5
J1-
1
J1-
5
J1-
5
POWER
SUPPLY
+10v
Vbatt
J1-
1
J1-
1
5
A
G
LOWER PANEL
GND SCREW
5
A
G
LOWER PANEL
GND SCREW
IDLER/ENGINE
SHUTDOWN PCB
(S
CHEM. # L11006-2C1)
located behind lower
control panel
IDLER/ENGINE
SHUTDOWN PCB
(S
CHEM. # L11006-2C1)
located behind lower
control panel
12 VOLT
BATTERY
START BUTTON
SWITCH
ENGINE
STARTER
+
POWER
SUPPLY
+10v
Vbatt
+
+
-
AMMETER
B
B
B
235
ALTERNATOR
B
IGNITION
SWITCH
B
236
B
220
IDLER
SWITCH
5
A
G
LOWER PANEL
GND SCREW
B
237
(SHOWN IN
AUTO IDLE
POSITION)
J1-
1
J1-
5
J1-
1
J1-
5
W
224
FROM
PC BD
J1-3
BOARD
POWER
55AMP MAX DRAW
*12-14vdc
B
+
ENGINE BLOCK
FRAME
FRAME
located engine right side
(viewfrom control panel end)
located engine right side
(viewfrom control panel end)
located generator
end of machine
ALTERNATOR
W
224
FROM
PC BD
J1-3
55AMP MAX DRAW
B
+
located engine right side
(viewfrom control panel end)
+
-
AMMETER
B
IGNITION
SWITCH
B
236
IDLER
SWITCH
5
A
G
LOWER PANEL
GND SCREW
(SHOWN IN
AUTO IDLE
POSITION)
J1-
5
POWER
SUPPLY
+10v
Vbatt
J1-
1
J1-
1
POWER
SUPPLY
+10v
Vbatt
J1-
1
J1-
5
J1-
1
J1-
5
J1-
5
POWER
SUPPLY
+10v
Vbatt
J1-
1
J1-
1
5
A
G
LOWER PANEL
GND SCREW
5
A
G
LOWER PANEL
GND SCREW
IDLER/ENGINE
SHUTDOWN PCB
(S
CHEM. # L11006-2C1)
located behind lower
control panel
IDLER/ENGINE
SHUTDOWN PCB
(S
CHEM. # L11006-2C1)
located behind lower
control panel
IDLER/ENGINE
SHUTDOWN PCB
(S
CHEM. # L11006-2C1)
located behind lower
control panel
30 SEC TIMER
Vbatt
J1-
3
J1-
3
TO EXC TERMINAL
ON ENGINE ALT
W
224
t
reset
TO EXC TERMINAL
ON ENGINE ALT
W
224
ENGINE ALT
FLASH & SENSE
*11.5-12.9vdc
30 SEC TIMER
(LOCKS OUT ENGINE
SENSORS AND TIMES ALT
FLASH AT POWER-UP)
Vbatt
J1-
3
J1-
3
t
reset
reset
hi
reset
 lo
*11.5-12.9vdc
ENGINE ALT
FLASH & SENSE
HOUR
METER
+
_
B
229
ALTERNATOR
ROTOR
R
W
238
B
201
B
UPPER PANEL
GND SCREW
D1
+
-
35A
800V
120 OHMS
2.5W
1A
1000V
140vdc
41.5 ohms +/- 1.0
@ 25C
*11-13vdc
located behind upper
control panel on
reactor box
located behind upper
control panel on
reactor box
diodes located behind
upper control panel
HOUR
METER
+
_
B
229
*11-13vdc
30 SEC TIMER
Vbatt
J1-1
0
J1-1
0
FUEL SOLENOID
DRIVE CIRCUIT
t
reset
reset
hi
P-CHNL
30 SEC TIMER
Vbatt
J1-1
0
J1-1
0
FUEL SOLENOID
DRIVE CIRCUIT
t
reset
reset
hi
P-CHNL
30 SEC TIMER
t
reset
30 SEC TIMER
(LOCKS OUT ENGINE
SENSORS AND TIMES ALT
FLASH AT POWER-UP)
t
reset
reset
hi
reset
 lo
IDLER/ENGINE
SHUTDOWN PCB
(S
CHEM. # L11006-2C1)
located behind lower
control panel
IDLER/ENGINE
SHUTDOWN PCB
(S
CHEM. # L11006-2C1)
located behind lower
control panel
IDLER/ENGINE
SHUTDOWN PCB
(S
CHEM. # L11006-2C1)
located behind lower
control panel
IDLER/ENGINE
SHUTDOWN PCB
(S
CHEM. # L11006-2C1)
located behind lower
control panel
IDLER/ENGINE
SHUTDOWN PCB
(S
CHEM. # L11006-2C1)
located behind lower
control panel
IDLER/ENGINE
SHUTDOWN PCB
(S
CHEM. # L11006-2C1)
located behind lower
control panel
POWER
SUPPLY
+10v
Vbatt
J1-
1
J1-
5
J1-
1
J1-
5
J1-
5
POWER
SUPPLY
+10v
Vbatt
J1-
1
J1-
1
POWER
SUPPLY
+10v
Vbatt
J1-
1
J1-
5
J1-
1
J1-
5
J1-
5
POWER
SUPPLY
+10v
Vbatt
J1-
1
J1-
1
POWER
SUPPLY
+10v
Vbatt
J1-
1
J1-
5
J1-
1
J1-
5
J1-
5
POWER
SUPPLY
+10v
Vbatt
J1-
1
J1-
1
POWER
SUPPLY
+10v
Vbatt
J1-
1
J1-
5
J1-
1
J1-
5
J1-
5
POWER
SUPPLY
+10v
Vbatt
J1-
1
J1-
1
*NOTE : measurement made with respect to frameground.
*NOTE : measurement made with respect to frameground.
*NOTE : measurement made with respect to frameground.
AUXILIARY
WINDINGS
15A
15A
20A
20A
B
B
B
B
B
W
B
R
W
B
B
TO PCB
J2
CURRENT
SENSE
TOROID
G
G
G
UPPER PANEL
GND SCREW
UPPER PANEL
GND SCREW
UPPER PANEL
GND SCREW
AUXILIARY POWER
CIRCUIT
AUXILIARY OUTPUT
OCV
115/230 VAC + 10% @ 1800RPM
MAX LOAD
3KW @ 100% D.C.
alternator &rotor located at
end of generator
ROTOR FIELDAND
FLASH CIRCUIT
EXCITER
WI
NDING
B
R
1
4
2
3
U
Y
R
600A
P8-1
600
Y-TERMINAL
R
Y
U
W-TERMINA
L
W
W
W
42
P8-3
42
A
W
602
P8-4
602
A
U
602
B
W
W
203
X-TERMINAL
X
B
n.c.
G-TERMINAL
G
41A
UPPER PANEL
GND SCREW
G
LO
CAL/
REMOTE
SWITCH
(SHOWN IN
LOCAL
POSITION)
OPTIONAL REMOTE
CONTROL BOX
TO D1
AC POSTS
TO D1
AC POST
D2
SHUNT
FIELD
WELDING
GENERATOR
A
1
2
E
F
U
500 OHMS
50W
GENERATOR SHUNT
FIELDCIRCUIT
REMOTE RECEPTACLE
  AND PLUG
+
-
GENERATO
R
LE
AD
BLOCK
N
N
(SHOWN IN
NEGATIVE
POISTION)
TO D1
AC POST
R
n.c.
n.c.
64ohms +/-
6.4
150 W
max
cc
w
64ohms +/- 6.4
150 W
25OHM
50W
x3
max
cc
w
JOB
SELECTOR
  R
HEOSTAT
35A
800V
CENTER OFF =NO WELD OUTPUT
38.2-40.6 ohms
@ 25C
MIN rheo=54vdc
MAX rheo=140vdc
MIN rheo=86vac
MAX rheo=0vac
located behind upper
control panel on
reactor box
located behind upper
control panel on reactor box
flywheel
diode
-
-
+
+
SERIES FIELD
BRUSH POSITION SHOWN AS
VIEWED FROMCONTROL PANEL
WELDING
GENERATOR
A
1
2
E
F
N
N
S
S
N
S
N
S
EL
ECTROD
E
WOR
K
2 CR
REED RELAY
WELDCIRCUIT
GENERATO
R
LE
AD
BLOCK
ARMATURE
&
BRUSHES
POLES
VARIABLE
REACTOR
located behind
work stud
output studs located on right fuel tank
rail (viewed from control panel end)
(electrode closest to control panel)
WELDING
GENERATOR
A
1
2
E
F
GENERATO
R
LE
AD
BLOCK
B
R
POLARITY
SWITCH
U
Y
D2
ALTERNATOR
ROTOR
R
B
201
B
UPPER PANEL
GND SCREW
D1
W
610
610
600
POWER
SUPPLY
+15VDC
608
J1-8
EXC. OVER-
VOLTAGE
PROTECTION
605
J1-7
J1-3
J1-4
600
606
J2-3
510
500
J2-2
2 AMP
PWM
J1-1
667
+140VDC
25V
+15VDC
1/8 AMP
J1-5
J1-6
J1-9
J1-2
77
76
75
521
+140VDC
+15VDC
J2-1
J2-5
J2-6
501
503
509
INPUTS
OUTPUTS
vv
c
v
no
no
no
510
613
n.c.
S1
A
CR1 CONTACTOR
DRIVE CIRCUIT
SHUNT FIELD
DRIVE CIRCUIT
10
K
HOUR
METER
+ _
G
5
B
LOWER PANEL
GND SCREW
W
238
612
611
POSITIVE
VV
NEG.
C
V
NEG.
vv
c
v
567
vv
c
v
GENERATOR
666
622
R1
25,000
uf
 75v
x
4
C1
C2
C3
C4
CR1
COIL
CR1
CONTACTS
vv
c
v
GENERATOR
SHUNT FIELD
30OHMS
100W
J1-8
J1-7
J1-3
J1-4
J2-3
J2-2
J1-1
J1-5
J1-6
J1-9
J1-2
J2-1
J2-5
J2-6
TO PC BD
J1-10
229
203
600
A
S1D
S1B
S1C
CV VOLTAGE
CONTROL POT
500 OHMS
50W
S2
+
-
BOARD
POWER
CR1 CONTACTOR
DRIVE INPUT
CR1 CONTACTOR
DRIVE RETURN
ARC VOLTAGE
FEEDBACK
WELDCOMMON
POWER OUTPUT
TO SHUNT
FIELD
CV SWITCH FOR
SHUNT FIELD
FLYWHEEL
DIODE
CV ADAPTER
CONTROL PCB
(S
CHEM. # L6922)
+
-
-
-
+
+
1
2
3
4
5
6
1
2
3
4
5
6
J
2
7
8
9
J
1
CV ADAPTER
CONTROL PCB
max
cw
120 OHMS
2.5W
100 OHMS
50W
R3
1A
1000V
35A
800V
35A
800V
74hz
CV WELD OUTPUT
MIN TO MAX OCV
8-41vdc
WELD RANGE
15-35vdc
MAX LOAD
400A @ 35V @ 60% D.C.
500A @ 35V @ 35% D.C.
1
4
2
3
(NO AFFECT W/CV
ADAPTER HOOKED UP)
12.8ms
5.2ms
0v
50-250v
MAX POT/NO LOAD
0v
50-250v
12.8ms
.5ms
MIN POT/NO LOAD
VOLTAGE WAVEFORM : J2-6 to J2-1 INCV MODE
360-440 OHMS
@ 25C
23-24vdc
 in CV
*SEE WAVEFORM
(J2-6 to J2-1)
140vdc
(J2-3 to J1-4)
*140vdc
(J1-8 to J1-4)
*8.6-42vdc
(J1-1 to J1-2)
*12.9vdc
(J1-5 to J1-2)
*3.1vdc
(J1-9 to J1-2)
* NOTE : measurement made in CV mode.
*0vdc
(J2-2 to J1-4)
140vdc (w/ rheo-
stat at max)
VVneg stud located on right fuel tank
rail (viewed from control panel end)
NOTE!! : WHEN INSTALLING CV ADAPTER,
"ELECTRODE" STUDBECOMES VV
 "NEGATIVE"
STUD,& "TO WORK" STUDBECOMES
"POSITIVE"
STUD.
positive stud located on right fuel tank
rail (viewed from control panel end)
flywheel
diode
B
R
POLARITY
SWITCH
U
Y
D2
ALTERNATOR
ROTOR
R
B
201
B
UPPER PANEL
GND SCREW
D1
W
610
J2-3
510
+140VDC
+140VDC
J2-5
J2-6
503
509
INPUTS
OUTPUTS
vv
c
v
S1
A
602
HOUR
METER
+ _
G
5
B
LOWER PANEL
GND SCREW
W
238
612
611
POSITIVE
VV
NEG.
GENERATOR
CR1
CONTACTS
vv
c
v
GENERATOR
SHUNT FIELD
602
J2-3
J2-5
J2-6
TO PC BD
J1-10
229
203
600
A
S1C
500 OHMS
50W
+
-
BOARD
POWER
POWER OUTPUT
TO SHUNT
FIELD
FLYWHEEL
DIODE
CV ADAPTER
CONTROL PCB
(S
CHEM. # L6922)
+
-
-
-
+
+
1
2
3
4
5
6
1
2
3
4
5
6
J
2
7
8
9
J
1
CV ADAPTER
CONTROL PCB
120 OHMS
2.5W
R3
1A
1000V
35A
800V
35A
800V
1
4
2
3
(NO AFFECT W/CV
ADAPTER HOOKED UP)
*SEE WAVEFORM
(J2-6 to J2-1)
140vdc
(J2-3 to J1-4)
* NOTE : measurement made in CV mode.
140vdc (w/ rheo-
stat at max)
NOTE!! : WHEN INSTALLING CV ADAPTER,
"ELECTRODE" STUDBECOMES VV
 "NEGATIVE"
STUD,& "TO WORK" STUDBECOMES
"POSITIVE"
STUD.
positive stud located on right fuel tank
rail (viewed from control panel end)
flywheel
diode
B
R
POLARITY
SWITCH
U
Y
D2
R
B
201
B
UPPER PANEL
GND SCREW
D1
W
610
J2-3
510
+140VDC
+140VDC
J2-5
J2-6
503
509
INPUTS
OUTPUTS
vv
c
v
S1
A
HOUR
METER
+ _
G
5
B
LOWER PANEL
GND SCREW
W
238
612
611
POSITIVE
GENERATOR
CR1
CONTACTS
vv
c
v
GENERATOR
SHUNT FIELD
J2-3
J2-5
J2-6
TO PC BD
J1-10
229
203
600
A
S1C
500 OHMS
50W
+
-
BOARD
POWER
POWER OUTPUT
TO SHUNT
FIELD
FLYWHEEL
DIODE
CV ADAPTER
CONTROL PCB
(S
CHEM. # L6922)
+
-
-
-
+
+
1
2
3
4
5
6
1
2
3
4
5
6
J
2
7
8
9
J
1
CV ADAPTER
CONTROL PCB
120 OHMS
2.5W
R3
1A
1000V
35A
800V
35A
800V
1
4
2
3
(NO AFFECT W/CV
ADAPTER HOOKED UP)
*SEE WAVEFORM
(J2-6 to J2-1)
140vdc
(J2-3 to J1-4)
* NOTE : measurement made in CV mode.
140vdc (w/ rheo-
stat at max)
NOTE!! : WHEN INSTALLING CV ADAPTER,
"ELECTRODE" STUDBECOMES VV
 "NEGATIVE"
STUD,& "TO WORK" STUDBECOMES
"POSITIVE"
STUD.
positive stud located on right fuel tank
rail (viewed from control panel end)
flywheel
diode
no
no
no
no
no
no
CVneg stud located on
adapter box mounted on left
fuel tank rail (viewed from
control panel end)
VVneg stud located on right fuel tank
rail (viewed from control panel end)
VVneg stud located on right fuel tank
rail (viewed from control panel end)
CV WELD OUTPUT
MIN TO MAX OCV
8-41vdc
WELD RANGE
15-35vdc
MAX LOAD
400A @ 35V @ 60% D.C.
500A @ 35V @ 35% D.C.
CC WELD OUTPUT
MIN TO MAX OCV 57-97VDC @ 1800 RPM
WELD RANGE
80-575 AMPS
MAX LOAD
400A @ 40V @ 60% D.C. (1725 RPM)
VV MODE – POWER UP SEQUENCE
Exciter rotor is flashed from 12v battery supply at
machine power up, exciter winding builds up power.
CR1 contactor and PC board do not power up.
Shunt fields receive power thru PC board.
Rheostat controls current thru the shunts.
TO D1AC
POST
TO P8-2
TO D1AC
POST
TO P8-2
TO D1AC
POST
TO P8-2
CV MODE – POWER UP SEQUENCE
Exciter rotor is flashed from 12v battery supply at
machine power up, exciter winding builds up power.
Exciter winding powers D2 bridge and CR1 contactor
drive circuit on PC board at J1 pins 4 & 8.
CR1 closes, applying power to PC board at J2 pins 2 & 3
and disconnecting flashing circuit.
PC Board PWM circuit regulates output voltage by using
voltage feedback from J1 pin 1 and control pot at J1 pin 6
to control current thru the shunt fields.
Note!!: Rheostat must be set to max for CV operation.
IDLER/ENGINE SHUTDOWN PC BOARD
POWER UP SEQUENCE
Upon receiving power, circuit to flash alternator is closed and 
engine protection is bypassed.  After time delay, alternator 
flashing circuit opens up and engine protection is enabled.
Note!!:  After time delay when engine protection is enabled, if
the engine is not started, oil pressure will be low, the fuel 
solenoid will drop out, and the engine fault light will turn on
because of the engine protection circuit.
CVneg stud located on
adapter box mounted on left
fuel tank rail (viewed from
control panel end)
SHOWN FOR REFERENCE
ONLY - NOT ACTUALLY PAR
T OF
CV ADAPTER
SHOWN FOR REFERENCE
ONLY - NOT ACTUALLY PAR
T OF
CV ADAPTER
CVneg stud located on
adapter box mounted on left
fuel tank rail (viewed from
control panel end)
S2 large switch located on
face of CVadapter box
S2 large switch located on
face of CVadapter box
Capacitor bank and bleeder resistor
located inside CVadapter box
Capacitor bank and bleeder resistor
located inside CVadapter box
located inside CV
adapter box
located inside CV
adapter box
S1 small switch
located on face of
CVadapter box
located inside CV
adapter box
CR1 located inside
CVadapter box
CR1 located inside
CVadapter box
LOWER PANEL
GND SCREW
LOWER PANEL
GND SCREW
top right of
generator frame
top right of
generator frame
located upper Rt
hand side behind
control panel
located upper Rt
hand side behind
control panel
top right of
generator frame
located upper Lt
hand side behind
control panel
located upper Lt
hand side behind
control panel
CR1 located inside
CVadapter box
CR1 located inside
CVadapter box
S1 small switch
located on face of
CVadapter box
S1 small switch
located on face of
CVadapter box
S1 small switch
located on face of
CVadapter box
S1 small switch
located on face of
CVadapter box
S1 small switch
located on face of
CVadapter box
S1 small switch
located on face of
CVadapter box
CR1 located inside
CVadapter box
located on face of
CVadapter box
located on face of
CVadapter box
SHOWN FOR REFERENCE
ONLY - NOT ACTUALLY PAR
T OF
CV ADAPTER
S1 small switch
located on face of
CVadapter box
located inside CV
adapter box
CR1 located inside
CVadapter box
S1 small switch
located on face of
CVadapter box
S1 small switch
located on face of
CVadapter box
located lower Lt hand
side of control panel
located lower Lt hand
side of control panel
located lower middle
of control panel
located lower middle
of control panel
located on
front panel
located on
front panel
located on
front panel
located on
front panel
B
242
R
240
LOWER PANEL
GND SCREW
FROM
HOUR MTR +
TERMINAL
RELAY
TO PC BD
R-TERMINAL
COMPRESSOR
ENABLE
SWITCH
G
B
241
LOWER PANEL
GND SCREW
G
Y
B
239
G
FROMAM-
METER +
POST
B
10A
FUSE
B
243
PRESSURE
SWITCH
B
85
30
87a
87
86
WELD'N AIR - AIR COMPRESSOR CIRCUIT
COMPRESSOR
CLUTCH
no
COMPRESSOR OUTPUT
DELIVERY
35CFM @ 100PSI @ 60% D.C.@ 1400RPM
MAX PRESSURE
150 PSI (11 GALLON TANK)
OPERATING PRESSURE LOADS @ 90 PSI
UNLOADS @ 130 PSI
located behind
lower control
panel
located behind
lower control
panel
loacted lower
front panel
loacted lower
front panel
loacted lower
front panel
loacted lower
front panel
COMPRESSOR
CI
RCUIT LAMP
ON=ACTIVE
COMPRESSOR
CI
RCUIT LAMP
ON=ACTIVE
FUEL INJ PUMP COILS
DO NOT HAVE OVER-
CURRENT PROTECTION
FUEL INJ PUMP COILS
DO NOT HAVE OVER-
CURRENT PROTECTION
mounted on engine block
belowfuel pump
output studs located on right fuel tank
rail (viewed from control panel end)
(electrode closest to control panel)
G
LOWER PANEL
GND SCREW
230V
RECEPTACLE
CB2
CB4
CB3
CB1
115V
RECEPTACLE
41
G-7
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.