Electrical diagrams, K924-5 remote control (optional), G-16 – Lincoln Electric CLASSIC SVM194-A Manuel d'utilisation

Page 222

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ELECTRICAL DIAGRAMS

G-16

CLASSIC® 300D & 300G

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

OIL PRESSURE SWITCH / SENDER

TEMPERATURE SWITCH / SENDER

AMMETER

ENGINE CONTROL UNIT (ECU)

ENGINE

PROTECTION
LIGHT

ALTERNATOR

NEGATIVE OUTPUT

TERMINAL

POSITIVE OUTPUT

TERMINAL

4
3
2

GENERATOR LEAD BLOCK

SHOWN AS VIEWED WITH

ENGINE IN THIS DIRECTION

INTERPOLE

COILS

SHUNT

FIELD

SERIES FIELD

TYPICAL CURRENT

DRAW IS 40 AMPS

HOUR METER

12 11 10 9 8 7 6 5 4 3 2 1

P10

SWITCH CLOSES
AT 6+/-2 PSI

SENDER OPERATION:

0 PSI -> 10+/-5 OHMS
40PSI -> 105+/-5 OHMS
80 PSI -> 187+/-5 OHMS

FJW-5AP
COIL PAIR:

25.2 - 26.7
OHMS EACH

FLYBACK DIODE PREVENTS
VOLTAGE SPIKES IN SHUNT FIELD
FROM DAMAGING LOCAL/REMOTE
TOGGLE SWITCH WHEN SWITCHED

SHOWN IN LOCAL
POSITION

3 TURNS

2 TURNS

SENSOR GROUNDS LEAD
ON SENSE OF WELD OR

AUXILIARY LOAD

RHEOSTAT

REMOTE

RECEPTACLE

LOCAL / REMOTE
SWITCH

SWITCH CLOSES

AT 230v+/-6vF

SENDER OPERATION:

140vF -> 134+/-13.5 OHMS

194vF -> 51.2+/-4.3 OHMS

212vF -> 38.5+/-3 OHMS

5 3

64+/-6.4 OHMS MAX

WITH AC AUXILIARY POWER,

ROUTING DIRECTIONS OF THESE

LEADS DOES NOT MATTER

BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL

COLOR: RED

12 VOLT
NORMALLY OFF

SHOWN IN "OFF"

POSITION

51C

50A

51A

212D

200

212A

212B

844A

841

844

67A

602B

602

SELECTOR SWITCH

90-MIN

130-80

190-120

240-160

220-MAX

WELDING
GENERATOR

CCW

-40 TO 40 AMPS

AMMETER SHOWS FULL

DISCHARGE WHILE PRESSING

GLOW PLUG SWITCH

40 AMP / 12 VOLT

IG
B

GLOW PLUGS

12.6 VOLTS MIN

AT REST

14-14.5 VOLTS
WHILE RUNNING

BACK, BOTTOM

OFMACHINE

JUMPER PLUG IS FOR CONNECTION

TO WIRE FEED MODULE

LOCATEDBEHINDUPPERPORTIONOFCONTROLPANEL

LOCATEDBEHINDUPPERLEFT

PORTIONOFCONTROLPANEL

TYPICAL OCV (WARM MACHINE):
94-99.0 VOLTS AT MAX RHEOSTAT

44-54.5 VOLTS AT MIN RHEOSTAT

DRIVER
CIRCUITS

JUMPERPLUGISWIRE-TIEDUP

BEHINDLOCAL/ REMOTESWITCHON

RIGHTSIDEOFMACHINE(ASVIEWED

FROMCONTROLPANEL)

SENDER IS APPROX.

500 OHMS AT 70vF

WATER

TEMP.
SENSOR

ENGINE

SPEED

SENSOR

60F

IGNITION

SWITCH

212C

START

BUTTON

52A

52B

STARTER
RELAY

RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY
OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED

WHEN THE IGNITION SWITCH IS "ON" AND THE ECU

SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT
DOWN DUE TO A FAULT

(EVEN IF THAT CONDITION

DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING
OUT OF FUEL),

THE IGNITION SWITCH WILL NEED TO BE

TURNED OFF THEN BACK ON TO RESTART THE ENGINE.

10,000 +/- 1,000 OHMS MAX

TURN POT COUNTERCLOCKWISE TO

REDUCE RESISTANCE AND SUBSEQUENTLY

REDUCE RPM BY UP TO 150RPM

RATED VOLTAGE: 12V

RATED CURRENT: 22mA MAX

SENSOR OPERATION:

-4vF -> 18.80 kOHMS

104vF -> 1.14 kOHMS

212vF -> .16 kOHMS

RATED VOLTAGE: 12V

RATED CURRENT: 4.5A(MAX.)-TERMINAL #15
LEAKAGE CURRENT 10micro A (MAX.)-TERMINAL #16

RATED VOLTAGE: 12V

RATED CURRENT: 2A

COIL RESISTENCE:

2.8 +/- .28 OHMS AT 20vC

ENERGIZED FOR RUN

DE-ENERGIZED FOR STOP

ACTUATOR CONTROLS RPM

MECHANICAL STOP WILL SHUT

DOWN THE ENGINE AT 115%

OF RATED SPEED.

841A

212E

51B

70A

70B

CONNECT TO
GROUND FOR
800RPM

CONNECT TO

GROUND FOR
1600RPM, LEAVE
UNCONNECTED

FOR 1800RPM

610A

215

810

820

SLIP RINGS

CB3

CB1

214

GND-E

CB4

20A

15A

400F

11A

11C

EXCITER STATOR

(ALTERNATOR)

11B

230 VOLT

RECEPTACLE

POSITIVE SLIP RING
IS NEAREST TO IRON

EXCITER REVOLVING
FIELD (ROTOR)

400E

400D

15A

610

600B

600A

600

602A

67B

60E

INTERPOLE

COILS

ACTUATOR

60A

CCW

RPM CONTROL POTENTIOMETER

WIRE-TIEDTOHARNESS

BEHINDCONTROLPANEL

FUSE

BOTHOPENLEADSAREWIRE-TIEDINSIDETHEHARNESSBEHINDCONTROLPANEL

SHOWN IN "AUTO

IDLE" POSITION

IDLER SWITCH

GND-B

841B

WINDING SPEC: ALT-241-3A

40.5 - 42.5 OHMS AT 25C

EXCITER CIRCUIT

LEAD 21A TO 21B

WINDING SPEC: ALT-214-2B
.488 OHMS MAX AT 25C

115 VOLT CIRCUIT

LEAD 810 TO 820

WINDING SPEC: ALT-214-2C
.230 OHMS MAX AT 25C

115 VOLT CIRCUIT

LEAD 820 TO 830

WINDING SPEC: ALT-214-2D
.424 OHMS MAX AT 25C

LIGHT CODE

FAILURE DETECTED

POSSIBLE CAUSE - CORRECTIVE MEASURE

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
FAULTY OIL PRESSURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS RUNNING
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED - CHECK
BROKEN OR LOOSE BELT - INSPECT
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE SHORTED TO GROUND - CHECK
FAULTY ALTERNATOR - CHECK
AMOUNT OR QUALITY OF COOLANT INCORRECT - CHECK
FAULTY WATER TEMPERATURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING
LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED - CHECK

LONG 1, SHORT 5

FAULTY RPM SENSOR - CHECK FOR GOOD CONNECTION
FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU
FAULTY ACTUATOR - CHECK FOR PROPER COIL RESISTANCE
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK

LONG 2, SHORT3

FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN - CHECK FOR CONTINUITY
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN - CHECK FOR CONTINUITY
BROKEN OR LOOSE BELT - INSPECT
FAULTY ALTERNATOR - CHECK
INCORRECT BATTERY - INSPECT
FAULTY ALTERNATOR - CHECK

LONG 2, SHORT 8

LESS THAN 4 VOLTS TO RPM SENSOR AND/OR
ACTUATOR SENSED BY ECU

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

NOT ENABLED FOR LINCOLN PRODUCTS

0 RPM IS DETECTED AND 12V IS DETECTED
FROM "L" TERMINAL ON ALTERNATOR

LONG 2, SHORT 1

LONG 1, SHORT 4

HIGH WATER TEMPERATURE DETECTED FOR 1
SECOND

LONG 1, SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND

LONG 1, SHORT 3

"L" TERMINAL IS GROUNDED ON ALTERNATOR
FOR 1 SECOND

LONG 2, SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR

CURRENT TO ACTUATOR IS OUT OF LIMIT

LONG 2, SHORT 2

LONG 2, SHORT 6

0 VOLTS DETECTED FROM "L" TERMINAL ON
ALTERNATOR FOR 1 SECOND

LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED

-50C WATER TEMPERATURE DETECTED

LONG 2, SHORT4

12 VOLT SUPPLY

THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING THE ENGINE

PROTECTION LIGHT IN A CODED SEQUENCE, SEE CHART FOR FAULT

CODES AND CORRECTIVE MEASURES. WHEN THE ENGINE IS SHUT

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

TURNED OFF THEN BACK ON TO RESTART THE ENGINE.

12 VOLT SUPPLY

GLOW PLUG

BUTTON

BATTERY

STARTER

MOTOR

STARTER

SOLENOID

842

MOUNTEDTONEGATIVE

BRUSHHOLDER

THIS CIRCUIT USES THE

RESIDUAL MAGNETISM OF

THE GENERATOR TO FLASH

THE EXCITE THE ROTOR
WHICH IN TURN PROVIDES
THE EXCITATION FOR THE

GENERATOR

DIODE AND MOV ASSEMBLY

IN-LINE BOLTED CONNECTION

BEHIND CONTROL PANEL

600C

BACK, LEFTSIDEOFENGINE

FRONT, LEFTSIDEOFENGINE

BACK, LEFTSIDEOFENGINE

JUMPERPLUGISBEHINDLOWER

RIGHTSIDEOFCONTROLPANEL

LOWER, RIGHTSIDEOFCONTROLPANEL

DIODE

LOWER,

RIGHTOF

CONTROL

PANEL

LOWERLEFTOF

CONTROLPANEL

LOWERLEFTOF

CONTROLPANEL

CENTEROF

CONTROLPANEL

BACK, RIGHT

SIDEOFENGINE

BACK, LEFT

SIDEOFENGINE

BACK, RIGHT

SIDEOFENGINE

CENTEROF

CONTROLPANEL

UNDERLEFTDOOR

LOWERRIGHTOFCONTROLPANEL

12 VOLT

SUPPLY

ECU CONNECTOR DETAIL

9
17
25
34

FLASHES ALTERNATOR

SENSES ALTERNATOR OUTPUT

THE P10 PLUG IS ONLY ON UNITS

WITHOUT THE WIRE FEED MODULE.

THE WIRE FEED MODULE HAS A

HARNESS THAT PLUGS DIRECTLY

INTO J5.

JUMPERPLUGIS

WIRE-TIEDUP

BEHINDLOCAL/

REMOTESWITCH

ONRIGHTSIDEOF

MACHINE

SCHEMATIC S25973

CURRENT SENSING PC BOARD

GND-T

GND-S

WHITE LOAD

WHITE LINE

HOT LOAD

HOT LINE

115 VOLT GFCI
RECEPTACLE

OIL PRESSURE

GAUGE

TEMPERATURE

GAUGE

K924-5 REMOTE CONTROL

(OPTIONAL)

RHEOSTAT

REMOTE CONTROL BOX

25+/-1.25 OHMS EACH

64+/-6.4 OHMS MAX

CCW

REMOTE CONTROL PLUG

L12265-1

CLASSIC 300D (KUBOTA V2203M)

MACHINE SCHEMATIC

NONE

L12265

Maglietta

N. TAYLOR

UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS ± .02

ON 3 PLACE DECIMALS IS ± .002

ON ALL ANGLES IS ± .5 OF A DEGREE

WITH PUBLISHED STANDARDS.

MATERIAL TOLERANCE (" ") TO AGREE

DO NOT SCALE THIS DRAWING

DRAWN BY:

DESIGN INFORMATION

ENGINEER:

APPROVED:

REFERENCE:

EQUIPMENT TYPE:

SUBJECT:

SCALE:

MATERIAL
DISPOSITION:

APPROVAL
DATE:

PROJECT
NUMBER:

CRM34902

PAGE ___ OF ___

ENGINEERING CONTROLLED
MANUFACTURER:

DOCUMENT
NUMBER:

DOCUMENT

REVISION:

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.

PROPRIETARY & CONFIDENTIAL:

03/11/2005

New

CHANGE DETAIL:

L12

265-1

LEAD COLOR CODE:

B-BLACK OR GRAY
G-GREEN
R-RED OR PINK
U-BLUE
W-WHITE
Y-YELLOW
N-BROWN

COMPONENT VALUE UNITS:

CAPACITOR: MFD/VOLTS

RESISTOR: OHMS/WATTS

CONNECTOR PIN NUMBERS: