Schematic - Complete Machine (L15879 - Lincoln Electric GENUINE SAE-300 Service Manual

G-3

SChEmaTiC - COmpLETE maChiNE (L15879)

CENTER OF CONTROL PANEL
12 VOLT - NORMALLY OFF
RED ENGINE
PROTECTION
LIGHT
INJECTION
PUMP
SOLENOID
APPROXIMATE
RESISTANCE: 3.3 OHMS
TYPICAL CURRENT DRAW: 3.3A
CENTER OF CONTROL PANEL
HOUR METER
ENGINE PROTECTION CIRCUIT LOGIC
1. UPON RECIEVING POWER FROM THE
IGNITION SWITCH, THE INJECTION PUMP
FUEL SOLENOID AND HOUR METER ARE
ENERGIZED.
2. ENGINE PROTECTION IS BYPASSED
FOR ONE MINUTE TO ALLOW OIL
PRESSURE BUILDUP. ENGINE MUST BE
STARTED WITHIN ONE MINUTE OF
TURNING IGNITION SWITCH ON OR THE
INJECTION PUMP FUEL SOLENOID AND
HOUR METER WILL TURN OFF. AFTER
ONE MINUTE, THE IGNITION SWITCH
MUST BE CYCLED OFF AND BACK ON TO
START ENGINE.
3. AFTER ENGINE STARTS, FLASHING
CURRENT IS SUPPLIED TO THE ENGINE
ALTERNATOR.
4. AFTER ONE MINUTE, TIMER IS TIMED
OUT. IF OIL PRESSURE IS LOW,
COOLANT TEMPERATURE IS HIGH OR
ALTERNATOR IS NOT CHARGING, THE
ENGINE WILL SHUT DOWN AND THE
ENGINE PROTECTION LIGHT WILL COME
ON.
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR
1
7
VIEW OF CONNECTOR ON PC BOARD
ENGINEERING CONTROLLED CHANGE DETAIL: CHANGED DC EXCITER TO AC EXCITER
No
MANUFACTURER:
IDLER / ENGINE PROTECTION PC BOARD
LOCATED BEHIND LOW ER CONTROL PANEL
ENGINE
60C 61 J1-4
SCHEMATIC G4828-1
SHUTDOWN
N.C.
N.O.
GND-C 58 J1-9 FLYBACK
DIODES
ENGINE
RIGHT SIDE OF ENGINE
RUNNING
BY INJECTION PUMP
ENGINE
PROTECTION
CIRCUITS (SEE
BELOW FOR
LOGIC)
+
60 93 J1-10
J1-5
J2-1
UNUSED
J2-2
B1
REVERSE VOLTAGE
PROTECTION DIODE
IDLE
60A
SOLENOID
AUX LOAD SENSING
CIRUITS
(SEE BELOW
WELD LOAD SENSING
FOR LOGI C)
J2-3 B2
J2-4
844 GND-B
IDLER SWITCH
400D
844A
400E
15A
20A
CB2
CB1
11A
7C
6A
810
7B
115 VOLT
RECEPTACLE
6C
6B
SILVER
GND-E
IDLE SOLENOID CIRUIT LOGIC
1. WHEN THE ENGINE IS RUNNING IN HIGH IDLE
OR UNDER LOAD, THE SOLENOID IS NOT
ENERGIZED.
2. IF NO AUXILIARY CURRENT DRAW OR WELD
LOAD IS SENSED FOR 15 SECONDS AND THE
IDLER SWITCH IS OPEN (AUTO), THE PULL AND
HOLD COIL OF THE IDLER SOLENOID ARE
ENERGIZED. THE PULL COIL IS DE-ENERGIZED
AFTER HALF A SECOND.
3. IF AN AU XILIARY CUR RE NT DRAW OR WELD
LOAD IS S EN SED OR THE IDLER SWITCH IS CLOS ED
(HIGH), THE IDLE SOLENOID IS DE- EN ERGIZED.
LEAD COLOR CODE:
LABELS:
NEGATIVE OUTPUT
B-BLACK OR GRAY
2 6 TERMINAL
G-GREEN
COMMON
R-RED OR PINK
TYPICAL OCV (WARM MACHINE):
U-BLUE
FRAME GROUND
94-99.0 VOLTS AT MAX RHEOSTAT
12
W-WHITE
44-54.5 VOLTS AT MIN RHEOSTAT
EARTH GROUND
LATCH
Y-YELLOW
N-BROWN
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELECTriCaL DiaGramS
THIS LEAD PROVIDES FLASH
FOR ALTERNATOR AND
SENSES ALTERNATOR OUTPUT
59
J1-3
BACK, RIGHT SIDE OF ENGINE
B3 55 WHITE
IDLE SOLENOID
PULL COIL
TYPICAL CURRENT DRAW AND
J1-8 57 RED
RESISTANCE:
HOLD COIL
BLACK HOLD COIL: 1A, 10-15 OHMS
PULL COIL: 40A, LESS THAN .1 OHM
212E
J1-2 212C 56
212D IGNITION
J1-1
SWITCH
212A SHOWN IN "OFF"
BACK, LEFT SIDE OF ENGINE
POSITION
S
J1-6 44 43 I
TEMPERATURE
W G
G
GAUGE
TEMPERATURE SWITCH / SENDER
LOW ER LEFT OF
SWITCH CLOSES
SENDER OPERATION: 212B
CONTROL PANEL
AT 230 v +/-6 v F
140 v F -> 134+/-13.5 OHMS
194 v F -> 51.2+/-4.3 OHMS
212 v F -> 38.5+/-3 OHMS
SENDER IS APPROX.
BACK, TOP OF ENGINE 500 OHMS AT 70
S
OIL PRESSURE
J1-7 54 200 I
GAUGE
W G
G
LOW ER LEFT OF
CONTROL PANEL
OIL PRESSURE SWITCH / SENDER
SWITCH CLOSES SENDER OPERATION:
AT 6+/-2 PSI 0 PSI -> 10+/-5 OHMS
40PSI -> 105+/-5 OHMS
B4
80 PSI -> 187+/-5 OHMS
B5 UNUSED
B6
ON NEWER BOARDS,
SHOWN IN "AUTO
J1 BECOMES J31, J2 BECOMES J32,
IDLE" POSITION
B5 AND B6 TERMINALS ARE DELETED.
AC EXCITER
+
WINDING SPEC: ALT-241-3A
+
610
610A
40.5 - 42.5 OHMS AT 25C
AC DIODE
AC
EXCITER REVOLVING
LOW ER, RIGHT SIDE OF CONTROL PANEL
FIELD (ROTOR)
7A
-
600C
-
21
SLIP RINGS 600
POSITIVE SLIP RING
FUSE
IS NEAREST TO IRON 15A
EXCITER CIRCUIT
215
LOW ER, LEAD 21A TO 21B
GND-S
RIGHT OF WINDING SPEC: ALT-214-2B
214
CONTROL .488 OHMS MAX AT 25C
230 VOLT
6A
RECEPTACLE PANEL
810
115 VOLT CIRCUIT
LEAD 810 TO 820
EXCITER STATOR
WINDING SPEC: ALT-214-2C
(ALTERNATOR)
820
.230 OHMS MAX AT 25C
115 VOLT CIRCUIT
11B
LEAD 820 TO 830
GENERATOR LEAD BLOCK
WINDING SPEC: ALT-214-2D
SHOWN AS VIEWED WITH
TOP, LEFT PORTION
.424 OHMS MAX AT 25C
ENGINE IN THIS DIRECTION
OF CONTROL PANEL
SERIES FIELD
REACTOR
MAX MIN.
OUTPUT OUTPUT
INTERPOLE INTERPOLE
COILS COILS
*844A
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
_
+
GND-A
BACK OF OUTPUT STUD
REED SWITCH
POSITIVE OUTPUT
PROPRIETARY & CONFIDENTIAL:
SWITCH CLOSES
TERMINAL
WITH FLOW OF
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE:
WELDING CURRENT
ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm)
UNDER LEFT DOOR
ON 3 PLACE DECIMALS IS ± .002 in. ( ± 0.05 mm)
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING
AMMETER SHOWS FULL
BACK, LEFT SIDE OF ENGINE
DISCHARGE WHILE PRESSING
65 AMP / 12 VOLT GLOW PLUG
GLOW PLUG SWITCH
ALTERNATOR SWITCH
D+
53
B+
51C
-40 TO 40 AMPS
AMMETER
+ -
51 GLOW PLUGS
51A TYPICAL CURRENT
10A
DRAW IS 40 +/- 3 AMPS
CB4
50A
LOW ER LEFT OF
CONTROL PANEL
50
START
SWITCH
BACK, BOTTOM
52
OF MACHINE
STARTER
+
SOLENOID
BATTERY
STARTER 12.6 VOLTS MIN
v F
MOTOR AT REST
14-14.5 VOLTS
WHILE RUNNING
PLUG IS LOCATED BEHIND LOCAL /
REMOTE SW ITCH ON RIGHT SIDE OF
MACHINE (ASVIEW ED FROM
CONTROL PANEL)
P10 PLUG IS REMOVED FOR WIRE
P10
FEED MODULE CONNECTION
12 11 10 9 8 7 6 5 4 3 2 1
J5
48
600B
TOP, RIGHT PORTION
OF CONTROL PANEL
RHEOSTAT
CCW
64+/-6.4 OHMS MAX
602B
42
41 600
602
G
Y
X
W
REMOTE
RECEPTACLE
SHUNT
LOCAL / REMOTE
-
+
FIELD
SWITCH
- SHOWN IN LOCAL
+ FJW-5AP
POSITION
COIL PAIR:
25.2 - 26.7
OHMS EACH
WELDING
GENERATOR
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.
SCALE:
CONTROL: CLEVELAND
EQUIPMENT TYPE: SAE-300
NONE
DRAWN BY: tsado
IF PRINTED
SUBJECT: MACHINE SCHEMATIC
@ A2 SIZE
DJB
t ENGINEER:
UNITS:
MATERIAL APPROVAL PROJECT
UF
9-23-2011
APPROVED: GWM INCH DATE:
DISPOSITION: NUMBER:
G-3
K924-4 REMOTE CONTROL
(OPTIONAL)
REMOTE CONTROL PLUG
G
Y
X
W
25+/-1.25 OHMS EACH
CCW
64+/-6.4 OHMS MAX
RHEOSTAT
REMOTE CONTROL BOX
THIS DIODE ALLOWS THE RESIDUAL MAGNETISM
OF THE GENERATOR TO FLASH THE EXCITER
ROTOR WHICH IN TURN PROVIDES THE
EXCITATION FOR THE GENERATOR
N
N
U
BRIDGEAND
U
MOV
LOCATED ON
MOV
RIGHT OUTER
SIDE OF
Y REACTOR
SHEET
METAL.
FLYBACK DIODE
612 602C PREVENTS VOLTAGE
W
SPIKES IN SHUNT FIELD
FROM DAMAGING
LOCAL/REMOTE
TOGGLE SWITCH WHEN
SWITCHED
W Y
U
N
1 1
PAGE ___ OF ___
DOCUMENT DOCUMENT
NUMBER: REVISION:
L15879
REFERENCE: B
CRM42466
L15767
SaE-300 ®