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G-14
SCHEMATIC - COMPLETE MACHINE - (CODES 11110, 11111) (L12412)
ELECTRICAL DIAGRAMS
CHANGE DETAIL:
SLIP RINGS, CHANGED POSITIVE TO NEGATIVE
L12412
ENGINEERING CONTROLLED
No
MANUFACTURER:
CENTER OF CONTROL PANEL
IDLER / ENGINE PROTECTION PC BOARD
12 VOLT - NORMALLY OFF
LOCATED BEHIND UPPER PORTION OF CONTROL PANEL
RED ENGINE
PROTECTION
SCHEMATIC G4828-1
60C
61
J1-4
ENGINE
LIGHT
SHUTDOWN
N.C.
RIGHT SIDEOF ENGINE
BY INJECTION PUMP
N.O.
INJECTION
J1-9
GND-C
58
FLYBACK
PUMP
DIODES
ENGINE
SOLENOID
RUNNING
58H
APPROXIMATE
RESISTANCE: 3.3 OHMS
TYPICAL CURRENT DRAW: 3.3A
RIGHT SIDEOF ENGINE
BY OIL FILLER
FUEL PUMP
ENGINE
APPROXIMATE
PROTECTION
RESISTANCE: 3-4 OHMS
CIRCUITS (SEE
BELOW FOR
TYPICAL CURRENT DRAW: 3A
LOGIC)
+
60
93
J1-10
HOUR METER
CENTER OF
J1-5
CONTROL PANEL
J2-1
UNUSED
J2-2
B1
REVERSE VOLTAGE
PROTECTION DIODE
IDLE
60A
SOLENOID
AUX LOAD SENSING
CIRUITS
(SEE BELOW
WELD LOAD SENSING
FOR LOGIC)
J2-3
B2
ENGINE PROTECTION CIRCUIT LOGIC
J2-4
1. UPON RECIEVING POWER FROM THE
GND-B
844
IGNITION SWITCH, THE FUEL SOLENOID,
IDLER SWITCH
FUEL PUMP AND HOUR METER ARE
400D
ENERGIZED.
400E
2. ENGINE PROTECTION IS BYPASSED
FOR ONE MINUTE TO ALLOW OIL
20A
PRESSURE BUILDUP. ENGINE MUST BE
CB1
STARTED WITHIN ONE MINUTE OF
11A
TURNING IGNITION SWITCH ON OR THE
FUEL SOLENOID, FUEL PUMP AND HOUR
400F
115 VOLT GFCI
METER WILL TURN OFF. AFTER ONE
RECEPTACLE
MINUTE, THE IGNITION SWITCH MUST BE
CYCLED OFF AND BACK ON TO START
HOT LINE
HOT LOAD
ENGINE.
WHITE LINE
WHITE LOAD
3. AFTER ENGINE STARTS, FLASHING
GND-E
CURRENT IS SUPPLIED TO THE ENGINE
ALTERNATOR.
GND-T
11C
GND-S
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.
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.
COMPONENT VALUE UNITS:
3. IF AN AUXILIARY CURRENT DRAW OR WELD
BACK OF OUTPUT STUD
CAPACITOR: MFD/VOLTS
LOAD IS SENSED OR THE IDLER SWITCH IS CLOSED
RESISTOR: OHMS/WATTS
REED SWITCH
(HIGH), THE IDLE SOLENOID IS DE-ENERGIZED.
SWITCH CLOSES
CONNECTOR PIN NUMBERS:
WITH FLOW OF
WELDING CURRENT
LEAD COLOR CODE:
EX. 12 PIN CONNECTOR
LABELS:
B-BLACK OR GRAY
1 2
6
G-GREEN
COMMON
R-RED OR PINK
U-BLUE
FRAME GROUND
TYPICAL OCV (WARM MACHINE):
7
12
W-WHITE
94-99.0 VOLTS AT MAX RHEOSTAT
EARTH GROUND
LATCH
Y-YELLOW
44-54.5 VOLTS AT MIN RHEOSTAT
VIEW OF CONNECTOR ON PC BOARD
N-BROWN
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
BACK, LEFT SIDEOF ENGINE
THIS LEAD PROVIDES FLASH
FOR ALTERNATOR AND
55 AMP / 12 VOLT
SENSES ALTERNATOR OUTPUT
ALTERNATOR
59
J1-3
BACK, RIGHT SIDEOF ENGINE
55
WHITE
B3
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
212C
56
J1-2
J1-1
212D
IGNITION
SWITCH
LOW ER LEFT OF
BACK, LEFT SIDEOF ENGINE
SHOWN IN "OFF"
212A
CONTROL PANEL
POSITION
S
J1-6
43
I
44
TEMPERATURE
W
G
G
GAUGE
TEMPERATURE SWITCH / SENDER
LOW ER LEFT OF
SWITCH CLOSES
SENDER OPERATION:
212B
CONTROL PANEL
AT 230
+/-6
F
140
F -> 134+/-13.5 OHMS
v
v
v
194
F -> 51.2+/-4.3 OHMS
v
212
F -> 38.5+/-3 OHMS
v
SENDER IS APPROX.
BACK, TOPOF ENGINE
500 OHMS AT 70
v
F
S
OIL PRESSURE
J1-7
54
200
I
GAUGE
WK
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
B4
40PSI -> 105+/-5 OHMS
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.
DC EXCITER
+
WINDING SPEC: ALT-241-3A
+
15A
610
610A
40.5 - 42.5 OHMS AT 25C
CB3
DIODE
AC
AC
LOW ER, RIGHT SIDEOF CONTROL PANEL
EXCITER REVOLVING
FIELD (ROTOR)
-
600C
-
21
SLIP RINGS
600A
7A
NEGATIVE SLIP RING
FUSE
15A
IS NEAREST TO IRON
EXCITER CIRCUIT
215
LOW ER,
LEAD 21A TO 21B
RIGHT OF
WINDING SPEC: ALT-214-2B
230 VOLT
CONTROL
214
.488 OHMS MAX AT 25C
RECEPTACLE
PANEL
6A
810
115 VOLT CIRCUIT
15A
LEAD 810 TO 820
CB2
EXCITER STATOR
WINDING SPEC: ALT-214-2C
820
(ALTERNATOR)
.230 OHMS MAX AT 25C
IN-LINE BOLTED CONNECTION
BEHIND CONTROL PANEL
115 VOLT CIRCUIT
11B
LEAD 820 TO 830
GENERATOR LEAD BLOCK
WINDING SPEC: ALT-214-2D
844A
SHOWN AS VIEWED WITH
.424 OHMS MAX AT 25C
TOP, LEFT PORTION
ENGINE IN THIS DIRECTION
OF CONTROL PANEL
SELECTOR SWITCH
SERIES FIELD
90-MIN
130-80
190-120
240-160
INTERPOLE
INTERPOLE
220-MAX
COILS
COILS
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
_
+
GND-A
PROPRIETARY & CONFIDENTIAL:
NEGATIVE OUTPUT
POSITIVE OUTPUT
TERMINAL
TERMINAL
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
UNDER LEFT DOOR
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING
K924-5 REMOTE CONTROL
AMMETER SHOWS FULL
DISCHARGE WHILE PRESSING
GLOW PLUG
GLOW PLUG SWITCH
SWITCH
FLASH
53
BAT
BAT
51C
-40 TO 40 AMPS
AMMETER
51
+
-
51G
GLOW PLUGS
51A
TYPICAL CURRENT
10A
DRAW IS 40 +/- 3 AMPS
CB4
50A
50
START
64+/-6.4 OHMS MAX
SWITCH
BACK, BOTTOM
OF MACHINE
52
STARTER
+
SOLENOID
BATTERY
STARTER
12.6 VOLTS MIN
AT REST
MOTOR
14-14.5 VOLTS
WHILE RUNNING
THE P10 PLUG IS ONLY ON UNITS WITHOUT
THE WIRE FEED MODULE. THE WIRE FEED
P10
MODULE HAS A HARNESS THAT PLUGS
12 11 10 9 8 7 6 5 4 3 2 1
DIRECTLY INTO J5.
J5
48
610
600B
TOP, RIGHT PORTION
OF CONTROL PANEL
RHEOSTAT
CCW
64+/-6.4 OHMS MAX
602B
41
42
602A
J8
6
4
5
3
1
2
P9
JUMPER PLUG IS
41
600
W IRE-TIED UPBEHIND
G
602
42
LOCAL / REMOTE
SW ITCH ON RIGHT
Y
SIDEOF MACHINE
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.
REFERENCE:
CLASSIC 300D PERKINS 404C-22
DESIGN INFORMATION
EQUIPMENT TYPE:
L12020
DRAWN BY:
DM / DFM
MACHINE SCHEMATIC
SUBJECT:
ENGINEER:
J.STAPP
SCALE:
t
MATERIAL
APPROVAL
PROJECT
UF
CRM22115-FZ
NA
09/21/2006
APPROVED:
DISPOSITION:
DATE:
NUMBER:
G-14
(OPTIONAL)
REMOTE CONTROL PLUG
G
Y
X
W
25+/-1.25 OHMS EACH
CCW
RHEOSTAT
REMOTE CONTROL BOX
FLYBACK DIODE PREVENTS
VOLTAGE SPIKES IN SHUNT FIELD
FROM DAMAGING LOCAL/REMOTE
TOGGLE SWITCH WHEN SWITCHED
JUMPER PLUG IS FOR CONNECTION
TO WIRE FEED MODULE
JUMPER PLUG ISW IRE-TIED UP
BEHIND LOCAL / REMOTE SW ITCH ON
RIGHT SIDEOF MACHINE (ASVIEW ED
FROM CONTROL PANEL)
N
U
W
Y
N
U
W
Y
MOUNTED TO NEGATIVE
BRUSH HOLDER
DIODE AND MOV ASSEMBLY
THIS CIRCUIT USES THE
RESIDUAL MAGNETISM OF
THE GENERATOR TO FLASH
THE EXCITE THE ROTOR
WHICH IN TURN PROVIDES
THE EXCITATION FOR THE
GENERATOR
1
1
PAGE ___ OF ___
DOCUMENT
DOCUMENT
NUMBER:
REVISION:
C
L12412
CLASSIC® 300D & 300G
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