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Lincoln Electric SVM194-A service manual D5.6 Classic 300D & 300G

Models: SVM194-A

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D5.6

NOTESD5.6

CLASSIC® 300D & 300G

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Lincoln Electric SVM194-A service manual D5.6 Classic 300D & 300G

Contents

Classic 300 D & 300 G For Engine SafetyPowered equipment Electric Magnetic FieldsCan be dangerous Electric Shock can kill ARC Rays can burnFumes and Gases Classic 300D & 300GIii Cylinder may explodeFor Electrically LES Machines À Souder À Précautions DE SûretéPrécautions DE Sûreté Pour Transformateur ET ÀElectromagnetic Compatibility EMC L10093 3-1-96H Master Table of Contents for ALL Sections Table of Contents Installation Section Welding Output Open Circuit Output Range Auxiliary Power InstallationTechnical Specifications Classic 300D Height Width Depth WeightRated Output Duty Cycle Design FeaturesOptional Features PRE-OPERATION Installation Diesel Fuel PRETrailer Vehicle MountingTo prevent Explosion when Battery ChargingEngine BREAK-IN To prevent Electrical Damage whenTable of Contents Operation Section See additional warning information at OperationEngine Operation Cold Weather StartingDo not Turn the Current Range Selec See Specifications forWelder Operation Auxiliary Power B1.4Table of Contents Accessories Section Maintenance section AccessoriesOptional Features TIG OptionsMagnum 250 Innershield Gun for LN-23P Wire Feed Module K623-1 Provides constant voltC1.3 Spool GUN WelderC1.4 Classic 300D & 300G Table of Contents Maintenance Section Maintenance MaintenanceEngine Idler MaintenancePurging Air from Fuel System Perkins NameplatesD1.4 For Codes 10658 and belowD1.5 For Codes 10911 and AboveResetting Procedure D1.6Figure D1.7 Major Component Location D1.7D1.8 Classic 300D & 300G A2.1 DC Current Range Volts @ Rated Amps Cycle Model Height Width Depth WeightDescription Rated DC Output Engine When starting and stopping welding or using auxilA2.3 MufflerLift Bail Machine GroundingExhaust Spark Arrester Do not Mount Over Combustible SUFuel Polarity Control and Cable Sizes PRE-OPERATION ServiceOIL Cooling SystemBattery Acid can burn eyes Skin Battery ChargingA2.6 Gases from Battery can explode A2.6B2.1 Stopping the Engine Maintenance secHigh Altitude Operation Starting the Classic 300D PerkinsContacts and damage the switch B2.3Idler Operation Auxiliary Power B2.4C2.1 Trailer K953-1 Stick Options Accessory SET K704TIG Options General Options C2.3 Wire Feeder OptionsWire Feed Module K623-1 Magnum Spool Gun K487-25 C2.4 Classic 300D & 300G D2.1 Safety Precautions Information atPerkins 404C-22 Engine Idler MaintenancePurging AIR from Fuel System NameplatesTension of alternator drive belt Service Decal for Codes 11249 and belowD2.4 All nuts and bolts for tightnessD2.5 MAINTENANCED2.5Service Decal for Codes 11250 and Above D2.6MAINTENANCED2.6 Gfci Receptacle Testing and Reset Ting ProcedureCase Front Assembly D2.7D2.8 Classic 300D & 300G A3.1 Technical Specifications Classic 300D Kubota A3.2Control Panel High Idle RPM OCV Adjustment A3.3Not Mount Over Combustible Surfaces This operatorʼs manualAngle of Operation FallingPolarity Control and Cable Sizes Fuel A3.6 Battery Charging WarningGAS ES from Battery can explode B3.1 Starting the Classic 300D Kubota V2203M Diesel EngineB3.3 Control of Welding CurrentB3.4 Idler OperationC3.1 TIG Options Stick OptionsWire Feed Options C3.3C3.4 Classic 300D & 300G D3.1 D3.2 Air Bleeding Kubota V2203M EngineD3.3 ValveEngine Service D3.4D3.5MAINTENANCED3.5 Figure D3.6 Major Component Location D3.6A4.1 A4.2 General Description A4.3See Optional Features A4.4Instructions supplied with this machine Read the engine operating and maintenanceA4.5 CanA4.6 B4.1 B4.2 404D-22 Diesel EngineSelector setting and lower open circuit voltage B4.3B4.4 C4.1 C4.2 Power Plug Kit K802DService Indicator Kit K1858-1 Water Valve Kit K844-1 Ball Hitch K958-1 K958-2 Control Cable Extension K937-45Magnum Spool Gun K487-25 Wire Feed Module K623-1 C4.3C4.4 Classic 300D & 300G D4.1 D4.2 Perkins 404D-22 Engine D4.3MAINTENANCED4.4 D4.4D4.5MAINTENANCED4.5 Figure D4.6 Major Component Location D4.6A5.1 Description Rated DC Output Duty Cycle DC Current Range Technical Specifications Classic 300G K1754-1A5.2 Exhaust Spark Arrester Lift Bail Do not Mount Over Combustible SURGasoline Vehicle MountingA5.5 A5.6 Classic 300D & 300G B5.1 B5.2 Design FeaturesStarting and stopping welding or using auxiliary Do not Mount Over Combustible SurfacesRefer to the Engine High Idle RPM OCV Adjustment- a potentiometer isB5.3 Starting the Classic 300G GM 3.0LIdler Control Operation B5.4Throttle Body Deicing System C5.1 Optional Equipment C5.2D5.1 General Instructions BearingsCommutator and Brushes Purging AIR from Fuel System GM Idler Control MaintenanceEngine Maintenance 0L EngineEngine Service D5.4Figure D5.5 Major Component Location D5.5D5.6 Classic 300D & 300G 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Gasoline EnginePerkins BATTERY, STARTER, Engine Alternator & Protection Circuits Classic 300G, Zenith Fuel System/GM EngineClassic 300D, Perkins Engine Classic 300D, Kubota EngineTOR and Rotor Fine Current AdjustmentAdjustment Coils Excitation FlashingFigure E.8 Classic 300D, Perkins Engine 11472, Engine Idler Circuit 11135 10657, 10658, 10911,Theory of Operation DC Generator Machines Classic 300D & 300G Troubleshooting and Repair Table of ContentsRecommended HOW to USE Troubleshooting GuideLocate Problem Symptom Perform External TestsPC Board Troubleshooting Procedures Electric ShockPerform the Brush and Slip Adjustment TestRing Service Procedure Perform the Flash VoltageCommutator Inspection Service ProcedureGenerator Brush Shunt Field CoilOutput takes a long time to Weld output is considerably Perform the Shunt Field Coil Rocker AdjustmentAdjustment Procedure if Procedure RPM Adjustment TestSlip Ring Service Exciter Rotor Resistance and Ground Test Shunt Field CoilFlash Voltage Brush and SlipWelding Engine will not crank when Function Problems System Voltage Tests Verify that the engine control Protection System Test Perform the Engine Alternator Machine will not idle down Kubota powered units For Classic 300GEngine goes to low idle, but Kubota powered Classic Perkins powered models Classic 300G Classic 300D Kubota Powered machinesTroubleshooting and Repair Exciter/Auxiliary Power Alternator 23TROUBLESHOOTING and REPAIRF-23Brush & Slip Ring Service Procedure Procedure DescriptionCleaning the Slip Rings 24TROUBLESHOOTING and REPAIRF-24Procedure Seating BrushesTest Description 25TROUBLESHOOTING and REPAIRF-25Engine Alternator Test Procedure Engine Alternator Test Procedure 27TROUBLESHOOTING and REPAIRF-27 Engine Fuel System Voltage Test ProcedureEngine Fuel System Voltage Test Procedure 29TROUBLESHOOTING and REPAIRF-29 Engine Protection System Test ProcedureTED to RUN White Overheated or with Engine Protection System Test ProcedureWarranty will not Cover the Damage TOW OIL PRESSURE, Severe Engine DAMMaterials Needed Miscellaneous hand tools Strobe tachometer 31TROUBLESHOOTING and REPAIRF-31Engine RPM Adjustment Test Procedure Classic 300D Perkins only Engine RPM Adjustment Test ProcedureEngine RPM Adjustment Procedure later in this section Strobe-Tach MethodLow idle adjustment Classic 300D & 300G 35TROUBLESHOOTING and REPAIRF-35 Flashing Voltage Test ProcedureFlashing Voltage Test Procedure Rocker Adjustment Procedure Initial rocker placement 38TROUBLESHOOTING and REPAIRF-38Rocker Adjustment Procedure TightenCheck for Max output Classic 300D & 300G Exciter / Auxiliary Power Alternator 41TROUBLESHOOTING and REPAIRF-41Exciter Rotor Resistance and Ground Tests Procedure Dynamic Tests 42TROUBLESHOOTING and REPAIRF-42Static Tests 43TROUBLESHOOTING and REPAIRF-43 Classic 300D & 300G 45TROUBLESHOOTING and REPAIRF-45 Shunt Field Coil Resistance and Ground Test ProcedureTest the shunt coil resistance Shunt Field Coil Resistance and Ground TestShunt coil ground test Shunt Field Coil Resistance and Ground47TROUBLESHOOTING and REPAIRF-47 Shunt Field Circuit Voltage Test ProcedureShunt Field Circuit Voltage Test Procedure 49TROUBLESHOOTING and REPAIRF-49 Exciter Stator Short Circuit & Ground Test ProcedureExciter Stator Short Circuit & Ground Test Procedure Weld Circuit Ground and Short Circuit Test Procedure Weld circuit ground test If the resistance is lower than 500k Ohms53TROUBLESHOOTING and REPAIRF-53 Welding Generator Brush and Commutator 54TROUBLESHOOTING and REPAIRF-54Inspection and Service Procedure Perform the Weld Circuit Ground and Short Circuit TestUneven Commutator appearance 55TROUBLESHOOTING and REPAIRF-55Pitted and Are Damaged Commutator Examine the brushesClassic 300D & 300G 57TROUBLESHOOTING and REPAIRF-57 Series Coil Short Circuit Test ProcedureSeries Coil Short Circuit Test Procedure 16.6 ms Scope SettingsHigh Idle no Load Fine Current Control Rheostat AT Maximum CH160TROUBLESHOOTING and REPAIRF-60 Normal Open Circuit DC Weld Voltage WaveformTypical DC Weld Output Voltage Waveform 61TROUBLESHOOTING and REPAIRF-61Machine Loaded Selector Switch AT Maximum Position Classic 300D & 300G Description 63TROUBLESHOOTING and REPAIRF-63Alternator Rotor Removal Replacement Procedure Materials Needed 3/8 wrenchAlternator Rotor Removal 64TROUBLESHOOTING and REPAIRF-64Replacement Procedure Troubleshooting and Repair 66TROUBLESHOOTING and REPAIRF-66 Figure F.6 Rotor RemovalReplacement Procedure ReplacementClassic 300D & 300G Materials Needed 3/8 nut driver 69TROUBLESHOOTING and REPAIRF-69Alternator Stator Removal and Replacement Procedure Procedure 70TROUBLESHOOTING and REPAIRF-70Alternator Stator Removal and Replacement Perform the Alternator Rotor Removal71TROUBLESHOOTING and REPAIRF-71 Figure F.8 Lead Disconnection PointsReplacement Genernator Brush HOLDER/COIL Cables73TROUBLESHOOTING and REPAIRF-73 Rotor Removal and Replacement proClassic 300D & 300G 75TROUBLESHOOTING and REPAIRF-75 Generator Frame Removal and Replacement ProcedureGenerator Frame 76TROUBLESHOOTING and REPAIRF-76Removal and Replacement Perform the Alternator Stator RemovalRemoval and Replacement 78TROUBLESHOOTING and REPAIRF-78 See Figure F.14 for steps 1479TROUBLESHOOTING and REPAIRF-79 Rope Sling80TROUBLESHOOTING and REPAIRF-80 81TROUBLESHOOTING and REPAIRF-81 Generator Armature Removal and Replacement ProcedureGenerator Armature 82TROUBLESHOOTING and REPAIRF-82Removal and Replacement Procedure RPM AC Auxiliary Power Receptacle OutputCurrent Rheostat at Maximum Classic 300D & 300G Table of Contents Diagram Section Electrical Diagrams Wiring Diagram Codes 10545, 10546, 10657, 10658 L10877Classic 300G Wiring Diagram Classic 300D Wiring Diagram Wiring Diagram Codes 10911, 10927 L11865Classic 300G Wiring Diagram Wiring Diagram Codes 10912, 11135 L11866Classic 300D Perkins Wiring Diagram Wiring Diagram Codes 11110, 11111 M20499Classic 300D Kubota Wiring Diagram Wiring Diagram Codes 11112, 11113 M20432Wiring Diagram Codes 11243, 11244 M20432-1 OU Tput TerminalsWiring Diagram Codes 11248, 11249, 11280, 11281 M20616 Wiring Diagram Codes 11411, 11412 M21292 Wiring Diagram Codes 11413, 11414 M21293 Wiring Diagram Codes 11472, 11473 M21684 Wiring Diagram Codes 11474, 11475 M21563 To IronSchematic Complete Machine Codes 11110, 11111 L12412 L12412Schematic Complete Machine Codes 11112, 11113 L12265 L12265Schematic Complete Machine Codes 11243, 11244 L12265-1 L12265-1L12561 Lower Left MachineSchematic Complete Machine Codes 11411, 11412 L13096 L13096Schematic Complete Machine Codes 11413, 11414 L13097 L13097Schematic Complete Machine Codes 11472, 11473 L13672 L13672Schematic Complete Machine Codes 11474, 11475 L13351 L13351Wire Feed Module Wiring Diagram Wiring Diagram Wire Feed Module Option L9259Schematic Wire Feed Module Option G2562 Classic 300D & 300G Electrical Diagrams Schematic Current Sensor PC BD Kubota Engine only S25973