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

Models: SVM194-A

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F-34

NOTESF-34

CLASSIC® 300D & 300G

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

Contents

Classic 300 D & 300 G Safety Powered equipmentFor Engine Electric Magnetic FieldsElectric Shock can kill ARC Rays can burn Fumes and GasesCan be dangerous Classic 300D & 300GCylinder may explode For ElectricallyIii Précautions DE Sûreté Précautions DE Sûreté PourLES Machines À Souder À Transformateur ET ÀElectromagnetic Compatibility EMC L10093 3-1-96H Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Classic 300DWelding Output Open Circuit Output Range Auxiliary Power Height Width Depth WeightDesign Features Optional FeaturesRated Output Duty Cycle PRE-OPERATION Installation PRE TrailerDiesel Fuel Vehicle MountingBattery Charging Engine BREAK-INTo prevent Explosion when To prevent Electrical Damage whenTable of Contents Operation Section Operation Engine OperationSee additional warning information at Cold Weather StartingSee Specifications for Welder OperationDo not Turn the Current Range Selec Auxiliary Power B1.4Table of Contents Accessories Section Accessories Optional FeaturesMaintenance section TIG OptionsWire Feed Module K623-1 Provides constant volt C1.3Magnum 250 Innershield Gun for LN-23P Spool GUN WelderC1.4 Classic 300D & 300G Table of Contents Maintenance Section Maintenance MaintenanceIdler Maintenance Purging Air from Fuel System PerkinsEngine 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 Model Height Width Depth Weight Description Rated DC OutputDC Current Range Volts @ Rated Amps Cycle When starting and stopping welding or using auxil A2.3Engine MufflerMachine Grounding Exhaust Spark ArresterLift Bail Do not Mount Over Combustible SUPRE-OPERATION Service OILFuel Polarity Control and Cable Sizes Cooling SystemBattery Charging A2.6 Gases from Battery can explodeBattery Acid can burn eyes Skin A2.6B2.1 Maintenance sec High Altitude OperationStopping the Engine Starting the Classic 300D PerkinsContacts and damage the switch B2.3Idler Operation Auxiliary Power B2.4C2.1 Stick Options Accessory SET K704 TIG Options General OptionsTrailer K953-1 Wire Feeder Options Wire Feed Module K623-1 Magnum Spool Gun K487-25C2.3 C2.4 Classic 300D & 300G D2.1 Safety Precautions Information atIdler Maintenance Purging AIR from Fuel SystemPerkins 404C-22 Engine NameplatesService Decal for Codes 11249 and below D2.4Tension of alternator drive belt All nuts and bolts for tightnessMAINTENANCED2.5 Service Decal for Codes 11250 and AboveD2.5 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 A3.3This operatorʼs manual Angle of OperationNot Mount Over Combustible Surfaces FallingPolarity Control and Cable Sizes Fuel Battery Charging Warning GAS ES from Battery can explodeA3.6 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 Kubota V2203M Engine D3.3Air Bleeding ValveEngine Service D3.4D3.5MAINTENANCED3.5 Figure D3.6 Major Component Location D3.6A4.1 A4.2 General Description A4.3See Optional Features A4.4Read the engine operating and maintenance A4.5Instructions supplied with this machine CanA4.6 B4.1 B4.2 404D-22 Diesel EngineSelector setting and lower open circuit voltage B4.3B4.4 C4.1 Power Plug Kit K802D Service Indicator Kit K1858-1 Water Valve Kit K844-1C4.2 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 Technical Specifications Classic 300G K1754-1 A5.2Description Rated DC Output Duty Cycle DC Current Range Exhaust Spark Arrester Lift Bail Do not Mount Over Combustible SURGasoline Vehicle MountingA5.5 A5.6 Classic 300D & 300G B5.1 Design Features Starting and stopping welding or using auxiliaryB5.2 Do not Mount Over Combustible SurfacesHigh Idle RPM OCV Adjustment- a potentiometer is B5.3Refer to the Engine Starting the Classic 300G GM 3.0LB5.4 Throttle Body Deicing SystemIdler Control Operation C5.1 Optional Equipment C5.2D5.1 Bearings Commutator and BrushesGeneral Instructions Idler Control Maintenance Engine MaintenancePurging AIR from Fuel System GM 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 EngineFine Current Adjustment Adjustment CoilsTOR and Rotor 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 ContentsHOW to USE Troubleshooting Guide Locate Problem SymptomRecommended Perform External TestsPC Board Troubleshooting Procedures Electric ShockAdjustment Test Ring Service ProcedurePerform the Brush and Slip Perform the Flash VoltageService Procedure Generator BrushCommutator Inspection Shunt Field CoilOutput takes a long time to Weld output is considerably Rocker Adjustment Adjustment Procedure ifPerform the Shunt Field Coil RPM Adjustment Test Slip Ring ServiceProcedure Exciter Rotor Resistance and Ground Test Shunt Field CoilBrush and Slip WeldingFlash Voltage 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 23TROUBLESHOOTING and REPAIRF-23 Brush & Slip Ring Service ProcedureExciter/Auxiliary Power Alternator Procedure Description24TROUBLESHOOTING and REPAIRF-24 ProcedureCleaning the Slip Rings Seating Brushes25TROUBLESHOOTING and REPAIRF-25 Engine Alternator Test ProcedureTest Description 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 ProcedureEngine Protection System Test Procedure Warranty will not Cover the DamageTED to RUN White Overheated or with TOW OIL PRESSURE, Severe Engine DAM31TROUBLESHOOTING and REPAIRF-31 Engine RPM Adjustment Test ProcedureMaterials Needed Miscellaneous hand tools Strobe tachometer Engine RPM Adjustment Test Procedure Engine RPM Adjustment Procedure later in this sectionClassic 300D Perkins only Strobe-Tach MethodLow idle adjustment Classic 300D & 300G 35TROUBLESHOOTING and REPAIRF-35 Flashing Voltage Test ProcedureFlashing Voltage Test Procedure Rocker Adjustment Procedure 38TROUBLESHOOTING and REPAIRF-38 Rocker Adjustment ProcedureInitial rocker placement TightenCheck for Max output Classic 300D & 300G 41TROUBLESHOOTING and REPAIRF-41 Exciter Rotor Resistance and Ground Tests ProcedureExciter / Auxiliary Power Alternator 42TROUBLESHOOTING and REPAIRF-42 Static TestsDynamic Tests 43TROUBLESHOOTING and REPAIRF-43 Classic 300D & 300G 45TROUBLESHOOTING and REPAIRF-45 Shunt Field Coil Resistance and Ground Test ProcedureShunt Field Coil Resistance and Ground Test Shunt coil ground testTest the shunt coil resistance 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 54TROUBLESHOOTING and REPAIRF-54 Inspection and Service ProcedureWelding Generator Brush and Commutator Perform the Weld Circuit Ground and Short Circuit Test55TROUBLESHOOTING and REPAIRF-55 Pitted and Are Damaged CommutatorUneven Commutator appearance Examine the brushesClassic 300D & 300G 57TROUBLESHOOTING and REPAIRF-57 Series Coil Short Circuit Test ProcedureSeries Coil Short Circuit Test Procedure Scope Settings High Idle no Load Fine Current Control Rheostat AT Maximum16.6 ms CH160TROUBLESHOOTING and REPAIRF-60 Normal Open Circuit DC Weld Voltage Waveform61TROUBLESHOOTING and REPAIRF-61 Machine Loaded Selector Switch AT Maximum PositionTypical DC Weld Output Voltage Waveform Classic 300D & 300G 63TROUBLESHOOTING and REPAIRF-63 Alternator Rotor Removal Replacement ProcedureDescription Materials Needed 3/8 wrench64TROUBLESHOOTING and REPAIRF-64 Replacement ProcedureAlternator Rotor Removal Troubleshooting and Repair 66TROUBLESHOOTING and REPAIRF-66 Figure F.6 Rotor RemovalReplacement Procedure ReplacementClassic 300D & 300G 69TROUBLESHOOTING and REPAIRF-69 Alternator Stator Removal and Replacement ProcedureMaterials Needed 3/8 nut driver 70TROUBLESHOOTING and REPAIRF-70 Alternator Stator Removal and ReplacementProcedure 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 Procedure76TROUBLESHOOTING and REPAIRF-76 Removal and ReplacementGenerator Frame 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 Procedure82TROUBLESHOOTING and REPAIRF-82 Removal and Replacement ProcedureGenerator Armature AC Auxiliary Power Receptacle Output Current Rheostat at MaximumRPM 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