64TROUBLESHOOTING and REPAIRF-64 | Lincoln Electric SVM194-A

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F-64TROUBLESHOOTING AND REPAIRF-64

ALTERNATOR ROTOR REMOVAL

AND REPLACEMENT PROCEDURE (continued)

PROCEDURE

1. Turn the engine off.

2. Using the 7/16” wrench, remove the two bolts and washers and partially slide out the battery mounting panel. See Figure F.4

3. With the 1/2" wrench, disconnect the negative battery cable.

FIGURE F.4 – BATTERY PANEL REMOVAL

NEGATIVE

BATTERY

CABLE

BATTERY

MOUNTING

PANEL

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CLASSIC® 300D & 300G

Image 186

Lincoln Electric SVM194-A service manual 64TROUBLESHOOTING and REPAIRF-64, Alternator Rotor Removal, Replacement Procedure

Contents

Classic 300 D & 300 G For Engine SafetyPowered equipment Electric Magnetic Fields Can be dangerous Electric Shock can kill ARC Rays can burnFumes and Gases Classic 300D & 300G Cylinder may explode For ElectricallyIii LES Machines À Souder À Précautions DE SûretéPrécautions DE Sûreté Pour Transformateur ET À Electromagnetic 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 Weight Design Features Optional FeaturesRated Output Duty Cycle PRE-OPERATION Installation Diesel Fuel PRETrailer Vehicle Mounting To prevent Explosion when Battery ChargingEngine BREAK-IN To prevent Electrical Damage when Table of Contents Operation Section See additional warning information at OperationEngine Operation Cold Weather Starting See Specifications for Welder OperationDo not Turn the Current Range Selec Auxiliary Power B1.4 Table of Contents Accessories Section Maintenance section AccessoriesOptional Features TIG Options Magnum 250 Innershield Gun for LN-23P Wire Feed Module K623-1 Provides constant voltC1.3 Spool GUN Welder C1.4 Classic 300D & 300G Table of Contents Maintenance Section Maintenance Maintenance Engine Idler MaintenancePurging Air from Fuel System Perkins Nameplates D1.4 For Codes 10658 and below D1.5 For Codes 10911 and Above Resetting Procedure D1.6 Figure D1.7 Major Component Location D1.7 D1.8 Classic 300D & 300G A2.1 Model Height Width Depth Weight Description Rated DC OutputDC Current Range Volts @ Rated Amps Cycle Engine When starting and stopping welding or using auxilA2.3 Muffler Lift Bail Machine GroundingExhaust Spark Arrester Do not Mount Over Combustible SU Fuel Polarity Control and Cable Sizes PRE-OPERATION ServiceOIL Cooling System Battery Acid can burn eyes Skin Battery ChargingA2.6 Gases from Battery can explode A2.6 B2.1 Stopping the Engine Maintenance secHigh Altitude Operation Starting the Classic 300D Perkins Contacts and damage the switch B2.3 Idler Operation Auxiliary Power B2.4 C2.1 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 at Perkins 404C-22 Engine Idler MaintenancePurging AIR from Fuel System Nameplates Tension of alternator drive belt Service Decal for Codes 11249 and belowD2.4 All nuts and bolts for tightness MAINTENANCED2.5 Service Decal for Codes 11250 and AboveD2.5 D2.6MAINTENANCED2.6 Gfci Receptacle Testing and Reset Ting Procedure Case Front Assembly D2.7 D2.8 Classic 300D & 300G A3.1 Technical Specifications Classic 300D Kubota A3.2 Control Panel High Idle RPM OCV Adjustment A3.3 Not Mount Over Combustible Surfaces This operatorʼs manualAngle of Operation Falling Polarity Control and Cable Sizes Fuel Battery Charging Warning GAS ES from Battery can explodeA3.6 B3.1 Starting the Classic 300D Kubota V2203M Diesel Engine B3.3 Control of Welding Current B3.4 Idler Operation C3.1 TIG Options Stick Options Wire Feed Options C3.3 C3.4 Classic 300D & 300G D3.1 D3.2 Air Bleeding Kubota V2203M EngineD3.3 Valve Engine Service D3.4 D3.5MAINTENANCED3.5 Figure D3.6 Major Component Location D3.6 A4.1 A4.2 General Description A4.3 See Optional Features A4.4 Instructions supplied with this machine Read the engine operating and maintenanceA4.5 Can A4.6 B4.1 B4.2 404D-22 Diesel Engine Selector setting and lower open circuit voltage B4.3 B4.4 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 K937-45 Magnum Spool Gun K487-25 Wire Feed Module K623-1 C4.3 C4.4 Classic 300D & 300G D4.1 D4.2 Perkins 404D-22 Engine D4.3 MAINTENANCED4.4 D4.4 D4.5MAINTENANCED4.5 Figure D4.6 Major Component Location D4.6 A5.1 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 SUR Gasoline Vehicle Mounting A5.5 A5.6 Classic 300D & 300G B5.1 B5.2 Design FeaturesStarting and stopping welding or using auxiliary Do not Mount Over Combustible Surfaces Refer to the Engine High Idle RPM OCV Adjustment- a potentiometer isB5.3 Starting the Classic 300G GM 3.0L B5.4 Throttle Body Deicing SystemIdler Control Operation C5.1 Optional Equipment C5.2 D5.1 Bearings Commutator and BrushesGeneral Instructions Purging AIR from Fuel System GM Idler Control MaintenanceEngine Maintenance 0L Engine Engine Service D5.4 Figure D5.5 Major Component Location D5.5 D5.6 Classic 300D & 300G 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Gasoline Engine Perkins BATTERY, STARTER, Engine Alternator & Protection Circuits Classic 300G, Zenith Fuel System/GM Engine Classic 300D, Perkins Engine Classic 300D, Kubota Engine TOR and Rotor Fine Current AdjustmentAdjustment Coils Excitation Flashing Figure 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 Contents Recommended HOW to USE Troubleshooting GuideLocate Problem Symptom Perform External Tests PC Board Troubleshooting Procedures Electric Shock Perform the Brush and Slip Adjustment TestRing Service Procedure Perform the Flash Voltage Commutator Inspection Service ProcedureGenerator Brush Shunt Field Coil Output takes a long time to Weld output is considerably Rocker Adjustment Adjustment Procedure ifPerform the Shunt Field Coil Procedure RPM Adjustment TestSlip Ring Service Exciter Rotor Resistance and Ground Test Shunt Field Coil Brush 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 300G Engine goes to low idle, but Kubota powered Classic Perkins powered models Classic 300G Classic 300D Kubota Powered machines Troubleshooting and Repair Exciter/Auxiliary Power Alternator 23TROUBLESHOOTING and REPAIRF-23Brush & Slip Ring Service Procedure Procedure Description Cleaning the Slip Rings 24TROUBLESHOOTING and REPAIRF-24Procedure Seating Brushes 25TROUBLESHOOTING and REPAIRF-25 Engine Alternator Test ProcedureTest Description Engine Alternator Test Procedure 27TROUBLESHOOTING and REPAIRF-27 Engine Fuel System Voltage Test Procedure Engine Fuel System Voltage Test Procedure 29TROUBLESHOOTING and REPAIRF-29 Engine Protection System Test Procedure TED to RUN White Overheated or with Engine Protection System Test ProcedureWarranty will not Cover the Damage TOW OIL PRESSURE, Severe Engine DAM 31TROUBLESHOOTING and REPAIRF-31 Engine RPM Adjustment Test ProcedureMaterials Needed Miscellaneous hand tools Strobe tachometer Classic 300D Perkins only Engine RPM Adjustment Test ProcedureEngine RPM Adjustment Procedure later in this section Strobe-Tach Method Low idle adjustment Classic 300D & 300G 35TROUBLESHOOTING and REPAIRF-35 Flashing Voltage Test Procedure Flashing Voltage Test Procedure Rocker Adjustment Procedure Initial rocker placement 38TROUBLESHOOTING and REPAIRF-38Rocker Adjustment Procedure Tighten Check 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 Procedure Test the shunt coil resistance Shunt Field Coil Resistance and Ground TestShunt coil ground test Shunt Field Coil Resistance and Ground 47TROUBLESHOOTING and REPAIRF-47 Shunt Field Circuit Voltage Test Procedure Shunt Field Circuit Voltage Test Procedure 49TROUBLESHOOTING and REPAIRF-49 Exciter Stator Short Circuit & Ground Test Procedure Exciter 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 Ohms 53TROUBLESHOOTING and REPAIRF-53 Welding Generator Brush and Commutator 54TROUBLESHOOTING and REPAIRF-54Inspection and Service Procedure Perform the Weld Circuit Ground and Short Circuit Test Uneven Commutator appearance 55TROUBLESHOOTING and REPAIRF-55Pitted and Are Damaged Commutator Examine the brushes Classic 300D & 300G 57TROUBLESHOOTING and REPAIRF-57 Series Coil Short Circuit Test Procedure Series Coil Short Circuit Test Procedure 16.6 ms Scope SettingsHigh Idle no Load Fine Current Control Rheostat AT Maximum CH1 60TROUBLESHOOTING and REPAIRF-60 Normal Open Circuit DC Weld Voltage Waveform 61TROUBLESHOOTING and REPAIRF-61 Machine Loaded Selector Switch AT Maximum PositionTypical DC Weld Output Voltage Waveform Classic 300D & 300G Description 63TROUBLESHOOTING and REPAIRF-63Alternator Rotor Removal Replacement Procedure Materials Needed 3/8 wrench 64TROUBLESHOOTING and REPAIRF-64 Replacement ProcedureAlternator Rotor Removal Troubleshooting and Repair 66TROUBLESHOOTING and REPAIRF-66 Figure F.6 Rotor Removal Replacement Procedure Replacement Classic 300D & 300G 69TROUBLESHOOTING and REPAIRF-69 Alternator Stator Removal and Replacement ProcedureMaterials Needed 3/8 nut driver Procedure 70TROUBLESHOOTING and REPAIRF-70Alternator Stator Removal and Replacement Perform the Alternator Rotor Removal 71TROUBLESHOOTING and REPAIRF-71 Figure F.8 Lead Disconnection Points Replacement Genernator Brush HOLDER/COIL Cables 73TROUBLESHOOTING and REPAIRF-73 Rotor Removal and Replacement pro Classic 300D & 300G 75TROUBLESHOOTING and REPAIRF-75 Generator Frame Removal and Replacement Procedure Generator Frame 76TROUBLESHOOTING and REPAIRF-76Removal and Replacement Perform the Alternator Stator Removal Removal and Replacement 78TROUBLESHOOTING and REPAIRF-78 See Figure F.14 for steps 14 79TROUBLESHOOTING and REPAIRF-79 Rope Sling 80TROUBLESHOOTING and REPAIRF-80 81TROUBLESHOOTING and REPAIRF-81 Generator Armature Removal and Replacement Procedure 82TROUBLESHOOTING 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 L10877 Classic 300G Wiring Diagram Classic 300D Wiring Diagram Wiring Diagram Codes 10911, 10927 L11865 Classic 300G Wiring Diagram Wiring Diagram Codes 10912, 11135 L11866 Classic 300D Perkins Wiring Diagram Wiring Diagram Codes 11110, 11111 M20499 Classic 300D Kubota Wiring Diagram Wiring Diagram Codes 11112, 11113 M20432 Wiring Diagram Codes 11243, 11244 M20432-1 OU Tput Terminals Wiring 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 Iron Schematic Complete Machine Codes 11110, 11111 L12412 L12412 Schematic Complete Machine Codes 11112, 11113 L12265 L12265 Schematic Complete Machine Codes 11243, 11244 L12265-1 L12265-1 L12561 Lower Left Machine Schematic Complete Machine Codes 11411, 11412 L13096 L13096 Schematic Complete Machine Codes 11413, 11414 L13097 L13097 Schematic Complete Machine Codes 11472, 11473 L13672 L13672 Schematic Complete Machine Codes 11474, 11475 L13351 L13351 Wire Feed Module Wiring Diagram Wiring Diagram Wire Feed Module Option L9259 Schematic Wire Feed Module Option G2562 Classic 300D & 300G Electrical Diagrams Schematic Current Sensor PC BD Kubota Engine only S25973