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Lincoln Electric SVM194-A service manual 75TROUBLESHOOTING and REPAIRF-75

Models: SVM194-A

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F-75TROUBLESHOOTING AND REPAIRF-75

GENERATOR FRAME

REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION

This procedure will aid the technician in the removal and replacement of the DC genera- tor frame.

MATERIALS NEEDED

Rope sling

3/4" wrench 1/2" wrench 9/16" wrench Wood or steel blocks Pry bars

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CLASSIC® 300D & 300G

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Lincoln Electric SVM194-A 75TROUBLESHOOTING and REPAIRF-75, Generator Frame Removal and Replacement Procedure

Contents

Classic 300 D & 300 G Powered equipment SafetyFor Engine Electric Magnetic Fields Fumes and Gases Electric Shock can kill ARC Rays can burnCan be dangerous Classic 300D & 300G Iii Cylinder may explodeFor Electrically Précautions DE Sûreté Pour Précautions DE SûretéLES Machines À Souder À Transformateur ET À Electromagnetic Compatibility EMC L10093 3-1-96H Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Classic 300D InstallationWelding Output Open Circuit Output Range Auxiliary Power Height Width Depth Weight Rated Output Duty Cycle Design FeaturesOptional Features PRE-OPERATION Installation Trailer PREDiesel Fuel Vehicle Mounting Engine BREAK-IN Battery ChargingTo prevent Explosion when To prevent Electrical Damage when Table of Contents Operation Section Engine Operation OperationSee additional warning information at Cold Weather Starting Do not Turn the Current Range Selec See Specifications forWelder Operation B1.4 Auxiliary Power Table of Contents Accessories Section Optional Features AccessoriesMaintenance section TIG Options C1.3 Wire Feed Module K623-1 Provides constant voltMagnum 250 Innershield Gun for LN-23P Spool GUN Welder C1.4 Classic 300D & 300G Table of Contents Maintenance Section Maintenance Maintenance Purging Air from Fuel System Perkins Idler MaintenanceEngine Nameplates For Codes 10658 and below D1.4 For Codes 10911 and Above D1.5 D1.6 Resetting Procedure D1.7 Figure D1.7 Major Component Location D1.8 Classic 300D & 300G A2.1 DC Current Range Volts @ Rated Amps Cycle Model Height Width Depth WeightDescription Rated DC Output A2.3 When starting and stopping welding or using auxilEngine Muffler Exhaust Spark Arrester Machine GroundingLift Bail Do not Mount Over Combustible SU OIL PRE-OPERATION ServiceFuel Polarity Control and Cable Sizes Cooling System A2.6 Gases from Battery can explode Battery ChargingBattery Acid can burn eyes Skin A2.6 B2.1 High Altitude Operation Maintenance secStopping the Engine Starting the Classic 300D Perkins B2.3 Contacts and damage the switch B2.4 Idler Operation Auxiliary Power C2.1 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 Information at Safety Precautions Purging AIR from Fuel System Idler MaintenancePerkins 404C-22 Engine Nameplates D2.4 Service Decal for Codes 11249 and belowTension of alternator drive belt All nuts and bolts for tightness D2.5 MAINTENANCED2.5Service Decal for Codes 11250 and Above Gfci Receptacle Testing and Reset Ting Procedure D2.6MAINTENANCED2.6 D2.7 Case Front Assembly D2.8 Classic 300D & 300G A3.1 A3.2 Technical Specifications Classic 300D Kubota A3.3 Control Panel High Idle RPM OCV Adjustment Angle of Operation This operatorʼs manualNot Mount Over Combustible Surfaces Falling Polarity Control and Cable Sizes Fuel A3.6 Battery Charging WarningGAS ES from Battery can explode B3.1 Diesel Engine Starting the Classic 300D Kubota V2203M Control of Welding Current B3.3 Idler Operation B3.4 C3.1 Stick Options TIG Options C3.3 Wire Feed Options C3.4 Classic 300D & 300G D3.1 D3.2 D3.3 Kubota V2203M EngineAir Bleeding Valve D3.4 Engine Service D3.5MAINTENANCED3.5 D3.6 Figure D3.6 Major Component Location A4.1 A4.2 A4.3 General Description A4.4 See Optional Features A4.5 Read the engine operating and maintenanceInstructions supplied with this machine Can A4.6 B4.1 404D-22 Diesel Engine B4.2 B4.3 Selector setting and lower open circuit voltage B4.4 C4.1 Service Indicator Kit K1858-1 Water Valve Kit K844-1 Power Plug Kit K802DC4.2 Ball Hitch K958-1 K958-2 Control Cable Extension K937-45 C4.3 Magnum Spool Gun K487-25 Wire Feed Module K623-1 C4.4 Classic 300D & 300G D4.1 D4.2 D4.3 Perkins 404D-22 Engine D4.4 MAINTENANCED4.4 D4.5MAINTENANCED4.5 D4.6 Figure D4.6 Major Component Location A5.1 Description Rated DC Output Duty Cycle DC Current Range Technical Specifications Classic 300G K1754-1A5.2 Do not Mount Over Combustible SUR Exhaust Spark Arrester Lift Bail Vehicle Mounting Gasoline A5.5 A5.6 Classic 300D & 300G B5.1 Starting and stopping welding or using auxiliary Design FeaturesB5.2 Do not Mount Over Combustible Surfaces B5.3 High Idle RPM OCV Adjustment- a potentiometer isRefer to the Engine Starting the Classic 300G GM 3.0L Idler Control Operation B5.4Throttle Body Deicing System C5.1 C5.2 Optional Equipment D5.1 General Instructions BearingsCommutator and Brushes Engine Maintenance Idler Control MaintenancePurging AIR from Fuel System GM 0L Engine D5.4 Engine Service D5.5 Figure D5.5 Major Component Location D5.6 Classic 300D & 300G 1TABLE of CONTENTS-THEORY of Operation Section E-1 Gasoline Engine Theory of Operation Perkins Classic 300G, Zenith Fuel System/GM Engine BATTERY, STARTER, Engine Alternator & Protection Circuits Classic 300D, Kubota Engine Classic 300D, Perkins Engine Adjustment Coils Fine Current AdjustmentTOR and Rotor Excitation Flashing Figure E.8 Classic 300D, Perkins Engine 11472, 11135 10657, 10658, 10911, Engine Idler Circuit Theory of Operation DC Generator Machines Classic 300D & 300G Table of Contents Troubleshooting and Repair Locate Problem Symptom HOW to USE Troubleshooting GuideRecommended Perform External Tests Electric Shock PC Board Troubleshooting Procedures Ring Service Procedure Adjustment TestPerform the Brush and Slip Perform the Flash Voltage Generator Brush Service ProcedureCommutator Inspection Shunt Field Coil Output takes a long time to Weld output is considerably Perform the Shunt Field Coil Rocker AdjustmentAdjustment Procedure if Slip Ring Service RPM Adjustment TestProcedure Exciter Rotor Resistance and Ground Test Shunt Field Coil Flash 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 For Classic 300G Kubota powered units Engine goes to low idle, but Kubota powered Classic Classic 300G Classic 300D Kubota Powered machines Perkins powered models Troubleshooting and Repair Brush & Slip Ring Service Procedure 23TROUBLESHOOTING and REPAIRF-23Exciter/Auxiliary Power Alternator Procedure Description Procedure 24TROUBLESHOOTING and REPAIRF-24Cleaning the Slip Rings Seating Brushes Test Description 25TROUBLESHOOTING and REPAIRF-25Engine Alternator Test Procedure Engine Alternator Test Procedure Engine Fuel System Voltage Test Procedure 27TROUBLESHOOTING and REPAIRF-27 Engine Fuel System Voltage Test Procedure Engine Protection System Test Procedure 29TROUBLESHOOTING and REPAIRF-29 Warranty will not Cover the Damage Engine Protection System Test ProcedureTED to RUN White Overheated or with TOW OIL PRESSURE, Severe Engine DAM Materials Needed Miscellaneous hand tools Strobe tachometer 31TROUBLESHOOTING and REPAIRF-31Engine RPM Adjustment Test Procedure Engine RPM Adjustment Procedure later in this section Engine RPM Adjustment Test ProcedureClassic 300D Perkins only Strobe-Tach Method Low idle adjustment Classic 300D & 300G Flashing Voltage Test Procedure 35TROUBLESHOOTING and REPAIRF-35 Flashing Voltage Test Procedure Rocker Adjustment Procedure Rocker Adjustment Procedure 38TROUBLESHOOTING and REPAIRF-38Initial rocker placement Tighten Check 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 Shunt Field Coil Resistance and Ground Test Procedure 45TROUBLESHOOTING and REPAIRF-45 Shunt coil ground test Shunt Field Coil Resistance and Ground TestTest the shunt coil resistance Shunt Field Coil Resistance and Ground Shunt Field Circuit Voltage Test Procedure 47TROUBLESHOOTING and REPAIRF-47 Shunt Field Circuit Voltage Test Procedure Exciter Stator Short Circuit & Ground Test Procedure 49TROUBLESHOOTING and REPAIRF-49 Exciter Stator Short Circuit & Ground Test Procedure Weld Circuit Ground and Short Circuit Test Procedure If the resistance is lower than 500k Ohms Weld circuit ground test 53TROUBLESHOOTING and REPAIRF-53 Inspection and Service Procedure 54TROUBLESHOOTING and REPAIRF-54Welding Generator Brush and Commutator Perform the Weld Circuit Ground and Short Circuit Test Pitted and Are Damaged Commutator 55TROUBLESHOOTING and REPAIRF-55Uneven Commutator appearance Examine the brushes Classic 300D & 300G Series Coil Short Circuit Test Procedure 57TROUBLESHOOTING and REPAIRF-57 Series Coil Short Circuit Test Procedure High Idle no Load Fine Current Control Rheostat AT Maximum Scope Settings16.6 ms CH1 Normal Open Circuit DC Weld Voltage Waveform 60TROUBLESHOOTING and REPAIRF-60 Typical DC Weld Output Voltage Waveform 61TROUBLESHOOTING and REPAIRF-61Machine Loaded Selector Switch AT Maximum Position Classic 300D & 300G Alternator Rotor Removal Replacement Procedure 63TROUBLESHOOTING and REPAIRF-63Description Materials Needed 3/8 wrench Alternator Rotor Removal 64TROUBLESHOOTING and REPAIRF-64Replacement Procedure Troubleshooting and Repair Figure F.6 Rotor Removal 66TROUBLESHOOTING and REPAIRF-66 Replacement Replacement Procedure Classic 300D & 300G Materials Needed 3/8 nut driver 69TROUBLESHOOTING and REPAIRF-69Alternator Stator Removal and Replacement Procedure Alternator Stator Removal and Replacement 70TROUBLESHOOTING and REPAIRF-70Procedure Perform the Alternator Rotor Removal Figure F.8 Lead Disconnection Points 71TROUBLESHOOTING and REPAIRF-71 Genernator Brush HOLDER/COIL Cables Replacement Rotor Removal and Replacement pro 73TROUBLESHOOTING and REPAIRF-73 Classic 300D & 300G Generator Frame Removal and Replacement Procedure 75TROUBLESHOOTING and REPAIRF-75 Removal and Replacement 76TROUBLESHOOTING and REPAIRF-76Generator Frame Perform the Alternator Stator Removal Removal and Replacement See Figure F.14 for steps 14 78TROUBLESHOOTING and REPAIRF-78 Rope Sling 79TROUBLESHOOTING and REPAIRF-79 80TROUBLESHOOTING and REPAIRF-80 Generator Armature Removal and Replacement Procedure 81TROUBLESHOOTING and REPAIRF-81 Generator 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 Wiring Diagram Codes 10545, 10546, 10657, 10658 L10877 Electrical Diagrams Classic 300G Wiring Diagram Wiring Diagram Codes 10911, 10927 L11865 Classic 300D Wiring Diagram Wiring Diagram Codes 10912, 11135 L11866 Classic 300G Wiring Diagram Wiring Diagram Codes 11110, 11111 M20499 Classic 300D Perkins Wiring Diagram Wiring Diagram Codes 11112, 11113 M20432 Classic 300D Kubota Wiring Diagram OU Tput Terminals Wiring Diagram Codes 11243, 11244 M20432-1 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 To Iron Wiring Diagram Codes 11474, 11475 M21563 L12412 Schematic Complete Machine Codes 11110, 11111 L12412 L12265 Schematic Complete Machine Codes 11112, 11113 L12265 L12265-1 Schematic Complete Machine Codes 11243, 11244 L12265-1 Lower Left Machine L12561 L13096 Schematic Complete Machine Codes 11411, 11412 L13096 L13097 Schematic Complete Machine Codes 11413, 11414 L13097 L13672 Schematic Complete Machine Codes 11472, 11473 L13672 L13351 Schematic Complete Machine Codes 11474, 11475 L13351 Wiring Diagram Wire Feed Module Option L9259 Wire Feed Module Wiring Diagram Schematic Wire Feed Module Option G2562 Classic 300D & 300G Electrical Diagrams Schematic Current Sensor PC BD Kubota Engine only S25973