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Lincoln Electric SVM194-A service manual Table of Contents Operation Section, B5.1

Models: SVM194-A

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B5.1

TABLE OF CONTENTS - OPERATION SECTION

B5.1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5.2

Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5.3

Control of Welding Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5.4

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CLASSIC® 300D & 300G

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Lincoln Electric SVM194-A service manual Table of Contents Operation Section, B5.1

Contents

Classic 300 D & 300 G Electric Magnetic Fields SafetyPowered equipment For EngineClassic 300D & 300G Electric Shock can kill ARC Rays can burnFumes and Gases Can be dangerousCylinder may explode For ElectricallyIii Transformateur ET À Précautions DE SûretéPrécautions DE Sûreté Pour LES Machines À Souder ÀElectromagnetic Compatibility EMC L10093 3-1-96H Master Table of Contents for ALL Sections Table of Contents Installation Section Height Width Depth Weight InstallationTechnical Specifications Classic 300D Welding Output Open Circuit Output Range Auxiliary PowerDesign Features Optional FeaturesRated Output Duty Cycle PRE-OPERATION Installation Vehicle Mounting PRETrailer Diesel FuelTo prevent Electrical Damage when Battery ChargingEngine BREAK-IN To prevent Explosion whenTable of Contents Operation Section Cold Weather Starting OperationEngine Operation See additional warning information atSee Specifications for Welder OperationDo not Turn the Current Range Selec B1.4 Auxiliary PowerTable of Contents Accessories Section TIG Options AccessoriesOptional Features Maintenance sectionSpool GUN Welder Wire Feed Module K623-1 Provides constant voltC1.3 Magnum 250 Innershield Gun for LN-23PC1.4 Classic 300D & 300G Table of Contents Maintenance Section Maintenance MaintenanceNameplates Idler MaintenancePurging Air from Fuel System Perkins EngineFor Codes 10658 and below D1.4For Codes 10911 and Above D1.5D1.6 Resetting ProcedureD1.7 Figure D1.7 Major Component LocationD1.8 Classic 300D & 300G A2.1 Model Height Width Depth Weight Description Rated DC OutputDC Current Range Volts @ Rated Amps Cycle Muffler When starting and stopping welding or using auxilA2.3 EngineDo not Mount Over Combustible SU Machine GroundingExhaust Spark Arrester Lift BailCooling System PRE-OPERATION ServiceOIL Fuel Polarity Control and Cable SizesA2.6 Battery ChargingA2.6 Gases from Battery can explode Battery Acid can burn eyes SkinB2.1 Starting the Classic 300D Perkins Maintenance secHigh Altitude Operation Stopping the EngineB2.3 Contacts and damage the switchB2.4 Idler Operation Auxiliary PowerC2.1 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 Information at Safety PrecautionsNameplates Idler MaintenancePurging AIR from Fuel System Perkins 404C-22 EngineAll nuts and bolts for tightness Service Decal for Codes 11249 and belowD2.4 Tension of alternator drive beltMAINTENANCED2.5 Service Decal for Codes 11250 and AboveD2.5 Gfci Receptacle Testing and Reset Ting Procedure D2.6MAINTENANCED2.6D2.7 Case Front AssemblyD2.8 Classic 300D & 300G A3.1 A3.2 Technical Specifications Classic 300D KubotaA3.3 Control Panel High Idle RPM OCV AdjustmentFalling This operatorʼs manualAngle of Operation Not Mount Over Combustible SurfacesPolarity Control and Cable Sizes Fuel Battery Charging Warning GAS ES from Battery can explodeA3.6 B3.1 Diesel Engine Starting the Classic 300D Kubota V2203MControl of Welding Current B3.3Idler Operation B3.4C3.1 Stick Options TIG OptionsC3.3 Wire Feed OptionsC3.4 Classic 300D & 300G D3.1 D3.2 Valve Kubota V2203M EngineD3.3 Air BleedingD3.4 Engine ServiceD3.5MAINTENANCED3.5 D3.6 Figure D3.6 Major Component LocationA4.1 A4.2 A4.3 General DescriptionA4.4 See Optional FeaturesCan Read the engine operating and maintenanceA4.5 Instructions supplied with this machineA4.6 B4.1 404D-22 Diesel Engine B4.2B4.3 Selector setting and lower open circuit voltageB4.4 C4.1 Ball Hitch K958-1 K958-2 Control Cable Extension K937-45 Power Plug Kit K802DService Indicator Kit K1858-1 Water Valve Kit K844-1 C4.2C4.3 Magnum Spool Gun K487-25 Wire Feed Module K623-1C4.4 Classic 300D & 300G D4.1 D4.2 D4.3 Perkins 404D-22 EngineD4.4 MAINTENANCED4.4D4.5MAINTENANCED4.5 D4.6 Figure D4.6 Major Component LocationA5.1 Technical Specifications Classic 300G K1754-1 A5.2Description Rated DC Output Duty Cycle DC Current Range Do not Mount Over Combustible SUR Exhaust Spark Arrester Lift BailVehicle Mounting GasolineA5.5 A5.6 Classic 300D & 300G B5.1 Do not Mount Over Combustible Surfaces Design FeaturesStarting and stopping welding or using auxiliary B5.2Starting the Classic 300G GM 3.0L High Idle RPM OCV Adjustment- a potentiometer isB5.3 Refer to the EngineB5.4 Throttle Body Deicing SystemIdler Control Operation C5.1 C5.2 Optional EquipmentD5.1 Bearings Commutator and BrushesGeneral Instructions 0L Engine Idler Control MaintenanceEngine Maintenance Purging AIR from Fuel System GMD5.4 Engine ServiceD5.5 Figure D5.5 Major Component LocationD5.6 Classic 300D & 300G 1TABLE of CONTENTS-THEORY of Operation Section E-1 Gasoline Engine Theory of OperationPerkins Classic 300G, Zenith Fuel System/GM Engine BATTERY, STARTER, Engine Alternator & Protection CircuitsClassic 300D, Kubota Engine Classic 300D, Perkins EngineExcitation Flashing Fine Current AdjustmentAdjustment Coils TOR and RotorFigure E.8 Classic 300D, Perkins Engine 11472, 11135 10657, 10658, 10911, Engine Idler CircuitTheory of Operation DC Generator Machines Classic 300D & 300G Table of Contents Troubleshooting and RepairPerform External Tests HOW to USE Troubleshooting GuideLocate Problem Symptom RecommendedElectric Shock PC Board Troubleshooting ProceduresPerform the Flash Voltage Adjustment TestRing Service Procedure Perform the Brush and SlipShunt Field Coil Service ProcedureGenerator Brush Commutator InspectionOutput takes a long time to Weld output is considerably Rocker Adjustment Adjustment Procedure ifPerform the Shunt Field Coil Exciter Rotor Resistance and Ground Test Shunt Field Coil RPM Adjustment TestSlip Ring Service ProcedureBrush 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 For Classic 300G Kubota powered unitsEngine goes to low idle, but Kubota powered Classic Classic 300G Classic 300D Kubota Powered machines Perkins powered modelsTroubleshooting and Repair Procedure Description 23TROUBLESHOOTING and REPAIRF-23Brush & Slip Ring Service Procedure Exciter/Auxiliary Power AlternatorSeating Brushes 24TROUBLESHOOTING and REPAIRF-24Procedure Cleaning the Slip Rings25TROUBLESHOOTING and REPAIRF-25 Engine Alternator Test ProcedureTest Description Engine Alternator Test Procedure Engine Fuel System Voltage Test Procedure 27TROUBLESHOOTING and REPAIRF-27Engine Fuel System Voltage Test Procedure Engine Protection System Test Procedure 29TROUBLESHOOTING and REPAIRF-29TOW OIL PRESSURE, Severe Engine DAM Engine Protection System Test ProcedureWarranty will not Cover the Damage TED to RUN White Overheated or with31TROUBLESHOOTING and REPAIRF-31 Engine RPM Adjustment Test ProcedureMaterials Needed Miscellaneous hand tools Strobe tachometer Strobe-Tach Method Engine RPM Adjustment Test ProcedureEngine RPM Adjustment Procedure later in this section Classic 300D Perkins onlyLow idle adjustment Classic 300D & 300G Flashing Voltage Test Procedure 35TROUBLESHOOTING and REPAIRF-35Flashing Voltage Test Procedure Rocker Adjustment Procedure Tighten 38TROUBLESHOOTING and REPAIRF-38Rocker Adjustment Procedure Initial rocker placementCheck 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 Shunt Field Coil Resistance and Ground Test Procedure 45TROUBLESHOOTING and REPAIRF-45Shunt Field Coil Resistance and Ground Shunt Field Coil Resistance and Ground TestShunt coil ground test Test the shunt coil resistanceShunt Field Circuit Voltage Test Procedure 47TROUBLESHOOTING and REPAIRF-47Shunt Field Circuit Voltage Test Procedure Exciter Stator Short Circuit & Ground Test Procedure 49TROUBLESHOOTING and REPAIRF-49Exciter 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 test53TROUBLESHOOTING and REPAIRF-53 Perform the Weld Circuit Ground and Short Circuit Test 54TROUBLESHOOTING and REPAIRF-54Inspection and Service Procedure Welding Generator Brush and CommutatorExamine the brushes 55TROUBLESHOOTING and REPAIRF-55Pitted and Are Damaged Commutator Uneven Commutator appearanceClassic 300D & 300G Series Coil Short Circuit Test Procedure 57TROUBLESHOOTING and REPAIRF-57Series Coil Short Circuit Test Procedure CH1 Scope SettingsHigh Idle no Load Fine Current Control Rheostat AT Maximum 16.6 msNormal Open Circuit DC Weld Voltage Waveform 60TROUBLESHOOTING and REPAIRF-6061TROUBLESHOOTING and REPAIRF-61 Machine Loaded Selector Switch AT Maximum PositionTypical DC Weld Output Voltage Waveform Classic 300D & 300G Materials Needed 3/8 wrench 63TROUBLESHOOTING and REPAIRF-63Alternator Rotor Removal Replacement Procedure Description64TROUBLESHOOTING and REPAIRF-64 Replacement ProcedureAlternator Rotor Removal Troubleshooting and Repair Figure F.6 Rotor Removal 66TROUBLESHOOTING and REPAIRF-66Replacement Replacement ProcedureClassic 300D & 300G 69TROUBLESHOOTING and REPAIRF-69 Alternator Stator Removal and Replacement ProcedureMaterials Needed 3/8 nut driver Perform the Alternator Rotor Removal 70TROUBLESHOOTING and REPAIRF-70Alternator Stator Removal and Replacement ProcedureFigure F.8 Lead Disconnection Points 71TROUBLESHOOTING and REPAIRF-71Genernator Brush HOLDER/COIL Cables ReplacementRotor Removal and Replacement pro 73TROUBLESHOOTING and REPAIRF-73Classic 300D & 300G Generator Frame Removal and Replacement Procedure 75TROUBLESHOOTING and REPAIRF-75Perform the Alternator Stator Removal 76TROUBLESHOOTING and REPAIRF-76Removal and Replacement Generator FrameRemoval and Replacement See Figure F.14 for steps 14 78TROUBLESHOOTING and REPAIRF-78Rope Sling 79TROUBLESHOOTING and REPAIRF-7980TROUBLESHOOTING and REPAIRF-80 Generator Armature Removal and Replacement Procedure 81TROUBLESHOOTING and REPAIRF-8182TROUBLESHOOTING 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 Wiring Diagram Codes 10545, 10546, 10657, 10658 L10877 Electrical DiagramsClassic 300G Wiring Diagram Wiring Diagram Codes 10911, 10927 L11865 Classic 300D Wiring DiagramWiring Diagram Codes 10912, 11135 L11866 Classic 300G Wiring DiagramWiring Diagram Codes 11110, 11111 M20499 Classic 300D Perkins Wiring DiagramWiring Diagram Codes 11112, 11113 M20432 Classic 300D Kubota Wiring DiagramOU Tput Terminals Wiring Diagram Codes 11243, 11244 M20432-1Wiring 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 M21563L12412 Schematic Complete Machine Codes 11110, 11111 L12412L12265 Schematic Complete Machine Codes 11112, 11113 L12265L12265-1 Schematic Complete Machine Codes 11243, 11244 L12265-1Lower Left Machine L12561L13096 Schematic Complete Machine Codes 11411, 11412 L13096L13097 Schematic Complete Machine Codes 11413, 11414 L13097L13672 Schematic Complete Machine Codes 11472, 11473 L13672L13351 Schematic Complete Machine Codes 11474, 11475 L13351Wiring Diagram Wire Feed Module Option L9259 Wire Feed Module Wiring DiagramSchematic Wire Feed Module Option G2562 Classic 300D & 300G Electrical Diagrams Schematic Current Sensor PC BD Kubota Engine only S25973