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Lincoln Electric CLASSIC SVM194-A Service Manual
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Lincoln Electric CLASSIC SVM194-A Service Manual

Lincoln electric welder user manual
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CLASSIC 300 D & 300 G

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Summary of Contents for Lincoln Electric CLASSIC SVM194-A

  • Page 1 RETURN TO MAIN MENU CLASSIC 300 D & 300 G...
  • Page 8 RETURN TO MAIN MENU...
  • Page 26 ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS FIRST SERVICE-(20 / 50 HOURS) EVERY 100 HOURS OR 3 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 400 HOURS OR 12 MONTHS EVERY 600 HOURS OR 18 MONTHS ENGINE SERVICE (NOTE 2) MAINTENANCE ITEM Coolant level Concentration of antifreeze...
  • Page 27 ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS FIRST SERVICE-(20 / 50 HOURS) EVERY 100 HOURS OR 3 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 400 HOURS OR 12 MONTHS EVERY 600 HOURS OR 18 MONTHS ENGINE SERVICE (NOTE 2) MAINTENANCE ITEM Coolant level Concentration of antifreeze...
  • Page 43 LN-25 Wire Feeder K449 Remote Voltage Control Kit for LN-25 Magnum® 350 Innershield Gun for LN-25 K126-2 Magnum® 300 MIG Gun for LN-25 LN-23P Wire Feeder K316L-1 LN-23P Adapter Kit K350-1 Magnum Spool Gun K487-25 SG Control Module K488 (For Magnum Spool Gun) Input Cable K691-10 ( For SG Control Module) K355-10...

  • Page 48: Engine Service

    EVERY DAY OR EVERY 8 HOURS FIRST SERVICE-(20 / 50 HOURS) EVERY 100 HOURS OR 3 MONTHS EVERY 250 HOURS OR 6 MONTHS EVERY 500 HOURS OR 12 MONTHS EVERY 1000 HOURS ENGINE SERVICE (NOTE 2) MAINTENANCE ITEM Coolant level Concentration of antifreeze Coolant (NOTE 3) Engine oil level (NOTE 1)
  • Page 70 EVERY DAY OR EVERY 8 HOURS FIRST SERVICE (50 HOURS) EVERY 100 HOURS OR 3 MONTHS EVERY 150 HOURS OR 4 MONTHS EVERY 30O HOURS OR 9 MONTHS EVERY 400 HOURS OR 12 MONTHS EVERY 500 HOURS OR 15 MONTHS EVERY 600 HOURS OR 18 MONTHS ENGINE SERVICE (NOTE 2) Coolant level...
  • Page 85 LN-25 Wire Feeder K449 Remote Voltage Control Kit for LN-25 Magnum® 350 Innershield Gun for LN-25 K126-2 Magnum® 300 MIG Gun for LN-25 LN-23P Wire Feeder K316L-1 LN-23P Adapter Kit K350-1 Magnum Spool Gun K487-25 SG Control Module K488 (For Magnum Spool Gun) Input Cable K691-10 ( For SG Control Module) K355-10...
  • Page 94 (1) 115V will operate either 60 Hz. or 50/60 Hz. power tools, lights etc. Based on a 10 min. period.

  • Page 108: Engine Service

    ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS FIRST SERVICE - (50 HOURS) EVERY 100 HOURS OR 3 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 600 HOURS OR 12 MONTHS ENG INE SERVICE (NOTE 2) MAINTENANCE ITEM Coolant level Conc entration of antifreeze Radiator for contamination or blockage...
  • Page 112 IDLE SWITCH ENGINE ENGINE RPM CONTROL CONTROL COMPONENTS FUEL PUMP ZENITH SENSORS HOUR METER E.C.U. GASOLINE ENGINE FAILURE LAMP IGNITION SWITCH ENGINE ALTERNATOR START AMMETER BATTERY SELECTOR SWITCH GENERATOR FRAME SERIES COILS GENERATOR ENGINE ARMATURE MECHANICAL COUPLING INTERPOLE RESIDUAL COILS MAGNETISM FIELD SHUNT...
  • Page 113 TEMP. SWITCH ENGINE FAILURE LAMP HOUR IDLER / ENGINE METER PROTECTION P.C. BOARD PRESSURE IGNITION SWITCH GLOW IDLER FUEL GLOW PLUGS SOLENOID PUMP PLUG SOLENOID (PERKINS) BUTTON DIESEL ENGINE ALTERNATOR ENGINE AMMETER START BUTTON STARTER MOTOR BATTERY ENGINE IDLE SWITCH ENGINE CONTROL HOUR...
  • Page 114 IDLE SWITCH ENGINE ENGINE RPM CONTROL CONTROL COMPONENTS FUEL PUMP ZENITH SENSORS HOUR METER E.C.U. GASOLINE ENGINE FAILURE LAMP IGNITION SWITCH ENGINE ALTERNATOR START AMMETER BATTERY SELECTOR SWITCH GENERATOR FRAME SERIES COILS GENERATOR ENGINE ARMATURE MECHANICAL COUPLING INTERPOLE RESIDUAL COILS MAGNETISM FIELD SHUNT...
  • Page 115 TEMP. SWITCH ENGINE FAILURE LAMP HOUR IDLER / ENGINE METER PROTECTION P.C. BOARD PRESSURE IGNITION SWITCH GLOW IDLER FUEL GLOW PLUGS SOLENOID PUMP PLUG SOLENOID (PERKINS) BUTTON DIESEL ENGINE ALTERNATOR ENGINE AMMETER START BUTTON STARTER MOTOR BATTERY ENGINE IDLE SWITCH ENGINE CONTROL ENGINE FAILURE LAMP...
  • Page 117 TEMP. SWITCH ENGINE FAILURE LAMP IDLER / ENGINE HOUR METER PROTECTION P.C. BOARD PRESSURE IGNITION SWITCH GLOW IDLER FUEL GLOW PLUGS SOLENOID PUMP PLUG SOLENOID (PERKINS) BUTTON DIESEL ENGINE ALTERNATOR ENGINE AMMETER START BUTTON STARTER MOTOR BATTERY ENGINE IDLE SWITCH ENGINE CONTROL HOUR...
  • Page 118 IDLE SWITCH ENGINE ENGINE RPM CONTROL CONTROL COMPONENTS FUEL PUMP ZENITH SENSORS HOUR METER E.C.U. GASOLINE ENGINE FAILURE LAMP IGNITION SWITCH ENGINE ALTERNATOR START AMMETER BATTERY SELECTOR SWITCH GENERATOR FRAME SERIES COILS GENERATOR ENGINE ARMATURE MECHANICAL COUPLING INTERPOLE RESIDUAL COILS MAGNETISM FIELD SHUNT...
  • Page 121 SHUNT FIELD WINDINGS MAGNETIC FIELD GENERATOR MECHANICAL COUPLING ARMATURE MAGNETIC FIELD SHUNT FIELD WINDINGS DC CURRENT BRUSH ARMATURE SHAFT BRUSH DC CURRENT...
  • Page 130 (Continued)
  • Page 135 (Continued)
  • Page 140 (Continued)
  • Page 142 (Continued)
  • Page 160 EXCITER BRACKET DRILL MARKS ROCKER...
  • Page 165 *NOTE: The resistance of the copper windings will change with temperature. Higher temperatures will produce higher resistance, and lower temperatures will produce lower resistance.
  • Page 168 *NOTE: The resistance in the copper windings will change with temperature. Higher temperatures will produce slightly higher resistance, and lower tem- peratures will produce slightly lower resistance.
  • Page 176 EXCITER BRACKET DRILL MARKS ROCKER...
  • Page 186 NEGATIVE BATTERY CABLE BATTERY MOUNTING PANEL...
  • Page 187 See Figure F.5 for steps 3 - 5. WRAPAROUND SLIP RINGS ALTERNATOR COVER BRUSHES...
  • Page 188 See Figure F.6 for steps 6 - 8. "BENT" WASHER SLEEVE COLLAR STATOR FRAME BRUSH HOLDER ASSEMBLY...
  • Page 192 COMMUTATOR WRAPAROUND ALTERNATOR BRUSH HOLDER ASSEMBLY (REMOVED)
  • Page 193 YELLOW AND WHITE WIRE IN-LINE CONNECTORS; YELLOW LEADS; BLACK CURRENT TRANSFORMER LEAD ALL LOCATED BEHIND CASE FRONT 230 VAC RECEPTACLE CB1 CIRCUIT BREAKER 115 VAC RECEPTACLE CB4 CIRCUIT BREAKER FIELD FUSE HOLDER FIELD RECTIFIER BRIDGE...
  • Page 194 ( ontinued) GENERNATOR BRUSH HOLDER/COIL CABLES (4)
  • Page 195 BRUSH HOLDER DRILL SPOT LOCATION STATOR/END BRACKET MOUNTING BOLT STATOR END BRACKET DRILL SPOT...
  • Page 198 POSITIVE CABLE COPPER STRAP See Figure F.12 for steps 4 - 9. (DIESEL ONLY) FUEL TANK RETURN LINE FUEL LINE FUEL BOWL FUEL TANK MOUNTING HARDWARE...
  • Page 199 FINE CURRENT ADJUSTMENT RHEOSTAT FIELD BRIDGE See Figure F.13 for steps 10 - 13. IDLER PC BOARD IN-LINE CONNECTORS BLUE/BROWN LEADS SELECTOR SWITCH...
  • Page 200 STEP #16 STEP #15 STEP #14 See Figure F.14 for steps 14 - 16.
  • Page 201 ROPE SLING ENGINE/GENERATOR MOUNTING HOLES See Figure F.15 for steps 17 - 20. See steps 14 - 16.
  • Page 204 ROPE SLING BLOWER PADDLE BLOWER PADDLE/ARMATURE MOUNTING BOLTS (8) CAUTION...
  • Page 208 250 AMP THERMOSTAT WHEN MAKING THESE CONNECTIONS. ASSEMBLY 602B 600B 600A 602A RHEOSTAT SELECTOR SWITCH GENERATOR 5 4 3 2 1 WELDER LEAD BLOCK POSITIVE (CC+) & (CV+ WITH W.F.M.) W IRE FEED MOD ULE 7-13-2001G L10877 CLASSIC® 300D & 300G...
  • Page 209 MACHINE MUST NOT BE RUNNING ASSEMBLY WHEN MAKING THESE CONNECTIONS. 602B 600B 600A 602A RHEOSTAT SELECTOR SWITCH GENERATOR 5 4 3 2 1 WELDER LEAD BLOCK POSITIVE (CC+) & (CV+ WITH W.F.M.) WIRE FEED MODULE L11194 CLASSIC® 300D & 300G...
  • Page 210 ALTERNATOR AUXILIARY POWER WINDINGS (GROUND SCREW NEAR FUSE) 5 4 3 2 1 CURRENT CR2 REED WELDER TRANSFORMER RELAY LEAD BLOCK NEGATIVE POSITIVE (CC+) & (CV+ WITH W.F.M.) (CC-) WIRE FEED MODULE (OPTIONAL) ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
  • Page 211 SWITCH ALTERNATOR AUXILIARY POWER WINDINGS GENERATOR (GROUND SCREW NEAR FUSE) 5 4 3 2 1 WELDER CURRENT LEAD BLOCK SENSOR POSITIVE NEGATIVE (CC+) & (CV+ WITH W.F.M.) (CC-) WIRE FEED MODULE (OPTIONAL) ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
  • Page 212 WIRING DIAGRAM - (CODES 11110, 11111) (M20499) GLOW PLUG GROUND TO BASE NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. CLASSIC 300D PERKINS WIRING DIAGRAM ON NEWER BOARDS, CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR.
  • Page 213 WIRING DIAGRAM - (CODES 11112, 11113) (M20432) GLOW PLUGS GLOW PLUG GROUND BASE NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. CLASSIC 300D KUBOTA WIRING DIAGRAM ENGINE CONTROL UNIT CONNECTOR DETAIL CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR.
  • Page 214 WIRING DIAGRAM - (CODES 11243, 11244) (M20432-1) GLOW PLUGS GLOW PLUG GROUND BASE NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. CLASSIC 300D KUBOTA WIRING DIAGRAM ENGINE CONTROL UNIT CONNECTOR DETAIL CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR.
  • Page 215 WIRING DIAGRAM - (CODES 11248, 11249, 11280, 11281) (M20616) GLOW PLUG GROUND TO BASE NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. CLASSIC 300D PERKINS WIRING DIAGRAM CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR.
  • Page 216 G-10 WIRING DIAGRAM - (CODES 11411, 11412) (M21292) GLOW PLUG GROUND TO BASE NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. CLASSIC 300D PERKINS WIRING DIAGRAM CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR.
  • Page 217 G-11 WIRING DIAGRAM - (CODES 11413, 11414) (M21293) GLOW PLUGS GLOW PLUG GROUND BASE NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. CLASSIC 300D KUBOTA WIRING DIAGRAM ENGINE CONTROL UNIT CONNECTOR DETAIL CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR.
  • Page 218 G-12 WIRING DIAGRAM - (CODES 11472, 11473) (M21684) GLOW PLUG GROUND TO BASE NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. CLASSIC 300D PERKINS WIRING DIAGRAM CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR.
  • Page 219 G-13 WIRING DIAGRAM - (CODES 11474, 11475) (M21563) GLOW PLUGS GLOW PLUG GROUND BASE NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. CLASSIC 300D KUBOTA WIRING DIAGRAM ENGINE CONTROL UNIT CONNECTOR DETAIL CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR.
  • Page 220 G-14 SCHEMATIC - COMPLETE MACHINE - (CODES 11110, 11111) (L12412) L12412 CENTER OF CONTROL PANEL 12 VOLT - NORMALLY OFF RED ENGINE PROTECTION LIGHT RIGHT SIDEOF ENGINE BY INJECTION PUMP INJECTION GND-C PUMP SOLENOID APPROXIMATE RESISTANCE: 3.3 OHMS TYPICAL CURRENT DRAW: 3.3A RIGHT SIDEOF ENGINE BY OIL FILLER FUEL PUMP...
  • Page 221 G-15 SCHEMATIC - COMPLETE MACHINE - (CODES 11112, 11113) (L12265) L12265 RATED VOLTAGE: 12V RATED CURRENT: 22mA MAX BACK, RIGHT SIDEOFENGINE SENSOR OPERATION: F -> 18.80 kOHMS F -> 1.14 kOHMS F -> .16 kOHMS RATED VOLTAGE: 12V RATED CURRENT: 2A COIL RESISTENCE: 2.8 +/- .28 OHMS AT 20 ENERGIZED FOR RUN...
  • Page 222 G-16 SCHEMATIC - COMPLETE MACHINE - (CODES 11243, 11244) (L12265-1) L12265-1 RATED VOLTAGE: 12V RATED CURRENT: 22mA MAX BACK, RIGHT SIDEOFENGINE SENSOR OPERATION: F -> 18.80 kOHMS F -> 1.14 kOHMS F -> .16 kOHMS BACK, LEFT SIDEOFENGINE RATED VOLTAGE: 12V RATED CURRENT: 2A COIL RESISTENCE: 2.8 +/- .28 OHMS AT 20...
  • Page 223 G-17 SCHEMATIC - COMPLETE MACHINE - (CODES 11248, 11249, 11280, 11281) (L12561) L12561 CENTER OF CONTROL PANEL 12 VOLT - NORMALLY OFF RED ENGINE PROTECTION LIGHT RIGHT SIDEOF ENGINE BY INJECTION PUMP INJECTION GND-C PUMP SOLENOID APPROXIMATE RESISTANCE: 3.3 OHMS TYPICAL CURRENT DRAW: 3.3A RIGHT SIDEOF ENGINE BYOIL FILLER...
  • Page 224 G-18 SCHEMATIC - COMPLETE MACHINE - (CODES 11411, 11412) (L13096) L13096 CENTER OF CONTROL PANEL 12 VOLT - NORMALLY OFF RED ENGINE PROTECTION LIGHT RIGHT SIDEOF ENGINE BY INJECTION PUMP INJECTION GND-C PUMP SOLENOID APPROXIMATE RESISTANCE: 3.3 OHMS TYPICAL CURRENT DRAW: 3.3A RIGHT SIDEOF ENGINE BY OIL FILLER FUEL PUMP...
  • Page 225 G-19 SCHEMATIC - COMPLETE MACHINE - (CODES 11413, 11414) (L13097) L13097 RATED VOLTAGE: 12V RATED CURRENT: 22mA MAX BACK, RIGHT SIDEOFENGINE SENSOR OPERATION: F -> 18.80 kOHMS F -> 1.14 kOHMS F -> .16 kOHMS RATED VOLTAGE: 12V RATED CURRENT: 2A COIL RESISTENCE: 2.8 +/- .28 OHMS AT 20 ENERGIZED FOR RUN...
  • Page 226 G-20 SCHEMATIC - COMPLETE MACHINE - (CODES 11472, 11473) (L13672) L13672 ENGINEERING CONTROLLED MANUFACTURER: CENTER OF CONTROL PANEL 12 VOLT - NORMALLY OFF RED ENGINE PROTECTION LIGHT GHT SIDEOF ENGINE YINJECTION PUMP GND-C INJECTION PUMP SOLENOID APPROXIMATE RESISTANCE: 3.3 OHMS TYPICAL CURRENT DRAW: 3.3A CENTER OF CONTROL PANEL HOUR METER...
  • Page 227 G-21 SCHEMATIC - COMPLETE MACHINE - (CODES 11474, 11475) (L13351) L13351 ENGINEERING CONTROLLED MANUFACTURER: ENGINE RATED VOLTAGE: 12V SPEED RATED CURRENT: 22mA MAX SENSOR BACK, RIGHT SIDEOFENGINE SENSOR OPERATION: WATER -> 18.80 kOHMS TEMP. F -> 1.14 kOHMS SENSOR F -> .16 kOHMS BACK, LEFT SIDEOFENGINE...
  • Page 228 W-WHITE Y-YELLOW SHUNT CONNECTOR CAVITY NUMBERING FIELD RHEOSTAT SEQUENCE VIEWED FROM COMPONENT SIDE OF BOARD. CONNECT S T O 115V ENGINE WELDER RECEPTACLE J5 115V CC/CV SWITCH S1 510 602 SHOWN IN CV MODE 610A 610A 503A 503A 609 501...

  • Page 229: Electrical Diagrams

    ELECTRICAL DIAGRAMS G-23 G-23 SCHEMATIC - WIRE FEED MODULE OPTION - (G2562) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. CLASSIC® 300D & 300G...
  • Page 230 ELECTRICAL DIAGRAMS G-24 G-24 SCHEMATIC - IDLER (CODES 10545, 10546, 10657, 10658, 10911, 10927) - (L10826) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. CLASSIC® 300D & 300G...
  • Page 231 ELECTRICAL DIAGRAMS G-25 G-25 SCHEMATIC - IDLER (CODES 11110 THRU 11475 PERKINS ENGINE ONLY) - (G4828) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. CLASSIC® 300D & 300G...
  • Page 232 ELECTRICAL DIAGRAMS G-26 G-26 SCHEMATIC - CURRENT SENSOR PC BD (KUBOTA ENGINE ONLY) - (S25973) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. CLASSIC® 300D & 300G...

This manual is also suitable for:

Classic 300 dClassic 300 g