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Lincoln Electric CLASSIC SVM194-A User Manual

Lincoln Electric CLASSIC SVM194-A
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SVM194-A
October, 2009
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
SERVICE MANUAL
For use with machine code number: 10545, 10546, 10657, 10658,10911, 10927,11110
11111, 11112, 11113, 11243, 11244, 11248, 11249,
11280, 11281, 11411, 11412, 11413, 11414, 11472,
11473, 11474, 11475
Classic® 300G: 10659, 10912, 11135
CLASSIC
®
300 D & 300 G
Sales and Service through Subsidiaries and Distributors Worldwide
Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
World's Leader in Welding and Cutting Products
Copyright © Lincoln Global Inc.
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Lincoln Electric CLASSIC SVM194-A Specifications

General IconGeneral
BrandLincoln Electric
ModelCLASSIC SVM194-A
CategoryWelding System
LanguageEnglish

Summary

Safety

FOR ENGINE powered equipment

Safety precautions for engine-powered equipment operation and maintenance.

ELECTRIC SHOCK can kill.

Hazards and precautions related to electrical shock from welding equipment.

WELDING and CUTTING SPARKS can cause fire or explosion.

Safety procedures to prevent fires and explosions caused by welding sparks.

FUMES & GASES can be dangerous.

Safety measures for avoiding inhalation of welding fumes and gases.

ARC RAYS can burn.

Precautions for protecting eyes and skin from arc rays and spatter.

FOR ELECTRICALLY powered equipment.

Safety precautions for electrically powered welding equipment installation.

Installation - Pre-Operation Installation

Operation - Engine Operation

Operation - Welder Operation

Maintenance - General Instructions

Maintenance - Engine Service (Codes 10658 & Below)

Maintenance - Safety Precautions

Maintenance - Engine Service (Codes 11249 & Below)

Maintenance - Engine Service

Installation - Technical Specifications (Classic® 300D Perkins 404D-22)

RATED OUTPUT @ 104°F(40°C) - WELDER

Welder output ratings, including DC output and duty cycle.

Installation - Technical Specifications (Classic® 300G (K1754-1))

RATED OUTPUT - WELDER

Welder output ratings, including DC output and duty cycle.

Installation - Safety Precautions

Troubleshooting and Repair - How to Use Guide

HOW TO USE TROUBLESHOOTING GUIDE

A three-step procedure for locating and repairing machine malfunctions.

Troubleshooting and Repair - PC Board Procedures

Troubleshooting and Repair - Output Problems

OUTPUT PROBLEMS

Troubleshooting steps for low weld and auxiliary output voltages.

OUTPUT PROBLEMS (No weld or auxiliary output)

Troubleshooting steps for no weld or auxiliary output.

Troubleshooting and Repair - Output Problems (Continued)

OUTPUT PROBLEMS (Low weld output, normal auxiliary)

Troubleshooting for low weld output with normal auxiliary output.

OUTPUT PROBLEMS (No auxiliary output, normal weld)

Troubleshooting for no auxiliary output with normal weld output.

Troubleshooting and Repair - Welding Problems

WELDING PROBLEMS (Loud arc, excessive spatter)

Troubleshooting steps for a loud arc and excessive spatter during welding.

Troubleshooting and Repair - Welding Problems (Continued)

WELDING PROBLEMS (Low output, abnormal variation)

Troubleshooting for low or varying weld output with normal auxiliary.

WELDING PROBLEMS (Arc pops out)

Troubleshooting for an arc that frequently pops out, with normal heat and auxiliary.

WELDING PROBLEMS (High output)

Troubleshooting steps for weld output being higher than indicated on dials.

Troubleshooting and Repair - Function Problems

FUNCTION PROBLEMS (Engine starts, shuts down after seconds)

Troubleshooting for engine shutdown shortly after starting.

Troubleshooting and Repair - Function Problems (Continued)

FUNCTION PROBLEMS (Engine will not crank)

Troubleshooting steps when the engine does not crank after pressing the start button.

FUNCTION PROBLEMS (Engine cranks but will not start)

Troubleshooting steps when the engine cranks but fails to start.

FUNCTION PROBLEMS (Engine starts, shuts down after running for several seconds)

Troubleshooting for engine shutdown shortly after starting, checking oil and belts.

FUNCTION PROBLEMS (Engine will not shut down)

Troubleshooting steps when the engine fails to shut down using the run/stop switch.

FUNCTION PROBLEMS (Engine will not develop full power)

Troubleshooting steps when the engine does not develop full power.

FUNCTION PROBLEMS (Machine will not idle down)

Troubleshooting for the machine not idling down to low RPM when loads are removed.

FUNCTION PROBLEMS (Machine will not idle down - continued)

Further troubleshooting for machines not idling down, checking sensors and PC boards.

FUNCTION PROBLEMS (Engine goes to low idle, but will not stay at low idle)

Troubleshooting for engine not staying at low idle while having normal output.

FUNCTION PROBLEMS (Engine will not go to high idle when idle switch is "High")

Troubleshooting when the engine fails to go to high idle with the switch in "High".

FUNCTION PROBLEMS (Battery does not stay charged)

Troubleshooting for a battery that does not maintain its charge.

FUNCTION PROBLEMS (Engine will not go to high idle when striking an arc)

Troubleshooting when the engine doesn't engage high idle for welding or auxiliary power.

Troubleshooting and Repair - Brush & Slip Ring Service

Troubleshooting and Repair - Engine Alternator Test

Troubleshooting and Repair - Engine Fuel System Test

Troubleshooting and Repair - Engine Protection System Test

ENGINE PROTECTION SYSTEM TEST PROCEDURE

Test to pinpoint failures in the engine protection system causing shutdowns.

Troubleshooting and Repair - Engine RPM Adjustment Test

ENGINE RPM ADJUSTMENT TEST PROCEDURE

Test to verify correct engine RPM for high and low idle positions.

Troubleshooting and Repair - Flashing Voltage Test

Troubleshooting and Repair - Rocker Adjustment

ROCKER ADJUSTMENT PROCEDURE

Procedure for adjusting the rocker to fine-tune weld output and characteristics.

Troubleshooting and Repair - Exciter Rotor Tests

Troubleshooting and Repair - Shunt Field Coil Tests

Troubleshooting and Repair - Shunt Field Circuit Voltage Test

Troubleshooting and Repair - Exciter Stator Tests

Troubleshooting and Repair - Weld Circuit Tests

Troubleshooting and Repair - Generator Brush & Commutator Service

Troubleshooting and Repair - Series Coil Test

Troubleshooting and Repair - Alternator Rotor Service

Troubleshooting and Repair - Alternator Stator Service

Troubleshooting and Repair - Generator Frame Service

Troubleshooting and Repair - Generator Armature Service

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