Lincoln Electric CLASSICII SVM125-A manual

SVM125-A October 1996 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRECAUTI[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY i i CLASSIC II FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-v[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY ii ii CLASSIC II ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standa[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CLASSIC II FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer [...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iv iv CLASSIC II PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sû[...]

MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v CLASSIC II Page Safety .................................................................................................................................................i-iv Installation .....................................................................................................................[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 CLASSIC II Installation T echnical Specifications ..............................................................................................................A-2 Input – Diesel Engine ........[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-2 A-2 CLASSIC II TECHNICAL SPECIFICA TIONS - CLASSIC II INPUT - DIESEL ENGINE Manufacturer Description Speed Displacement Ignition Capacities Deutz 3 cyl., 1725 [...]

Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintenance instructions; and parts list[...]

ST ACKING Classic II machines CANNOT be stacked. TIL TING Place the machine on a secure, level surface whenev- er you use it or store it. Any surfaces you place it on other than the ground must be firm, non-skid, and structurally sound. The diesel engine is designed to run in a level position for best performance. If you do operate it at a slight a[...]

MUFFLER This welder is supplied with an adjustable rain cap for the muffler . Install the rain cap using the clamp provid- ed with the outlet facing away from the direction in which this unit will be transported. This will minimize the amount of water and debris that could enter the muffler during transportation. SP ARK ARRESTER Diesel engine muffl[...]

ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the 1 15 and 230 volt receptacles, weld output terminals, and ground stud. WELDING CABLE CONNECTIONS CABLE INST ALLA TION, POLARITY CONTROL, AND CABLE SIZES With the engine off, route the electrode and work cables through the strain relief bracket on the base and connect to the termin[...]

MACHINE GROUNDING Because the Classic II creates its own power from its diesel-engine driven gener- ator , you do not need to connect the machine frame to an earth ground. However , for best protection against elec- trical shock, connect a heavy gauge wire (#8 A WG or larger) from the ground stud located on the welding generator frame foot. (See Fi[...]

NOTES A-8 A-8 CLASSIC II Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section B-1 Section B-1 CLASSIC II T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Instructions .....................[...]

OPERA TING INSTRUCTIONS Read and understand this entire section before operat- ing your Classic II. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintena[...]

RECOMMENDED APPLICA TIONS WELDER The Classic II provides excellent constant current DC welding output for stick (SMA W) welding and for DC TIG welding. It also offers constant voltage output for DC semiautomatic wire feed welding. For more details on using the machine as a welder , see Welding Operation in the Operation section of this manual. GENE[...]

WELDING CAP ABILITY The Classic II is rated 250 amps, 30 volts constant cur- rent DC at 60% duty cycle based on a ten minute time period. Longer duty cycles at lower output currents are possible. The current is continuously variable from 40 to 325 amps DC. LIMIT A TIONS • The Classic II is not recommended for any process- es besides those that ar[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-5 B-5 CLASSIC II FIGURE B.1 – OUTPUT CONTROLS 1. CURRENT RANGE SELECTOR 2. FINE CURRENT ADJUSTMENT 3. 230 VOL T RECEPT ACLE 4. 1 15 VOL T RECEPT ACLE 5. WELD OUTPU[...]

CONTROL OF WELDING CURRENT DO NOT turn the CURRENT RANGE SELECTOR while welding because the current may arc between the contacts and damage the switch. See Figure B.2. The CURRENT RANGE SELECTOR provides five overlapping current ranges. The FINE CURRENT ADJUSTMENT adjusts the current from minimum to maximum within each range. Open circuit voltage i[...]

DIESEL ENGINE CONTROLS See Figure B.3 for the location of the following fea- tures: 1. IDLER CONTROL TOGGLE SWITCH: Adjusts the running speed of the engine. The switch has two positions, "HIGH" and "AUTO." In "HIGH," the engine runs continuously at high idle. In "AUTO," the idler control works as follows: Wel[...]

ENGINE OPERA TION DO NOT RUN THE ENGINE A T EXCESSIVE SPEEDS. The maximum allowable high idle speed for the Classic II is 1800 RPM, no load. Do NOT increase the idle speed on the engine. Severe personal injury and damage to the machine can result if it is operated at speeds above the maximum rated speed. Read and understand all safety instructions [...]

STOPPING THE ENGINE 1. Remove all welding and generator power loads and let the engine cool by running it for several minutes at low idle. 2. Place the IGNITION switch in the OFF position. When an engine is started for the first time, some of the oil will be needed to fill the passages of the lubricating system. Therefore, on initial starting, run [...]

WELDING OPERA TION GENERAL INFORMA TION The Classic II can deliver from 40 to 325 amps of con- stant current for DC stick welding or DC semiautomat- ic wire feed welding (with wire feed module). DC TIG welding is possible across the entire range from 40 to 325 amps. Output can be adjusted by setting the CUR- RENT RANGE SELECTOR and the FINE CURRENT[...]

TO USE THE CLASSIC II FOR DC CONST ANT CURRENT STICK OR TIG WELDING: 1. Remove the flange nuts from the weld output ter- minals and place the work and electrode welding cables over the terminals. For positive electrode, connect the electrode cable to the + terminal and the work cable to –. For negative electrode, reverse the electrode and work ca[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-12 B-12 CLASSIC II T ABLE B.1 RANGE SETTINGS FOR WIRE SIZE/SPEED Diameter (inches) Wire Speed Range Appropriate Curr ent Range (inches/minute) .035 80-1 10 75 to 120[...]

AUXILIAR Y POWER Be sure that any electrical equipment plugged into the generator AC power receptacles can withstand a ± 10% voltage and a ± 3% frequency variation. The AC auxiliary power , supplied as a standard, has a rating of 3.0 kV A of 1 15/230V AC power (60 hertz). One 1 15V duplex and one 230V grounding type recep- tacle are provided. The[...]

T ABLE B.2 – GENERA TOR POWER APPLICA TIONS Suggested Power Applications Running W atts *Start-up W atts *Air Compressor - 3/4 HP 1,250 3,100 - 5,000 *Airless Sprayer - 1/3 HP 600 1,500 - 2,400 Chain Saw 1,200 Circular Saw 1,200 Coffee Maker 1,000 *Deep Freezer 500 750 - 2,000 *Electric Motor - 1 HP 1,000 2,500 - 4,000 Electric Range (1 element) [...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories .................................................................[...]

OPTIONS/ACCESSORIES The following options/accessories are available for your Classic II from your local Lincoln Distributor . Undercarriage - Under 10 MPH (K768) - For in-plant or yard towing of the Classic II. Not intended for high- way towing. Undercarriage (K913-1) - T wo-wheeled undercarriage for in-plant and yard towing. Includes fender and li[...]

TIG WELDING TIG Module (K930-1) - The TIG Module is an acces- sory that provides high frequency and shielding gas control for DC GT A W (TIG) welding applications. It provides contactor control of constant current welding power sources having an internal contactor . The K930-1 TIG Module is supplied without acces- sories. Arc Start switches, Amptro[...]

ELECTRIC SHOCK can kill. • Do not operate with panels open. • Disconnect NEGA TIVE (-) BA TTERY LEAD before servicing. • Do not touch electrically live parts. MOVING P ARTS can injure. • Keep guards in place. • Keep away from moving parts. • Only qualified personnel should install, use or service this equipment. CONNECTION OF THE LN-7 T[...]

CONNECTION OF THE LN-7 TO THE CLASSIC II USING K584 INPUT CABLE ASSEMBL Y (SEE FIGURE C.2.) 1. Shut the welder off. 2. Connect the electrode cable fr om the LN-7 to the “+” terminal of the welder . Connect the work cable to the “CV -” terminal of the welder . NOTE: W elding cable must be sized for current and duty cycle of application. NOTE[...]

CONNECTION OF THE LN-25 TO THE CLASSIC II USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.3.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-25 to the “+” terminal of the welder . Connect the work cable to the “CV -” terminal of the welder . NOTE: W elding cable must be sized for current and duty cycle of application. NOTE: F[...]

CONNECTION OF THE LN-25 TO THE CLASSIC II “ACROSS THE ARC” (SEE FIGURE C.4.) 1. Shut the welder off. 2. Connect the electrode cable fr om the LN-25 to the “+” terminal of the welder . Connect the work cable to the “CV–” terminal of the welder . NOTE: W elding cable must be sized for current and duty cycle of application. NOTE: Figure [...]

CONNECTION OF THE K488 SG CONTROL MODULE AND K487 MAGNUM SPOOL GUN TO THE CLASSIC II (SEE FIGURE C.5.) 1. Shut the welder off. 2. Connect the electrode cable from the SG Contr ol Module to the “+” terminal of the welder . Connect the work cable to the “CV–” terminal of the welder . NOTE: W elding cable must be sized for current and duty c[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 CLASSIC II T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Safety Precautions ...................................[...]

SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. • If covers or guards are missing from the machin[...]

CHANGE THE OIL FIL TER: Change the oil filter the first time after 50 hours of operation. Then, under nor- mal operating conditions, change the oil filter after every 750 hours of operation. If the engine is operated under heavy load or in high ambient temperatures, change the oil filter more frequently . See T able D.1 for recommended maintenance [...]

FUEL FIL TER: Inspect the fuel filter daily . Drain any accumulated water from the engine fuel filter/water separator daily . Change the fuel filter after the first 50 hours of operation and every 1000 hours thereafter . Dust and dirt in the fuel system can cause the injection pump and injection nozzle to wear quickly . Change the fuel filter as fo[...]

MAINTENANCE D-5 D-5 CLASSIC II Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE D.1 DEUTZ ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before Starting Engine • Fill fuel tank. • Check oil level[...]

BA TTER Y MAINTENANCE GASES FROM BA TTERY can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY ACID can burn eyes and skin. • W ear gloves and eye protection and be careful when working near a battery . Follow the instructions printed on the battery . T o prevent EXPLOSION when: • INST ALLING A NEW BA TTERY - Disconn[...]

WELDER/GENERA TOR MAINTENANCE STORAGE: Store the Classic II in clean, dry , protect- ed areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air . Do this at least once a week in particularly dirty areas. AL TERNA TOR BRUSH REMOV AL AND REPLACE- MENT : It's normal for the brushes and slip rings to wear and dark[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-8 D-8 CLASSIC II FIGURE D.3 - MAJOR COMPONENT LOCA TIONS  2  3 4 15 8 12 13 11 9 10 14 1 6 5 7 1. RIGHT CASE SIDE (DOOR) 2. BASE (WITH BA TTERY) 3. AL TERNA T[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 CLASSIC II Theory of Operation ............................................................................................................. Section E General Description .......................................................................[...]

GENERAL DESCRIPTION The Classic II is a heavy duty , engine driven DC arc welding power source capable of providing constant current output for stick welding or DC TIG welding. Also, a total of 3000 watts of auxiliary power is avail- able at the 1 15 or 230V AC receptacles. The Classic II is manufactured with all copper windings. BA TTER Y , ST ART[...]

ENGINE, GENERA TOR ARMA TURE AND FRAME, AL TERNA TOR ST A TOR AND ROTOR EXCIT A TION (FLASHING) When the engine is started and running, the residual magnetism voltage is applied to the alternator rotor via a brush and slip ring configuration. This excitation (“flashing”) voltage magnetizes the rotor lamination. The alternator rotor is connected[...]

ENGINE, GENERA TOR ARMA TURE AND FRAME, AL TERNA TOR ST A- T OR AND ROTOR (CONTINUED) CURRENT RANGE SELECTOR The selector switch acts as a coarse current adjust- ment by allowing for varying amounts of series wind- ings to be included in the welding current path. The series coils and selector switch are connected in series with the negative output [...]

DC GENERA TOR MACHINES The armature winding of a DC generator is located on the rotating member . Current is conducted from it by means of carbon brushes. The field winding is located in the stator , which is stationary , and is excited by direct current. The armature coil sides are placed at opposite points on the rotating shaft with the conductor[...]

NOTES E-6 E-6 CLASSIC II Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 CLASSIC II T roubleshooting & Repair Section ................................................................................ Section F How to Use T roubleshooting Guide ....................................................................[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HOW T O USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may [...]

ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. T urn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting an[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 CLASSIC II Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not un[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 CLASSIC II TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not un[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 CLASSIC II Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not un[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-7 F-7 CLASSIC II TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not un[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-8 F-8 CLASSIC II Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not un[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 CLASSIC II TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not un[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-10 F-10 CLASSIC II Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-11 F-11 CLASSIC II TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-12 F-12 CLASSIC II TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-13 F-13 CLASSIC II AL TERNA TOR ROT OR TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Un[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 F-14 CLASSIC II LOOSEN 5 SCREWS ALTERNATOR COVER SLIP RINGS BRUSHES FIGURE F .1 – AL TERNA TOR COVER REMOV AL AL TERNA TOR ROT OR TEST (conti[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-15 F-15 CLASSIC II FIGURE F .2 – MEASURING ROTOR RESIST ANCE 9. Working from the left side of the machine, measure the resistance across the rot[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-16 F-16 CLASSIC II FIGURE F .3 – MEASURING ROTOR RESIST ANCE TO GROUND 10. Measure the rotor resistance to ground. A. Set the ohmmeter on the hi[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SHUNT FIELD WINDING TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-18 F-18 CLASSIC II SHUNT FIELD WINDING TEST (continued) FIGURE F .4 – PLUG P10 LOCA TIONS PLUG P10 TEST PROCEDURE 1. T urn engine off. 2. Unlatc[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-19 F-19 CLASSIC II SHUNT FIELD WINDING TEST (continued) 6. Using the volt/ohmmeter set on the low scale (X1), measure the resistance between the b[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC IDLER SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dang[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-21 F-21 CLASSIC II IDLER SOLENOID TEST (continued) FIGURE F .6 - SOLENOID/HARNESS LEAD CONNECTIONS LEADS #56, #57 TEST PROCEDURE 1. T urn engine o[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may re[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-23 F-23 CLASSIC II ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F .7 - STROBE MARK LOCA TION STROBE MARK TEST PROCEDURE Strobe T ach Method [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-24 F-24 CLASSIC II ENGINE THROTTLE ADJUSTMENT TEST (continued) 6. If either of the readings is incorrect, adjust the throttle as follows: Adjust H[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-25 F-25 CLASSIC II ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F .8 - HIGH IDLE ADJUSTMENT LOCKING NUT ADJUSTING SCREW FIGURE F .9 - LOW ID[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FLASHING THE FIELDS Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dang[...]

TROUBLESHOOTING & REP AIR F-27 F-27 CLASSIC II Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FLASHING THE FIELDS (continued) FIGURE F .10 - FLASHING THE FIELDS NEGATIVE (-) BRUSH HOLDER POSITIVE (+) BRUSH HOLDER 12 VOLT [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-28 F-28 CLASSIC II This is the typical auxiliary output voltage generated from a properly operating machine. Note that each vertical division repr[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-29 F-29 CLASSIC II This is the typical DC output voltage generated from a properly operating machine. Note that each vertical divi- sion represent[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-30 F-30 CLASSIC II This is the typical DC output voltage generated from a properly operating machine. Note that each vertical divi- sion represent[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC AL TERNA TOR ROT OR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equ[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-32 F-32 CLASSIC II AL TERNA TOR ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .1 1 – CASE FRONT REMOV AL PREP ARA TION REMOVE FASTENERS B[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-33 F-33 CLASSIC II AL TERNA TOR ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .12 – FUEL T ANK REMOV AL CABLE RETAINER FUEL BOWL FUEL LIN[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-34 F-34 CLASSIC II AL TERNA TOR ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .13 – OUTPUT TERMINAL STRAP AND CASE FRONT REMOV AL NEGATIV[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-35 F-35 CLASSIC II AL TERNA TOR ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .14 – AL TERNA TOR COVER REMOV AL LOOSEN 5 SCREWS ALTERNATO[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-36 F-36 CLASSIC II AL TERNA TOR ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .15 – ROTOR REMOV AL STATOR FRAME NUT SLEEVE COLLAR "B[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION F-37 F-37 CLASSIC II AL TERNA TOR ROT OR REMOV AL AND REPLACEMENT (continued) Replacement 25. Carefully mount the rotor onto the generator shaft. Install a new sle[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC AL TERNA TOR ST A TOR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this e[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-39 F-39 CLASSIC II AL TERNA TOR ST A TOR REMOV AL AND REPLACEMENT (continued) FIGURE F .16 – COMMUT A TOR WRAP-AROUND REMOV AL COMMUTATOR WRAP-A[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-40 F-40 CLASSIC II FIGURE F .17 - LEAD DISCONNECTION POINTS YELLOW AND WHITE WIRE IN-LINE CONNECTORS LOCATED BEHIND CASE FRONT AL TERNA TOR ST A T[...]

14. Clear the leads in preparation for remov- ing the stator/end bracket. 15. Lift the eight brushes from the commuta- tor . Note the position of the brushes for reassembly . TROUBLESHOOTING & REP AIR F-41 F-41 CLASSIC II Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Maste[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-42 F-42 CLASSIC II FIGURE F .20 - DRILL SPOT LOCA TIONS DRILL SPOT STATOR/ENDBRACKET MOUNTING BOLT 17. With the 5/8" wrench, remove the four [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GENERA TOR FRAME REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipm[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-44 F-44 CLASSIC II GENERA TOR FRAME REMOV AL AND REPLACEMENT (continued) FIGURE F .21 – GENERA TOR LEAD AND CABLE CONNECTIONS SELECTOR SWITCH CA[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-45 F-45 CLASSIC II GENERA TOR FRAME REMOV AL AND REPLACEMENT (continued) FIGURE F .22 – FRAME MOUNTING DET AILS ENGINE/GENERATOR MOUNTING HOLES [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GENERA TOR ARMA TURE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this eq[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-47 F-47 CLASSIC II GENERA TOR ARMA TURE REMOV AL AND REPLACEMENT (continued) FIGURE F .23 – BLOWER P ADDLE REMOV AL BLOWER PADDLE/ARMATURE MOUNT[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-48 F-48 CLASSIC II RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanic[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-1 G-1 CLASSIC II Electrical Diagrams Section .......................................................................................... Section G Wiring Diagram (Code 9805 ) ......................................................................[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES CLASSIC II[...]

G-2 ELECTRICAL DIAGRAMS CLASSIC II Wiring Diagram (Code 9805 ) 8594 5-1-92 CLASSIC II (WITH CV ADAPTER) WIRING DIAGRAM JE NONE 8594 7-9-91 t UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS .02 WITH PUBLISHED STANDARDS. ON 3 PLACE DECIMALS IS .002 ON ALL ANGLES IS .5 OF A DEGREE MATERIAL TOLERANCE (" ") [...]

G-3 ELECTRICAL DIAGRAMS CLASSIC II Wiring Diagram (Code 10000) 9-25-92L CLASSIC II (WITH CV ADAPTER) WIRING DIAGRAM R.T. NONE 9071 J.J. 9-14-92 L8594 t UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS .02 WITH PUBLISHED STANDARDS. ON 3 PLACE DECIMALS IS .002 ON ALL ANGLES IS .5 OF A DEGREE MATERIAL TOLERANCE (&quo[...]

G-4 ELECTRICAL DIAGRAMS CLASSIC II Wiring Diagram (Code 10070 ) CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR. LEAD COLOR CODE B-BLACK G-GREEN N-BROWN R-RED U-BLUE W-WHITE Y-YELLOW B R + - + - Y R W B B U U SLIP RINGS TO IRON R N A 54 3 2 1 ALTERNATOR AUXILIARY POWER WINDINGS CURRENT TRANSFORMER CB3 CB1 115 VOLT RECEPTACLE 230 VOLT RECEPTACLE [...]

G-5 ELECTRICAL DIAGRAMS CLASSIC II Wiring Diagram (Code 10071 ) CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR. LEAD COLOR CODE B-BLACK G-GREEN N-BROWN R-RED U-BLUE W-WHITE Y-YELLOW B R + - + - Y R W B B U U SLIP RINGS TO IRON R N A 54 3 2 1 ALTERNATOR AUXILIARY POWER WINDINGS CURRENT TRANSFORMER CB1 115 VOLT RECEPTACLE 230 VOLT RECEPTACLE Y NE[...]

G-6 ELECTRICAL DIAGRAMS CLASSIC II Wiring Diagram (Code 10219 ) R SWITCH START STARTING MOTOR + ENGINE + 52 D+ D- B+ W 1 + A FUEL SOLENOID IDLER SOLENOID SENSOR 7 8 3 4 5 6 ALTERNATOR OIL PRESSURE GAUGE SI GND OIL TEMP. . - HOUR METER - 50A 50 51 51A 60 56 55 60B CLEVELAND, OHIO U.S.A. , .. . L9920 R 60E 1 2 3 4 1 2 3 45 6 7 8 9 10 IDLER/ENGINE [...]

G-7 ELECTRICAL DIAGRAMS CLASSIC II Wiring Diagram (Code 10220) CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR. LEAD COLOR CODE B-BLACK G-GREEN N-BROWN R-RED U-BLUE W-WHITE Y-YELLOW B R + - + - Y R W B B W W SLIP RINGS TO IRON R N A 54 3 2 1 ALTERNATOR AUXILIARY POWER WINDINGS CURRENT TRANSFORMER CB1 115 VOLT RECEPTACLE 230 VOLT RECEPTACLE Y NEG[...]

G-8 ELECTRICAL DIAGRAMS CLASSIC II Idler PC Board (M13708) Schematic -A X1 6 1 7 B209 T13157-14 1 D7 13.7K R18 5.11K R21 C3 X1 13 10 11 511 R16 5W 10V DZ1 LM2901 X1 3 12 22.1K R3 X1 8 14 9 4536B X2 16 8 C1 10K R2 133K R6 D1 47.5K R7 10K R1 + t 56 R8 13.7K R13 D G S 15A 60V Q1 B212 1 D2 33.2K R20 100V .047 C10 B213 1 15.0 R9 15.0 R15 26.7K R12 D8 10[...]

G-9 ELECTRICAL DIAGRAMS CLASSIC II Idler PC Board (M13708) Components CAPACITORS = MFD/VOLTS RESISTORS = OHMS IDLER ENGINE WELDER R20 R17 R15 R9 R13 R1 R21 R16 R12 R2 R7 R4 R10 R3 R14 R18 R6 R19 R5 C9 C1 C8 C7 C5 C3 C2 C10 C6 D5 DZ3 D8 D7 D3 D2 D1 DZ2 X1 X2 R11 Q1 Q2 DZ1 C4 B210 B212 B211 B209 B213 R8 M13708 G-9 Return to Section TOC Return to Sect[...]

G-10 ELECTRICAL DIAGRAMS CLASSIC II Idler PC Board (l9902) Schematic +10V COM +10V COM +10V COM +10V GND COM +10V COM COM 1N4936 D1 COM J1 8 26.7K R16 +10V 1W 15V DZ2 15J 50V TP1 1W 15V DZ3 1N4936 D3 12Vdc CR1 2 1 J1 10 100K R36 CR1 5 4 J1 4 CR1 5 3 1N4936 D6 1N4936 D4 GND +12V +12V COM COM IDLER SWITCH TO FRAME GND THRU MOUNTING SCREW SOLENOID FRA[...]

G-11 ELECTRICAL DIAGRAMS CLASSIC II Idler PC Board (l9902) Components IDENTIFICATION PART NO. REQ'D ITEM CAPACITORS = MFD/VOLTS INDUCTANCE = HENRYS N.A. N.A. N.A. CR1 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 DZ1 DZ2 DZ3 D1 D2 D3 D4 D5 D6 D7 J1 J2 Q1 Q2 Q3 Q4 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23 R[...]