Lincoln Electric SVM 137-A manual

SVM 137-A Jan uar y , 1998 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with saf ety in mind. Howe v er , your o ver all saf ety can be in- creased by proper installation . . . and thoughtful operation on your part. DO NO T INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANU AL AND THE SA[...]

SAFETY i i Classic III and IIID FOR ENGINE po wered equipment. 1.a. T ur n the engine off bef ore troubleshooting and maintenance wor k unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Oper ate engines in open, well-v entilated areas or vent the engine e xhaust fumes outdoors. _______[...]

SAFETY ii ii Classic III and IIID ARC RA YS can b urn. 4.a. Use a shield with the proper filter and cov er plates to protect your e yes from sparks and the ra ys of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b . Use suitable clothing made from dur ab le flame-resistant m[...]

Classic III and IIID FOR ELECTRICALL Y po wered equipment. 8.a. T ur n off input pow er using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manuf acturer’ s recommendations. 8.c. Ground the equipment in accordance with t[...]

SAFETY iv iv Classic III and IIID PRÉCA UTIONS DE SÛRETÉ P our v otre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce man uel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté P our Soudage A L ’Arc 1. Protegez-vous contre la secousse él[...]

MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v Classic III and IIID Page Safety .................................................................................................................................................i-iv Installation ...........................................................................................................[...]

T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 Classic III and IIID Installation T echnical Specifications ..............................................................................................................A-2 Saf ety Precautions ......................................................................................[...]

Retur n 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 III and IIID TECHNICAL SPECIFICA TIONS - CLASSIC III AND IIID INPUT - ENGINE Manufacturer Description Speed Displacement Ignition Capacities Class[...]

Read this entire installation section bef ore you start installation. SAFETY PRECA UTIONS Do not attempt to use this equipment until y ou hav e thoroughly read all the operation and maintenance man uals supplied with y our machine. They include impor tant saf ety precautions; detailed engine star ting, oper ating, and maintenance instructions; and [...]

ST A CKING Classic III and Classic IIID machines CANNO T be stack ed. TIL TING Place the machine on a secure, le vel surf ace whenev- er you use it or store it. Any surf aces you place it on other than the ground must be firm, non-skid, and structur ally sound. The engine is designed to run in a lev el position for best perf ormance. If y ou do ope[...]

COOLING SYSTEM The cooling system has been filled at the f actor y with a 50-50 mixture of eth ylene glycol antifreeze and w ater . Chec k the r adiator le vel and add a 50-50 solution as needed. (See your engine man ual or antifreeze con- tainer f or alter nate antifreeze recommendations .) MUFFLER This welder is supplied with an adjustab le rain [...]

ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 f or the location of the 115 and 230 v olt receptacles , w eld output ter minals, and ground stud. WELDING CABLE CONNECTIONS CABLE INST ALLA TION AND CABLE SIZES With the engine off , connect the electrode and work cab les to the terminals located on the fuel tank mount- ing rail. (See size recommendatio[...]

MA CHINE GROUNDING According to the United States National Electrical Code , the fr ame of this por table generator is not required to be grounded and is permitted to ser v e as the grounding means f or cord connected equipment plugged into its receptacles. Some state, local or other codes or un usual operating circumstances ma y require the machin[...]

NO TES A-8 A-8 Classic III and IIID 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[...]

Section B-1 Section B-1 Classic III and IIID T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Saf ety Instructions ..............................................................................................[...]

OPERA TING INSTR UCTIONS Read and understand this entire section bef ore operat- ing your Classic III or Classic IIID . SAFETY INSTR UCTIONS Do not attempt to use this equipment until y ou hav e thoroughly read all the operation and maintenance man uals supplied with y our machine. They include impor tant saf ety precautions; detailed engine star t[...]

RECOMMENDED APPLICA TIONS WELDER The Classic III and Classic IIID provide e xcellent con- stant current DC welding output f or stic k (SMA W) weld- ing and f or DC TIG welding. When equipped with the wire f eed module, the y also off er constant voltage out- put f or DC semiautomatic wire f eed welding. F or more details on using the machine as a w[...]

WELDING CAP ABILITY The Classic III and Classic IIID are rated 300 amps , 32 v olts constant current DC at 50% duty cycle based on a ten minute time period. Longer duty cycles at lower output currents are possible . The current is continuously v ar iable from 40 to 350 amps DC . LIMIT A TIONS The Classic III and Classic IIID are not recommended f o[...]

Retur n 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 III and IIID FIGURE B.1 – OUTPUT CONTROLS 1. CURRENT RANGE SELECT OR 2. FINE CURRENT ADJUSTMENT 3. 230 V OL T DUPLEX RECEPT ACLE 4. 115 V OL T DUPLE[...]

CONTR OL OF WELDING CURRENT • DO NO T tur n the CURRENT RANGE SELECT OR while welding because the current ma y arc between the contacts and damage the s witch. • DO NO T attempt to set the CURRENT RANGE SELECT OR between the five points designated on the nameplate. See Figure B.2. The CURRENT RANGE SELECT OR pro vides fiv e overlapping current [...]

GASOLINE ENGINE CONTROLS (CLASSIC III) See Figure B.3 f or the location of the f ollo wing f eatures: 1. IDLER CONTROL T OGGLE SWITCH: Adjusts the r unning speed of the engine. The switch has two positions , "HIGH" and "A UTO ." In "HIGH," the engine runs continuously at high idle. In "A UTO ," the idler cont[...]

OPERA TION B-8 DIESEL ENGINE CONTROLS (CLASSIC IIID) See Figure B.4 f or the location of the f ollowing f eatures: 1. IDLER CONTROL T OGGLE SWITCH: Adjusts the r unning speed of the engine. The switch has tw o positions , "HIGH" and "A UTO ." In "HIGH," the engine runs continuously at high idle. In "A UT O ,"[...]

ENGINE OPERA TION DO NO T RUN THE ENGINE A T EXCESSIVE SPEEDS. The maxim um allow able high idle speed f or the Classic III and Classic IIID is 1800 RPM, no load. Do NO T increase the idle speed on the engine . Sev ere personal injur y and damage to the machine can result if it is operated at speeds abo ve the maxim um rated speed. Read and underst[...]

ST OPPING THE ENGINE (GASOLINE OR DIESEL) 1. Place the IGNITION s witch in the OFF position. At the end of each da y’ s welding, drain accumulated dir t and water from the sediment bo wl under the fuel tank and from the fuel filter (diesel engine, Classic IIID) per instructions in the engine manuf acturer’ s operating manual. Refill the fuel ta[...]

WELDING OPERA TION T O USE THE CLASSIC III OR CLASSIC IIID FOR DC CONST ANT CURRENT STICK OR TIG WELDING: 1. Remov e the flange nuts from the weld output ter- minals and place the work and electrode welding cab les o ver the terminals. See Figure B .5. Replace and tighten the flange nuts securely . Be sure the connections are tight. 2. Select the a[...]

T O USE THE CLASSIC III OR CLASSIC IIID FOR DC WIRE FEED WELDING (CONST ANT V OL T A GE WITH WIRE FEED MODULE): 1. Connect the LN-25, LN-23P , or LN-7 Wire Feeder . F ollo w the installation instructions provided with the wire f eeder . 2. Set the machine f or CV operation. 3. Star t the engine. See Engine Operation in this section of the manual. 4[...]

A UXILIAR Y PO WER Be sure that any electrical equipment plugged into the gener ator A C po wer receptacles can withstand a ±10% v oltage and a ±3% frequency variation. The A C auxiliar y power , supplied as a standard, has a r ating of 3.0 kV A of 115/230V AC pow er (60 her tz). One 115V duple x and one 230V duple x grounding type receptacle are[...]

NO TES B-14 B-14 Classic III and IIID 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 OF CONTENTS - A CCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories ...................................................................................................................C-2 TIG Welding Accessories .....[...]

OPTIONS/A CCESSORIES The f ollowing options/accessories are av ailable f or y our Classic III or Classic IIID from y our local Lincoln Distributor . T railer (K913) - T wo-wheeled trailer f or in-plant and y ard to wing. V arious hitches and accessor ies are av ailable. F or highwa y use, consult applicab le federal, state , and local la ws. T rail[...]

TIG WELDING A CCESSORIES K930-2 TIG Module - The TIG Module is an accessory that provides high frequency & shielding gas control f or DC GT A W ( TIG) welding applications. The TIG Module is supplied without accessor ies. Arc star t s witches, amptrols , cables , torches and mounting brac kets m ust be purchased separately . SEMIA UT OMA TIC WE[...]

CONNECTION OF THE LN-7 T O THE CLASSIC III OR CLASSIC IIID (EQUIPPED WITH K623-1 WIRE FEED MODULE) USING K867 UNIVERSAL AD APTER (SEE FIGURE C.1.) 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 [...]

CONNECTION OF THE LN-7 T O THE CLASSIC III OR CLASSIC IIID (EQUIPPED WITH K623-1 WIRE FEED MODULE) USING K584 INPUT CABLE ASSEMBL Y (SEE FIGURE C.2.) 1. Shut the welder off. 2. Connect the electr ode cable from the LN-7 to the “+” terminal of the welder . Connect the work cable to the “CV -” terminal of the welder . NOTE: W elding cable mus[...]

CONNECTION OF THE LN-25 T O THE CLASSIC III OR CLASSIC IIID (EQUIPPED WITH K623-1 WIRE FEED MODULE) USING K867 UNIVERSAL AD APTER (SEE FIGURE C.3.) 1. Shut the welder off. 2. Connect the electr ode 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[...]

CONNECTION OF THE LN-25 T O THE CLASSIC III OR CLASSIC IIID (EQUIPPED WITH K623-1 WIRE FEED MODULE) “A CROSS THE ARC” (SEE FIGURE C.4.) 1. Shut the welder off. 2. Connect the electr ode 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 siz[...]

CONNECTION OF THE LN-23P TO THE CLASSIC III OR CLASSIC IIID (EQUIPPED WITH K623-1 WIRE FEED MODULE) USING THE K-350-1 ADAPTER KIT (SEE FIGURE C.5) 1. Shut the welder off. 2. Connect the electrode cable fr om the LN-23P to the “CV” output terminal of the engine welder . Connect the work cable to the “+” output terminal. NOTE: W elding cable [...]

CONNECTION OF THE K488 SG CONTROL MODULE AND K487 MA GNUM SPOOL GUN T O THE CLASSIC III OR CLASSIC IIID (EQUIPPED WITH K623-1 WIRE FEED MODULE) (SEE FIGURE C.6.) 1. Shut the welder off. 2. Connect the electr ode cable from the SG Contr ol Module to the “+” terminal of the welder . Connect the work cable to the “CV–” terminal of the welder[...]

NO TES C-10 C-10 Classic III and IIID 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[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 Classic III and IIID T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Saf ety Precautions .......................[...]

SAFETY PRECA UTIONS • Ha v e qualified personnel do all maintenance and troub leshooting w ork. • T ur n the engine off before w orking inside the machine. • Remo v e co vers or guards only when necessary to perf or m maintenance and replace them when the maintenance requiring their remov al is complete. • If co vers or guards are missing f[...]

CHANGE THE OIL FIL TER: Change the oil filter the first time between 25 and 50 hours of operation. Then, under normal operating conditions, change the oil filter per T ab le D .1 or consult your engine Owner’ s Manual. If the engine is operated under hea vy load or in high ambient temperatures , change the oil filter more fre- quently . See T ab [...]

FUEL FIL TER - DIESEL ENGINE (CLASSIC IIID CODES ABO VE 10061 WITH ST ANAD YNE FUEL FIL TER): The diesel engine fuel filter is a metal canister ele- ment type. It cannot be cleaned. Replace the filter per T able D .1 or if there is reason to belie v e it is plugged. Change the fuel filter as f ollows: 1. See Figure D .2. Release the two spring clam[...]

HO W T O ELIMINA TE AIR FROM THE FUEL SYSTEM – DIESEL ENGINE (CLASSIC IIID) The f ollowing procedure is f or Classic IIID diesel engines with a Stanadyne type fuel filter (Figure D .2). If your filter is diff erent, refer to y our engine Owner’ s Man ual f or the correct procedure for eliminating air from the system. 1. Set the IDLER s witch to[...]

COOLING SYSTEM: The Continental engine, gaso- line or diesel, is water cooled. Check the coolant le vel at the radiator filler daily . Add a 50-50 mixture of water and antifreeze as needed. T o drain and refill the sys- tem, do the f ollowing: 1. Ensure that the machine is on lev el ground. T o av oid personal injur y , nev er remove the r adiator [...]

TIGHTENING THE F AN BEL T: F an belts tend to loosen after the first 50 hours of operation. If the f an belts are loose, the engine can o verheat and the bat- ter y can lose its charge . Check belt tightness b y press- ing on the belt midwa y between the pulleys . The belt should deflect no more than 13 mm (0.5 in.). See Figure D .6. T o adjust the[...]

MAINTENANCE D-8 D-8 Classic III and IIID 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 ENGINE MAINTENANCE SCHEDULE HOURS BETWEEN SER VICING D AIL Y I I I 50 R R C C I (3) 250 R C C or R 500 C R R R I I MAINTENANCE[...]

B A TTER Y MAINTENANCE GASES FROM BA TTER Y can explode. • K eep sparks, flame, and cigarettes a wa y from batter y . BA TTER Y ACID can b ur n ey es and skin. • W ear glo ves and ey e protection and be careful when working near a batter y . F ollo w the instructions printed on the batter y . T o pre vent EXPLOSION when: • INST ALLING A NEW B[...]

WELDER/GENERA T OR MAINTENANCE ST ORA GE: Store the Classic III or Classic IIID in clean, dr y , protected areas. CLEANING: Blo w out the gener ator and controls peri- odically with low pressure air . Do this at least once a w eek in par ticularly dir ty areas. NAMEPLA TES: Whene v er routine maintenance is perf or med on this machine - or at least[...]

IDLER MAINTENANCE 1. The solenoid plunger must work freely because binding can cause engine surging. If surging occurs , be sure the plunger is properly lined up with the throttle le v er . Dust the plunger about once a year with g raphite powder . 2. When any service is done, reassemble the rubber bello ws on the solenoid plunger with the v ent ho[...]

Retur n 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-12 D-12 Classic III and IIID FIGURE D .7 - MAJOR COMPONENT LOCA TIONS (CLASSIC IIID SHO WN) 1 2 4 6 8 7 3 5 11 10 9 12 13 14 15 1. RIGHT CASE SIDE (DOOR) 2. BASE ([...]

NO TES D-13 D-13 Classic III and IIID Return to Section TOC Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

NO TES D-14 D-14 Classic III and IIID 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[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 Classic III and IIID Theory of Operation ............................................................................................................. Section E General Description ............................................................[...]

THEOR Y OF OPERA TION E-2 E-2 Classic III and IIID 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 FIGURE E.1a – CLASSIC III BLOCK LOGIC DIA GRAM GENERAL DESCRIPTION The Classic III and Classic IIID are heavy duty , engine d[...]

THEOR Y OF OPERA TION E-3 E-3 Classic III and IIID 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 B A TTER Y , ST ARTER, ENGINE AL TERNA T OR AND OIL SWITCH CIRCUIT (CLASSIC III) The 12VDC batter y po wers the star ter motor [...]

Retur n 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 B A TTER Y , ST ARTER, ENGINE AL TERNA T OR AND PRO TECTION CIRCUITR Y (CLASSIC IIID) The 12VDC batter y po wers the star ter motor , glow plugs and the engine protection circui[...]

Retur n 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, GENERA T OR ARMA TURE AND FRAME, AL TERNA T OR ST A T OR AND RO T OR EXCIT A TION (FLASHING) When the engine is star ted and running, the residual magnetism v oltage is [...]

Retur n 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 THEOR Y OF OPERA TION E-6 E-6 Classic III and IIID CURRENT RANGE SELECT OR The selector s witch acts as a coarse current adjustment b y allo wing v ar ying amounts of series win[...]

Retur n 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 THEOR Y OF OPERA TION E-7 E-7 Classic III and IIID FIGURE E.4 – DC GENERA TOR MA CHINES ARMATURE SHAFT GENERATOR ARMATURE SHUNT WINDINGS FIELD MECHANICAL COUPLING SHUNT WINDIN[...]

NO TES E-8 E-8 Classic III and IIID 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[...]

Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 Classic III and IIID T roubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide ........................................................[...]

Retur n 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 HO W T O USE TROUBLESHOO TING GUIDE Ser vice and repair should be perf or med by only Lincoln Electric F actor y T rained P ersonnel. Unauthoriz ed repairs perf or med on this e[...]

Retur n 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 ELECTRIC SHOCK can kill. Hav e an electr ician install and service this equipment. T ur n the machine OFF bef ore working on equipment. Do not touch electrically hot par ts. Som[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-4 F-4 Classic III and IIID Observe Safety Guidelines TR OUBLESHOO TING GUIDE detailed in the beginning of this manual. CA UTION If f or any rea[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-5 F-5 Classic III and IIID TR OUBLESHOO TING GUIDE Obser ve Safety Guidelines detailed in the beginning of this manual. CA UTION If f or any re[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-6 F-6 Classic III and IIID Observe Safety Guidelines TR OUBLESHOO TING GUIDE detailed in the beginning of this manual. CA UTION If f or any rea[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-7 F-7 Classic III and IIID TR OUBLESHOO TING GUIDE Obser ve Safety Guidelines detailed in the beginning of this manual. CA UTION If f or any re[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-8 F-8 Classic III and IIID Observe Safety Guidelines TR OUBLESHOO TING GUIDE detailed in the beginning of this manual. CA UTION If f or any rea[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-9 F-9 Classic III and IIID TR OUBLESHOO TING GUIDE Obser ve Safety Guidelines detailed in the beginning of this manual. CA UTION If f or any re[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-10 F-10 Classic III and IIID Observe Safety Guidelines TR OUBLESHOO TING GUIDE detailed in the beginning of this manual. CA UTION If f or any r[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-11 F-11 Classic III and IIID TR OUBLESHOO TING GUIDE Obser ve Safety Guidelines detailed in the beginning of this manual. CA UTION If f or any [...]

TR OUBLESHOO TING & REP AIR F-12 F-12 Classic III and IIID 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 TR OUBLESHOO TING GUIDE Obser ve Safety Guidelines detailed in the beginning of this manual. CA UTION If f or any r[...]

Retur n 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-13 F-13 Classic III and IIID TR OUBLESHOO TING & REP AIR TR OUBLESHOO TING GUIDE Obser ve Safety Guidelines detailed in the beginning of this manual. CA UTION If f or any [...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-14 F-14 Classic III and IIID AL TERNA T OR RO T OR TEST W ARNING Ser vice and repair should be perf or med by only Lincoln Electric f actor y t[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-15 F-15 Classic III and IIID AL TERNA T OR CO VER BR USHES WRAP AROUND SLIP RINGS FIGURE F .1 – AL TERNA TOR COVER REMOV AL AL TERNA T OR RO [...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-16 F-16 Classic III and IIID FIGURE F .2 – MEASURING ROTOR RESIST ANCE 6. W or king from the left side of the machine, measure the resistance[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-17 F-17 Classic III and IIID FIGURE F .3 – MEASURING ROTOR RESIST ANCE TO GROUND 7. Measure the rotor resistance to ground. a. Set the ohmmet[...]

FIELD SHUNT WINDING TEST Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthoriz ed repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate y our factory warranty . For y our safety and to a void elec- tr ical shock, please observe all [...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-19 F-19 Classic III and IIID FIELD SHUNT WINDING TEST (continued) FIGURE F .4 – PLUG P10 LOCA TIONS PLUG P10 TEST PROCEDURE 1. T ur n engine [...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-20 F-20 Classic III and IIID FIELD SHUNT WINDING TEST (continued) 5. Using the v olt/ohmmeter set on the low scale (X1), measure the resistance[...]

FLASHING THE FIELDS Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthoriz ed repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate y our factory warranty . F or your saf ety and to av oid elec- tr ical shock, please observe all saf [...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-22 F-22 Classic III and IIID FLASHING THE FIELDS (continued) FIGURE F .6 - FLASHING THE FIELDS PROCEDURE 1. T ur n engine OFF . 2. Remov e the [...]

IDLER SOLENOID TEST Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthoriz ed repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate y our factory warranty . For y our saf ety and to av oid elec- tr ical shock, please observe all saf [...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-24 F-24 Classic III and IIID IDLER SOLENOID TEST (continued) FIGURE F .7 - SOLENOID LEAD CONNECTIONS LEADS 56 & 57 SOLENOID TEST PROCEDURE [...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-25 F-25 Classic III and IIID ENGINE THRO TTLE ADJUSTMENT TEST - CLASSIC IIID (DIESEL) Ser vice and repair should be perf or med by only Lincoln[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-26 F-26 Classic III and IIID ENGINE THRO TTLE ADJUSTMENT TEST (continued) FIGURE F .8 - STROBE MARK LOCA TION STROBE MARK TEST PROCEDURE Strobe[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-27 F-27 Classic III and IIID ENGINE THRO TTLE ADJUSTMENT TEST (continued) 6. If either of the readings is incorrect, adjust the throttle as f o[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-28 F-28 Classic III and IIID ENGINE THRO TTLE ADJUSTMENT TEST (continued) FIGURE F .9 - HIGH IDLE ADJUSTMENT LOCKING NUT ADJUSTING SCREW FIGURE[...]

TR OUBLESHOO TING & REP AIR F-29 F-29 Classic III and IIID 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 THRO TTLE ADJUSTMENT TEST - CLASSIC III (GASOLINE) Ser vice and repair should be perf or med by only Lincoln[...]

TR OUBLESHOO TING & REP AIR F-30 F-30 Classic III and IIID 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 THRO TTLE ADJUSTMENT TEST (continued) FIGURE F .11 - BLOWER P ADDLE MARK LOCA TION STROBE MARK TEST PROCEDUR[...]

TR OUBLESHOO TING & REP AIR F-31 F-31 Classic III and IIID 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 6. If either of these readings is incorrect, adjust the throttle as f ollows: Adjust High Idle a. Make sure there i[...]

TR OUBLESHOO TING & REP AIR F-32 F-32 Classic III and IIID 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 FIGURE F .12 - HIGH IDLE ADJUSTMENT GOVERNOR LOCKING NUT ADJUSTMENT SCREW OSCILLOSCOPE METHOD 1. Connect the oscill[...]

INST ALLA TION F-33 F-33 Classic III and IIID 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 THRO TTLE ADJUSTMENT TEST (continued) FIGURE F .13 - LOW IDLE ADJUSTMENT SPEED ADJUSTMENT SCREW LOCKING NUT IDLER ROD[...]

TR OUBLESHOO TING & REP AIR F-34 F-34 Classic III and IIID 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 This is the typical auxiliar y output voltage gener ated from a proper ly operating machine . Note that each vertic[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-35 F-35 Classic III and IIID This is the typical DC output v oltage generated from a properly operating machine. Note that each vertical divi- [...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-36 F-36 Classic III and IIID This is the typical DC output v oltage generated from a properly operating machine. Note that each vertical divi- [...]

AL TERNA T OR RO T OR REMO V AL AND REPLA CEMENT Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthoriz ed repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate y our factory warranty . F or your saf ety and to av oid elec- tr ical s[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-38 F-38 Classic III and IIID AL TERNA T OR RO T OR REMO V AL AND REPLA CEMENT (continued) FIGURE F .14 – BA TTER Y P ANEL REMO V AL NEGA TIVE[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-39 F-39 Classic III and IIID AL TERNA T OR RO T OR REMO V AL AND REPLA CEMENT (continued) FIGURE F .15 – AL TERNA T OR CO VER AND WRAP AROUND[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-40 F-40 Classic III and IIID AL TERNA T OR RO T OR REMO V AL AND REPLA CEMENT (continued) FIGURE F .16 – RO T OR REMO V AL STATOR FRAME NUT S[...]

Retur n 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-41 F-41 Classic III and IIID AL TERNA T OR RO T OR REMO V AL AND REPLA CEMENT (continued) Replacement 9. Carefully mount the rotor onto the generator shaft. Ins[...]

AL TERNA T OR ST A T OR REMO V AL AND REPLA CEMENT Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthoriz ed repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate y our factory warranty . F or your saf ety and to av oid elec- tr ical[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-43 F-43 Classic III and IIID AL TERNA T OR ST A T OR REMO V AL AND REPLA CEMENT (continued) FIGURE F .17 – COMMUT A T OR WRAP-AROUND REMO V A[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-44 F-44 Classic III and IIID FIGURE F .18 - LEAD DISCONNECTION POINTS YELLO W AND WHITE WIRE IN-LINE CONNECT ORS; YELLO W LEADS; BLACK CURRENT [...]

Retur n 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 13. Clear the leads in preparation f or remov- ing the stator/end brac ket. 14. Lift the eight brushes from the commuta- tor . Note the position of the brushes for reassembly . [...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-46 F-46 Classic III and IIID FIGURE F .21 - DRILL SPOT LOCA TIONS BRUSH HOLDER DRILL SPOT LOCATION STATOR/END BRACKET MOUNTING BOLT STATOR END [...]

GENERA T OR FRAME REMO V AL AND REPLA CEMENT Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthoriz ed repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate y our factory warranty . F or your saf ety and to av oid elec- tr ical shock[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-48 F-48 Classic III and IIID GENERA T OR FRAME REMO V AL AND REPLA CEMENT (continued) FIGURE F .22 – FUEL T ANK / OUTPUT CABLE REMOV AL FUEL [...]

See Figure F .23 for steps 10 - 13. 10. Cut all necessar y cable ties. 11. Disconnect the blue and the bro wn wires at the in- line connectors. See Figure F .23 and the Wiring Diagram. 12. Label the cables that are connected to the selector s witch. Otherwise , y ou will need to see the Wir ing Diagr am during reassemb ly . 13. With the 1/2" w[...]

See Figure F .24 for steps 14 - 16. 14. With the 9/16" wrench, remov e the four bolts and loc k w ashers holding the case front to the welder frame . There are two bolts on each side. 15. With the 1/2" wrench, remov e the two bolts and n uts and w ashers from the fuel tank rails - one on each side. 16. Carefully clear and disconnect an y [...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-51 F-51 Classic III and IIID GENERA T OR FRAME REMO V AL AND REPLA CEMENT (continued) FIGURE F .25 – FRAME MOUNTING DET AILS ENGINE/GENERATOR[...]

27. Re-attach the positiv e output ter minal cable . 28. Set the fuel tank into position on the rails and secure it with the f our bolts, w ashers, and nuts . 29. Attach the fuel return line at the top of the fuel tank (Diesel engine only). Remove the plug from the fuel line and attach it to the fuel bowl. 30. P erfor m the replacement procedures a[...]

GENERA T OR ARMA TURE REMO V AL AND REPLA CEMENT Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthoriz ed repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate y our factory warranty . F or your saf ety and to av oid elec- tr ical s[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-54 F-54 Classic III and IIID GENERA T OR ARMA TURE REMO V AL AND REPLA CEMENT (continued) FIGURE F .26 – BLOWER P ADDLE REMOV AL BLOWER PADDL[...]

Retur n 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 TR OUBLESHOO TING & REP AIR F-55 F-55 Classic III and IIID RETEST AFTER REP AIR Retest a machine: • If it is rejected under test f or any reason that requires you to remo [...]

NO TES F-56 F-56 Classic III and IIID 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[...]

ELECTRICAL DIA GRAMS G-1 G-1 CLASSIC III/IIID Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Electrical Diagrams Section ........................................................................................... Section G Wiring Diagram ...........................................................................[...]

Notes G-2 G-2 CLASSIC III/IIID 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[...]

ELECTRICAL DIA GRAMS G-3 G-3 CLASSIC III/IIID 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 Wiring Diagram- Classic IIID NO TE: This diagram is f or reference only . It may not be accurate f or all machines covered by this m[...]

Notes G-4 G-4 CLASSIC III/IIID 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[...]

ELECTRICAL DIA GRAMS G-5 G-5 CLASSIC III/IIID 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 Wiring Diagram- Classic III NO TE: Lincoln Electric assumes no responsibility for liab lilities resulting from board lev el troubles[...]

Notes G-6 G-6 CLASSIC III/IIID 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[...]

ELECTRICAL DIA GRAMS G-7 G-7 CLASSIC III/IIID 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 Wiring Diagram - Wire Feed Module CLEVELAND, OHIO U.S.A. 3-18-94 L9259 R AMPHENOL 1 A D F 510 602 610A 503A 609 501 CONTACTOR CONTAC[...]

Notes G-8 G-8 CLASSIC III/IIID 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[...]

ELECTRICAL DIA GRAMS G-9 G-9 CLASSIC III/IIID 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 PC Board Sc hematic NO TE: Lincoln Electric assumes no responsibility for liab lilities resulting from board lev el troublesho[...]

Notes G-10 G-10 CLASSIC III/IIID 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[...]

ELECTRICAL DIA GRAMS G-11 G-11 CLASSIC III/IIID 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 PC Board La yout NO TE: Lincoln Electric assumes no responsibility for liab lilities resulting from board lev el troubleshoo[...]

Notes G-12 G-12 CLASSIC III/IIID 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[...]