Lincoln Electric CLASSICII SVM125-A Service Manual
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Lincoln Electric CLASSICII SVM125-A Service Manual

Lincoln electric welder user manual
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RETURN TO MAIN INDEX
SVM125-A
October 1996
TM
CLASSIC II
For use with machine code numbers 9805 to 10220
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
World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
Sales and Service through subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100

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Summary of Contents for Lincoln Electric CLASSICII SVM125-A

  • Page 1 RETURN TO MAIN INDEX SVM125-A October 1996 CLASSIC II For use with machine code numbers 9805 to 10220 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 .

  • Page 2: Safety

    Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 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: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety ...i-iv Installation...Section A Technical Specifications ...A-2 Safety Precautions ...A-3 Location and Ventilation ...A-3 Pre-operation Engine Service ...A-4 Electrical Output Connections...A-6 Operation...Section B Safety Instructions...B-2 General Description ...B-2 Recommended Applications...B-3 Operational Features and Controls...B-3 Design Features...B-3 Welding Capability ...B-4 Limitations ...B-4...
  • Page 7 Section A-1 - INSTALLATION SECTION - Installation Technical Specifications ...A-2 Input – Diesel Engine ...A-2 Rated Output – Welder...A-2 Output – Welder and Generator ...A-2 Physical Dimensions...A-2 Safety Precautions ...A-3 Location and Ventilation ...A-3 Storing ...A-3 Stacking ...A-4 Tilting ...A-4 Lifting ...A-4...

  • Page 8: Installation

    28 HP @ 1700 RPM Duty Cycle 100% Duty Cycle 60% Duty Cycle 40% Duty Cycle OUTPUT - WELDER AND GENERATOR Welding Ranges Max. Open Circuit Voltage 40-325 Amps DC Height 49.94 in. 1040 mm CSA machines can draw 15 amps from either half of the receptacle. Non-CSA machines can draw 20 amps from either half of the receptacle.

  • Page 9: Safety Precautions

    Leaving the doors open changes the designed air flow and may cause overheating. Always operate the welder with the case roof on and all machine compo- nents completely assembled. This will protect you from the dangers of moving parts, hot metal surfaces, and live electrical devices.

  • Page 10: Stacking

    Lift only with equipment of adequate lifting capacity. Be sure machine is stable when lifting. HIGH ALTITUDE OPERATION It may be necessary to derate welder output at higher altitudes. Some engine adjustment may be required. Contact a Deutz Service Representative.

  • Page 11: Muffler

    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.

  • Page 12: Electrical Output Connections

    Cable diameters are increased for long cable lengths to reduce voltage drops. Lincoln Electric offers a welding accessory kit with the properly specified welding cables. Accessories section of this manual for more information.

  • Page 13: Machine Grounding

    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 AWG or larger) from the ground stud located on the welding generator frame foot.
  • Page 14 NOTES CLASSIC II...
  • Page 15 Section B-1 - OPERATION SECTION - Operation...Section B Safety Instructions...B-2 General Description ...B-2 Recommended Applications...B-3 Welder ...B-3 Generator...B-3 Operational Features and Controls...B-3 Design Features...B-3 Welding Capability ...B-4 Limitations ...B-4 Controls and Settings...B-5 Welder/Generator Controls...B-5 Control of Welding Current ...B-6 Diesel Engine Controls: ...B-7 Engine Operation ...B-8...

  • Page 16: Operation

    OPERATING INSTRUCTIONS Read and understand this entire section before operat- ing your Classic II. SAFETY INSTRUCTIONS WARNING 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;...

  • Page 17: Recommended Applications

    (SMAW) 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. GENERATOR The Classic II is also capable of providing 3.0 kVA of...

  • Page 18: Welding Capability

    WELDING CAPABILITY 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.

  • Page 19: Controls And Settings

    The amperages on the dial correspond to the average amperages needed for specific Lincoln welder rods. See Control of Welding Current for more information. 2. FINE CURRENT ADJUSTMENT: Allows fine adjustment of current within the selected output range.

  • Page 20: Control Of Welding Current

    CONTROL OF WELDING CURRENT CAUTION 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.

  • Page 21: Diesel Engine Controls

    FIGURE B.3 – DIESEL ENGINE CONTROLS 1. IDLER CONTROL TOGGLE SWITCH 2. IGNITION TOGGLE SWITCH 3. ENGINE PROTECTION WARNING LIGHT 4. START PUSHBUTTON 5. ENGINE HOUR METER 6. AMMETER 7. OIL PRESSURE GAUGE DIESEL ENGINE CONTROLS See Figure B.3 for the location of the following fea- tures: 1.

  • Page 22: Engine Operation

    ENGINE OPERATION WARNING DO NOT RUN THE ENGINE AT 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.

  • Page 23: Stopping The Engine

    OPERATION COLD WEATHER STARTING Follow the instructions on the nameplate and in the engine manual shipped with the welder. With a fully charged battery and the proper weight oil, the engine should start satisfactorily even when the air tempera- ture is down to about 0 If the engine is frequently started below 10 want to install the optional ether starter kit.

  • Page 24: Welding Operation

    Specifications in the Installation section for operating speeds. The idler is controlled by the IDLER toggle switch on the welder control panel. The switch has two positions as follows: 1 . In the "HIGH" position, the idler is off, and the engine high speed is controlled by the governor.
  • Page 25 + terminal and the work cable to –. For negative electrode, reverse the electrode and work cables at the welder’s output terminals. Replace and tighten the flange nuts securely. Be sure the connections are tight. 2. Select the appropriate electrode.
  • Page 26 B-12 TO USE THE CLASSIC II FOR DC WIRE FEED WELDING (CONSTANT VOLTAGE) WITH WIRE FEED MODULE: 1. Connect the LN-25 or LN-7 Wire Feeder (with wire feed module). Follow the installation instructions provided with the wire feeder. 2. Select the appropriate electrode. 3.

  • Page 27: Auxiliary Power

    B-13 AUXILIARY POWER WARNING 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 kVA of 115/230V AC power (60 hertz). One 115V duplex and one 230V grounding type recep- tacle are provided.
  • Page 28 *Sump Pump Toaster Weed Trimmer Lincoln 100 or 125 Amp Wire Feeder/Welder NOTES: Wattages listed are approximate. Check your equipment for actual wattage. Equipment with unusually high *START-UP WATTS are listed. For start-up of other equipment listed in the table, multiply RUNNING WATTS by 2.
  • Page 29 Options/Accessories ...C-2 TIG Welding...C-3 Semiautomatic FCAW and MIG Welding ...C-3 Connection of Lincoln Electric Wire Feeders...C-4 Connection of the LN-7 using K867 Universal Adapter...C-4 Connection of the LN-7 using K584 Input Cable Assembly ...C-5 Connection of the LN-25 using K867 Universal Adapter...C-6 Connection of the LN-25 “Across the Arc”...

  • Page 30: Accessories

    WARNING PIPE THAWING can result in fire, explosion, damage to pipes, wiring, and the welder as well as other unsafe or hazardous conditions. Do not use a welder to thaw pipes before reviewing Lincoln Bulletin E695.1 (dated October 1987 or later).

  • Page 31: Tig Welding

    TIG WELDING TIG Module (K930-1) - The TIG Module is an acces- sory that provides high frequency and shielding gas control for DC GTAW (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.

  • Page 32: Connection Of Lincoln Electric Wire Feeders

    CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING ELECTRIC SHOCK can kill. • Do not operate with panels open. • Disconnect NEGATIVE (-) BATTERY LEAD before servicing. • Do not touch electrically live parts. MOVING PARTS can injure. • Keep guards in place.
  • Page 33 6. Adjust wire feed speed and voltage at the LN-7. NOTE: For remote control, a K857 control is required. Connect it to the K864 adapter. CAUTION When the welder is in local control, the electrode is always "HOT." FIGURE C.2 14 PIN...

  • Page 34: Installation

    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: Welding cable must be sized for current and duty cycle of application.
  • Page 35 (SEE FIGURE C.4.) 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: Welding cable must be sized for current and duty cycle of application.

  • Page 36: Connection Of The K488 Sg Control Module And K487 Magnum Spool Gun

    2. Connect the electrode cable from the SG Control Module to the “+” terminal of the welder. Connect the work cable to the “CV–” terminal of the welder. NOTE: Welding cable must be sized for current and duty cycle of application.

  • Page 37: Safety Precautions

    Engine Maintenance Schedule...D-5 Battery Maintenance ...D-6 Cleaning the Battery ...D-6 Checking Specific Gravity ...D-6 Checking Electrolyte Level ...D-6 Charging the Battery ...D-6 Welder/Generator Maintenance ...D-7 Storage ...D-7 Cleaning ...D-7 Brush Removal and Replacement...D-7 Commutator and Brushes ...D-7 Receptacles ...D-7 Cable Connections ...D-7 Idler Maintenance...D-7...

  • Page 38: Safety Precautions

    SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn 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. •...

  • Page 39: Change The Oil Filter

    CHANGE THE OIL FILTER: 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.

  • Page 40: Air Cleaner

    Consult the Engine Operation Manual. It is important to locate the welder to provide an unrestricted flow of clean, cool air. BEARINGS: The Classic II is equipped with double- shielded ball bearings having sufficient grease to last indefinitely under normal service.

  • Page 41: Engine Maintenance Schedule

    DEUTZ ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before • Fill fuel tank. Starting Engine • Check oil level. • Check air cleaner for dirty, loose, or damaged parts. • Check air intake and cooling areas, clean as necessary. First 50 Hours •...

  • Page 42: Battery Maintenance

    GROUND - Damage to the engine alternator and the printed circuit board can result from incorrect connection. • CONNECTING A BATTERY CHARGER - Remove the battery from the welder by disconnecting the negative cable first, then the positive cable and battery clamp. When reinstalling, connect the negative cable last.

  • Page 43: Welder/Generator Maintenance

    2. Proper operation of the idler requires good ground- ing of the PC board, reed switch, and battery. 3. If desired, the welder can be used without automatic idling by setting the IDLER switch to the “HIGH” position.

  • Page 44: Major Component Locations

    FIGURE D.3 - MAJOR COMPONENT LOCATIONS 1. RIGHT CASE SIDE (DOOR) 2. BASE (WITH BATTERY) 3. ALTERNATOR BRUSHES 4. ALTERNATOR 5. GENERATOR 6. GENERATOR BRUSHES 7. OUTPUT TERMINALS 8. FUEL TANK 9. CASE FRONT WITH CONTROL PANEL 10. LEFT CASE SIDE 11.

  • Page 45: Theory Of Operation Section

    Section E-1 -THEORY OF OPERATION SECTION- Theory of Operation ...Section E General Description ...E-2 Battery, Starter, Engine Alternator, and Protection Circuits ...E-2 Engine, Generator Armature and Frame, Alternator Stator and Rotor ...E-3 Excitation (Flashing)...E-3 Auxiliary and Field Feedback Coils...E-3 Interpole and Series Coil...E-3 Current Range Selector ...E-4 Fine Current Adjustment ...E-4 Engine Idler Circuit...E-4...

  • Page 46: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 – BATTERY, STARTER, ENGINE ALTERNATOR, AND PROTECTION CIRCUITS ON LATER MODELS PROTECTION AND IDLER CIRCUITS ARE ON ONE PC BOARD PROTECTION RELAY TEMPERATURE PRESSURE SENSOR SENSOR FUEL SOLENOID RELAY (NOT PRESENT ON LATER MODELS) ENGINE IGNITION ENGINE SWITCH...

  • Page 47: Engine, Generator Armature And Frame, Alternator Stator And Rotor

    THEORY OF OPERATION FIGURE E.3 – ENGINE, GENERATOR ARMATURE AND FRAME, ALTERNATOR STATOR AND ROTOR ON LATER MODELS PROTECTION AND IDLER CIRCUITS ARE ON ONE PC BOARD PROTECTION RELAY IDLER BOARD TEMPERATURE PRESSURE SENSOR SENSOR FUEL SOLENOID RELAY (NOT PRESENT ON LATER MODELS) ENGINE IGNITION...

  • Page 48: Current Range Selector

    THEORY OF OPERATION FIGURE E.4 – CURRENT RANGE SELECTOR, FINE CURRENT ADJUSTMENT AND ENGINE IDLER CIRCUIT ON LATER MODELS PROTECTION AND IDLER CIRCUITS ARE ON ONE PC BOARD PROTECTION RELAY IDLER BOARD TEMPERATURE PRESSURE SENSOR SENSOR FUEL SOLENOID RELAY (NOT PRESENT ON LATER MODELS) ENGINE IGNITION...

  • Page 49: Dc Generator Machines

    THEORY OF OPERATION DC GENERATOR 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.
  • Page 50 NOTES CLASSIC II...

  • Page 51: Troubleshooting & Repair Section

    Section F-1 TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section ...Section F How to Use Troubleshooting Guide ...F-2 PC Board Troubleshooting Procedures ...F-3 Troubleshooting Guide ...F4 - F-12 Test Procedures ...F-13 Alternator Rotor Test...F-13 Shunt Field Winding Test...F-17 Idler Solenoid Test ...F-20 Engine Throttle Adjustment Test...F-22 Flashing the Fields ...F-26 Oscilloscope Waveforms...F-28...

  • Page 52: How To Use Troubleshooting Guide

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 53: Pc Board Troubleshooting Procedures

    • If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete. • If you return a PC Board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- er failure analysis.

  • Page 54: Troubleshooting Guide

    AC auxiliary output voltage. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 55 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216- 383-2531 or 1-800-833-9353.
  • Page 56 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 57 Control Rheostat is adjusted. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216- 383-2531 or 1-800-833-9353.
  • Page 58 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 59 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353. detailed in the beginning of this manual.
  • Page 60 The engine will not shut down. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 61 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216- 383-2531 or 1-800-833-9353.
  • Page 62 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216- 383-2531 or 1-800-833-9353. detailed in the beginning of this manual.

  • Page 63: Test Description

    TROUBLESHOOTING & REPAIR ALTERNATOR ROTOR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 64 F-14 TROUBLESHOOTING & REPAIR ALTERNATOR ROTOR TEST (continued) ALTERNATOR COVER SLIP RINGS TEST PROCEDURE 1. Turn engine off. 2. With the 3/8" socket wrench, remove the left case side. 3. Unlatch, lift and secure the right side door. Note that there are latches at both ends of the door.
  • Page 65 F-15 TROUBLESHOOTING & REPAIR ALTERNATOR ROTOR TEST (continued) 9. Working from the left side of the machine, measure the resistance across the rotor slip rings. A. Set the ohmmeter on the low scale (X1). B. Place one meter probe on one of the rotor slip rings.
  • Page 66 F-16 TROUBLESHOOTING & REPAIR ALTERNATOR ROTOR TEST (continued) 10. Measure the rotor resistance to ground. A. Set the ohmmeter on the high scale (X100,000). B. Place one probe on either of the rotor slip rings. Place the other probe on any good, unpainted ground.

  • Page 67: Shunt Field Winding Test

    TROUBLESHOOTING & REPAIR 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 danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 68 F-18 TROUBLESHOOTING & REPAIR SHUNT FIELD WINDING TEST (continued) TEST PROCEDURE 1. Turn engine off. 2. Unlatch, lift and secure the right side door. Note that there are latches at both ends of the door. 3. Locate plug P10. See Figure F.4. FIGURE F.4 –...
  • Page 69 F-19 TROUBLESHOOTING & REPAIR SHUNT FIELD WINDING TEST (continued) FIGURE F.5 – SHUNT LEAD RESISTANCE CHECK PIN 5 6. Using the volt/ohmmeter set on the low scale (X1), measure the resistance between the blue and the brown leads. See Figure F.5. approximately 57 ohms.

  • Page 70: Idler Solenoid Test

    F-20 TROUBLESHOOTING & REPAIR Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 71 F-21 TROUBLESHOOTING & REPAIR IDLER SOLENOID TEST (continued) FIGURE F.6 - SOLENOID/HARNESS LEAD CONNECTIONS TEST PROCEDURE 1. Turn engine off. 2. Unlatch, lift and secure the right side door. Note that there are latches at both ends of the door. 3.

  • Page 72: Engine Throttle Adjustment Test

    TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 73 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.7 - STROBE MARK LOCATION TEST PROCEDURE Strobe Tach Method 1. Turn the engine welder OFF. 2. Unlatch, lift and secure the right side door. Note that there are latches at both ends of the door.
  • Page 74 F-24 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) 6. If either of the readings is incorrect, adjust the throttle as follows: Adjust HIGH IDLE: Use the 10mm wrench to loosen the locking nut. See Figure F.8 for location of the adjusting screw and locking nut.
  • Page 75 F-25 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.8 - HIGH IDLE ADJUSTMENT FIGURE F.9 - LOW IDLE ADJUSTMENT ADJUSTING SCREW LOCKING LOCKING COLLAR CLASSIC II F-25...

  • Page 76: Flashing The Fields

    F-26 TROUBLESHOOTING & REPAIR Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 77 FIGURE F.10 - FLASHING THE FIELDS 12 VOLT BATTERY PROCEDURE 1. Turn engine welder OFF. 2. Unlatch, lift and secure the right side door. Note that there are latches at both ends of the door. 3. Remove the cover from the exciter.

  • Page 78: Normal Open Circuit Voltage Waveform (115Vac Supply

    F-28 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM 16.6 ms 5 ms 50 volts This is the typical auxiliary output voltage generated from a properly operating machine.

  • Page 79: Normal Open Circuit Dc Weld Voltage Waveform

    F-29 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AND SELECTOR SWITCH AT MAXIMUM 5 ms 50 volts This is the typical DC output voltage generated from a properly operating machine.

  • Page 80: Typical Dc Weld Output Voltage Waveform

    F-30 TROUBLESHOOTING & REPAIR TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM MACHINE LOADED – SELECTOR SWITCH AT MAXIMUM POSITION MACHINE LOADED TO 250 AMPS AT 40 VDC 5 ms 20 volts This is the typical DC output voltage generated from a properly operating machine.

  • Page 81: Alternator Rotor Removal And Replacement

    TROUBLESHOOTING & REPAIR ALTERNATOR ROTOR REMOVAL Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 82 F-32 TROUBLESHOOTING & REPAIR ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Turn the engine off. 2. Unlatch, lift and secure the right side door. There are latches on both sides. 3. With the 1/2" wrench, disconnect the negative battery cable. 4.
  • Page 83 F-33 TROUBLESHOOTING & REPAIR ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued) See Figure F.12 for steps 11 - 15. 11. Turn off the fuel at the fuel bowl and remove the fuel line. Plug the line to prevent spillage. 12. With the 9/16" wrench, remove the four nuts, bolts and washers that mount the fuel tank to the rails.
  • Page 84 F-34 TROUBLESHOOTING & REPAIR ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued) See Figure F.13 for steps 16 - 17. 16. With the 3/4" wrench, remove the copper strap from the negative output terminal. Clear the strap from cable ties. FIGURE F.13 – OUTPUT TERMINAL STRAP AND CASE FRONT REMOVAL 17.
  • Page 85 F-35 TROUBLESHOOTING & REPAIR ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued) See Figure F.14 for steps 18 - 21. 18. With the 3/8" wrench, loosen the two screws on the left side of the alternator cover. 19. With the 3/8" wrench, remove the screw and lock washer from the top center of the alter- nator cover.

  • Page 86: Brush Holder Assembly

    F-36 TROUBLESHOOTING & REPAIR ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued) See Figure F.15 for steps 22 - 24. 22. With the 7/16" wrench, remove the two bolts, nuts and washers mounting the brush hold- er assembly to the stator frame. 23.
  • Page 87 F-37 ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued) Replacement 25. Carefully mount the rotor onto the generator shaft. Install a new sleeve collar (part num- ber T14337), washer, and rotor locking nut. NOTE: Be careful not to damage or deform the new sleeve collar. Carefully tap the new sleeve collar into position.

  • Page 88: Alternator Stator Removal And Replacement

    TROUBLESHOOTING & REPAIR ALTERNATOR STATOR REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 89 F-39 TROUBLESHOOTING & REPAIR ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued) FIGURE F.16 – COMMUTATOR WRAP-AROUND REMOVAL PROCEDURE 1. Turn the engine OFF. 2. Perform the Alternator Rotor Removal procedure. 3. With the 3/8" nut driver, remove the two leads from the alternator brush holder assembly.

  • Page 90: Circuit Breaker

    F-40 TROUBLESHOOTING & REPAIR ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued) FIGURE F.17 - LEAD DISCONNECTION POINTS FIGURE F.18 - LEAD DISCONNECTION – CIRCUIT BREAKER, RECEPTACLES AND FIELD BRIDGE RECTIFIER YELLOW AND WHITE WIRE IN-LINE CONNECTORS LOCATED BEHIND CASE FRONT 230 VAC RECEPTACLE 115 VAC RECEPTACLE CIRCUIT BREAKER FIELD BRIDGE...
  • Page 91 F-41 TROUBLESHOOTING & REPAIR ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued) 14. Clear the leads in preparation for remov- ing the stator/end bracket. FIGURE F.19 - GENERATOR BRUSH HOLDER CABLE REMOVAL GENERNATOR BRUSH HOLDER/COIL CABLES (4) 16. With the 1/2" wrench, disconnect and clear the four heavy cables from the gen- erator brush holders to the coils in the generator frame.
  • Page 92 F-42 TROUBLESHOOTING & REPAIR ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued) FIGURE F.20 - DRILL SPOT LOCATIONS STATOR/ENDBRACKET 17. With the 5/8" wrench, remove the four bolts mounting the stator/end bracket assembly to the generator frame. Note the "drill spot" for reassembly. See Figure F.20.

  • Page 93: Generator Frame Removal And Replacement

    TROUBLESHOOTING & REPAIR REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 94 F-44 TROUBLESHOOTING & REPAIR GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.21 – GENERATOR LEAD AND CABLE CONNECTIONS SELECTOR SWITCH CABLES BROWN LEADS PROCEDURE 1. Turn the engine OFF. 2. Perform the Alternator Rotor Removal procedure. 3. Perform the Alternator Stator Removal procedure.
  • Page 95 F-45 TROUBLESHOOTING & REPAIR GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.22 – FRAME MOUNTING DETAILS See Figure 22 for steps 10 - 13. 10. With the 3/4" wrench, remove the frame mounting bolts, nuts and spacers from the feet of the generator frame. 11.

  • Page 96: Generator Armature Removal And Replacement

    TROUBLESHOOTING & REPAIR REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 97 F-47 TROUBLESHOOTING & REPAIR GENERATOR ARMATURE REMOVAL AND REPLACEMENT (continued) FIGURE F.23 – BLOWER PADDLE REMOVAL PROCEDURE 1. Turn the engine OFF. 2. Perform the Alternator Rotor Removal pro- cedure. 3. Perform the Alternator Stator Removal pro- cedure. 4. Perform the Generator Frame Removal pro- cedure.

  • Page 98: Retest After Repair

    240-254 210-225 Exciter DC Volts Shunt Field Amps 123 - 133 RETEST AFTER REPAIR ENGINE OUTPUT No Load RPM 1350-1400 1780-1810 WELDER DC OUTPUT Open Circuit Voltage 91-98.5 Load Amps Open Circuit Voltage 13.8 118-128 FIELD AMPS AND VOLTS (Current Rheostat at Maximum) Alt.
  • Page 99 ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams Section ...Section G Wiring Diagram (Code 9805 ) ...G-2 Wiring Diagram (Code 10000) ...G-3 Wiring Diagram (Code 10070 ) ...G-4 Wiring Diagram (Code 10071 ) ...G-5 Wiring Diagram (Code 10219 ) ...G-6 Wiring Diagram (Code 10220) ...G-7 Idler PC Board (M13708) Schematic ...G-8 Idler PC Board (M13708) Components...G-9...
  • Page 100 NOTES CLASSIC II...

  • Page 101: Wiring Diagram (Code 9805

    600A START IGNITION POTENTIOMETER SELECTOR SWITCH ENGINE 602A SWITCH HOUR METER STARTING MOTOR 5 4 3 CR2 REED WELDER RELAY LEAD BLOCK POSITIVE CV & VV OUTPUT NEGATIVE TERMINAL VV OUTPUT TERMINAL CV ADAPTER COPPER TERMINAL COPPER PLUG FOR TERMINAL...

  • Page 102: Wiring Diagram (Code 10000

    600A START IGNITION POTENTIOMETER SELECTOR SWITCH ENGINE 602A SWITCH HOUR METER STARTING MOTOR 5 4 3 CR2 REED WELDER RELAY LEAD BLOCK POSITIVE CV & VV OUTPUT NEGATIVE TERMINAL VV OUTPUT TERMINAL CV ADAPTER COPPER TERMINAL COPPER PLUG FOR TERMINAL...

  • Page 103: Wiring Diagram (Code 10070

    FUSE 602A RHEOSTAT SELECTOR SWITCH ALTERNATOR AUXILIARY POWER WINDINGS GENERATOR 5 4 3 CR2 REED WELDER RELAY LEAD BLOCK NEGATIVE POSITIVE (CC- ) WIRE FEED MODULE (OPTIONAL) ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5". INLINE PLUG CONNECTORS (P5) #8 LEAD...

  • Page 104: Wiring Diagram (Code 10071

    RHEOSTAT SELECTOR SWITCH ALTERNATOR AUXILIARY (15AMP) POWER WINDINGS GENERATOR 5 4 3 CURRENT CR2 REED WELDER TRANSFORMER RELAY LEAD BLOCK NEGATIVE POSITIVE (CC- ) WIRE FEED MODULE (OPTIONAL) ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5". INLINE PLUG CONNECTORS (P5)

  • Page 105: Wiring Diagram (Code 10219

    SELECTOR SWITCH ALTERNATOR AUXILIARY POWER WINDINGS GENERATOR 5 4 3 CR2 REED WELDER LEAD BLOCK RELAY NEGATIVE POSITIVE (CC- ) (CC+) & (CV+ WITH W.F.M.) WIRE FEED MODULE (OPTIONAL) ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5". CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.

  • Page 106: Wiring Diagram (Code 10220

    SWITCH ALTERNATOR AUXILIARY (15AMP) POWER WINDINGS GENERATOR 5 4 3 CURRENT CR2 REED WELDER TRANSFORMER RELAY LEAD BLOCK NEGATIVE POSITIVE (CC- ) (CC+) & (CV+ WITH W.F.M.) WIRE FEED MODULE (OPTIONAL) ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5". CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.

  • Page 107: Electrical Diagrams

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

  • Page 108: Idler Pc Board (M13708) Components

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

  • Page 109: Idler Pc Board (L9902) Schematic

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 110 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

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