Home

Lincoln Electric CLASSICII SVM125-A User's Manual

1. I TEM REQ D PART DESCRIPTION 8209 8210 B211 B212 4 T13157 14 TAB TERMI NAL B2 13 T13157 15 TAB TERMI NAL C1 C2 C3 C5 C7 C8 C9 7 516668 5 022 50 C4 5 13490 35 50 16 C6 S 13490 39 8 15 9 C10 5 13490 102 047 100 Fle D1 02 03 D7 08 5 12199 1 4004 5 5 05 T12705 34 4936 5 9 3 n 021 112702 33 53478 gt B211 B209 B213 B210 2 022 T12702 17 5361B ZENER DIODE elg ais Ne 073 T12702 29 47444 Rit oS ogee 01 12704 54 N CHANNEL FET 55 TIN N oc 5135 SS 0 02 12704 68 24440 Ltt p Q1 1 R2 RS R19 4 519400 1002 OK 1 4W 8 85 E lel E dn E R3 R4 2 519400 2212 22 1 1 4W T PHB sie Bal z z RG S 19400 1333 33K 1 4W R7 S19400 4752 47 5K 1 4W C4 ns n cio Um R8 518380 1 PTC THERMI STOR R9 R15 2 519400 1580 5 1 4W i re R10 519400 3321 3 32K 1 4W ees 2 R11 T 12300 80 5 WATT 0 5 OHM RESI STOR M bee aN R12 S 19400 2672 26 7K 1 4W v
2. O E E 55 2 5 ELECTRICAL SYMBOLS CONTROL PANEL COMPONENTS le PER E1537 SHOWN AS VIEWED FROM REAR 8 8 LEAD COLOR CODE NEUTRAL BONDED TO FRAME NEUTRE RACCORDE AU BATS 1941598765142 1i 5 61 B BLACK R RED 8 5 ENGINE G GREEN U BLUE w EL FAILURE 12325678910 1 D BRONNE e ETO B MER d LAMP 58 538 IDLER ENGINE dt ALTERNATOR ROTOR 0 PROTECTIO Z N P C BOARD J2 45 SLIP RINGS C oak 57 SLIP RING a E TN NEAREST 610 sop 53 tA TO IRON 600 d IDLER 60 9 SOLENOID 41 gt 1 gt d q 115 VOLT 230 VOLT 600 o2 es 5 SWITCH SWITH OIL TEMP RECEPTACLE RECEPTACLE 42 p 58A SENSOR G pao do 51 ge 275 FUSE T L4 RNC 5 60 548 4 5 9 61 v RHEOSTAT Dol 519 OL PRESSURE rh rh Y J8 Pg 5 2 2 55 54 d A A 60 C G 225 i NB CB3 AUXILIARY iz m 1769 27 POWER c STARTING GAUGE k SOLENOID G WINDINGS
3. Qjo O E S3 2 o 212 Dlo c ITEM REQ D PART NO IDENTIFICATION 2 2 13490 102 047 190 C2 C4 C5 C6 C7 C9 6 516668 5 022 50 1 613490 49 47 50 C8 1 513490 39 18 15 CIg 1 513490 4 022 200 C11 1 S16668 11 1750 1 515122 7 D C RELAY lo D1 03 04 06 4 T12705 34 1N4936 02 1 112705 45 84 400 c 021 1 112702 33 1N5347B 09109 8 072 073 2 112702 29 1N4744A 5 01 1 112704 68 2N4401 6015 LP3O MEN 02 03 2 12704 61 184 200v MOSFET SS o 2 _ 5 56 04 1 127 4 37 16 100V PNP olo a2 C RI 1 S1 9400 1372 13 7K 174W d R2 RG 810 R11 519400 1500 150 1 4 EJE R3 R8 R20 3 519400 1000 100 1 4 5 5 5 R4 R26 2 19400 3322 33 2K 1 4 9 m E R5 R24 R25 3 519400 4751 4 75K c R6 1 519400 1501 1 5 1 4W R7 1 519400 1 620 162 1 4 SI R12 R18 R38 3 S19409 6131 6 19K 1 4 UOI R13 1 619400 4752 47 5K 1 4W IDLER ENGINE SHUTDOWN IT 814 1 Tl 4648 24 0 5 OHM 5 WATT RESISTOR RIS 1 619400 1333 133K 174W 816 1 519400 2672 26 7K 1 4 817 1 T1 4648 2 25 819 1 619400 2671 2 67K 1 4W R21 1 S19400 2213 221K 1 4W R22 1 619400 1822 18 2K 1
4. 5 WELDER GENERATOR CONTROLS See Figure B 1 for the location of the following fea tures 1 CURRENT RANGE SELECTOR Selects continu ous current output for constant current stick or TIG applications and constant voltage wire feed applica tions The amperages on the dial correspond to the average amperages needed for specific Lincoln welder rods See Control of Welding Current more information 2 FINE CURRENT ADJUSTMENT Allows fine adjustment of current within the selected output range See Control of Welding more information 3 230 VOLT DUPLEX RECEPTACLE Connection point for supplying 230 volt power to operate one or two electrical devices CURRENT RANGE SELECTOR FINE CURRENT ADJUSTMENT 1 2 3 230 VOLT RECEPTACLE 4 115 VOLT RECEPTACLE 5 WELD OUTPUT TERMINAL 6 WELD OUTPUT TERMINAL 7 GROUND STUD 115 VOLT DUPLEX RECEPTACLE Connection point for supplying 115 volt power to operate one or two electrical devices WELD OUTPUT TERMINAL WITH FLANGE NUT Provides the connection point for either the electrode holder or the work cable WELD OUTPUT TERMINAL WITH FLANGE NUT Provides the connection point for either the electrode holder or the work cable GROUND STUD Provides a connection point for connecting the machine case to earth ground for the saf
5. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE NOTES O o 9 2 c 5 tc G 2 5 o 2 Vss 4536B 1 gt gt FUEL SOLENOID Return to Section TOC Return to Master TOC 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 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 ELECTRIC in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine CLASSIC Il G 11 ELECTRICAL DIAGRAMS 6 11 Idler PC Board 19902 Components
6. Return to Section TOC Return to Master TOC ojo Fle 515 PEN 5 2 1 Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B 1 Section E 1 TABLE OF CONTENTS O 5 5 i Theory of Operation ttt tret Section E General 1 spere ha veta aaa E 2 c Battery Starter Engine Alternator and Protection E 2 Engine Generator Armature and Frame Alternator Stator and Rotor E 3 Excitation Flashing eset EE a E 3 Auxiliary and Field Feedback Coils essere E 3 Interpole and Series E 3 Current Range Selector E 4 Fine Current Adjustmoellt ee aede a E 4 TRE Engine Dm 4 DC Generator 5 a aaa aa 5 D c ON LATER MODELS d PROTECTION AND IDLER CIRCUITS ARE ONE PC BOARD c BELAY ier 1 RELAY NEGATIVE
7. COUPLING GENERATOR ARMATURE ENGINE IGNITION cues ALTERNATOR Return to Master TOC INTERPOLE COILS RESIDUAL MAGNETISM __ FIELD Return to Section TOC WINDINGS O o Fie ci 91 5 nl 212 2 1 Return to Section TOC Return to Master TOC Hl ENGINE GENERATOR ARMATURE AND FRAME ALTERNATOR STA TOR 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 terminal FINE CURRENT ADJUSTMENT The field rheostat control functions as a fine output cur rent adjustment by controlling the current through the shunt windings This controls the amount of magnet ism created in the shunt field windings Open circuit weld voltage can also be controlled by the field rheo stat control FIELD RECTIFIER GENERATOR FIELD CONTROL POSITIVE OUTPUT TERMINAL ENGINE IDLER CIRCUIT The idler solenoid is mechanically connected to the engine governor linkage When welding current is being drawn the reed switch CR2 is closed This sig nals the idler PC board to release deactivate the idler solenoid which then lets the machine go to a high speed condition Also when auxiliary po
8. 2 2 o Oja ELECTRICAL SYMBOLS CONTROL PANEL COMPONENTS mm PIN CONFIGURATION PER E1537 SHOWN AS VIEWED FROM REAR g z 7 8 ON ENGINE NEUTRAL BONDED TO FRAME PIO CONNECTOR LEAD COLOR CODE E rid 317 NEUTRE RACCORDE AU 140987654327 2 8 216 T G GREEN U BLUE 5 Pc 115 UURWY N BROWN W WHITE B ac Y YELLOW N B IDLER None ALTERNATOR ROTOR 0 SS ENGINE BOARD N A EARLIER MODELS DO NOT SLIP RINGS TE HOUR HAVE THIS DIODE dug 6 610 INE mec s o 59 WB 53B 57 TO IRON R AC AC 600B ay Ld IDLER Rd Md E B E 56 q SOLENOID 115 VOLT 230 VOLT e 500 G 5 B IGNITION IDLER o2 NON A 58A SWITCH SWITCH OIL TEMP RECEPTACLE RECEPTACLE Y 42 4 i SENSOR 5 5 G 15A ESSE O 58B 51A 3 E Y 602A S 54 4 4 5 t GA G RHEOSTAT Eo c lt TE gt l 1 6 P9 2912 OIL PRESSURE 519 53 53A SENSOR SELECTOR 45 p AN AN 55 i G 2 2 60 9 2 9 go TG SI ALTERNATOR EJE 52 4 513 ND G S15 GAUGE 8 d FUEL WINDINGS TARTIN SARI 5 OIL PRESSURE lt 7 SOLENOID B GENERATOR G T 50 608 dh 1 2 D WA 4 M CURRENT cR2 REED WELDER 7 sj D TRANSFORMER BELAY N LEAD BL CK U _ ALTERNATOR R 60D N ojo m NEGATIVE
9. D 8 5 g E 2 o CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 Return to Section TOC Return to Master TOC 5 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 f covers or guards are missing from the machine get replacements from a Lincoln Distributor See the Exploded View and Parts List at the back of this manual Read the Safety Precautions in the front of this manu al and in the instruction manual for the diesel engine used with your machine before working on the Classic Il Keep all equipment safety guards covers and devices in position and in good repair Keep your hands hair clothing and tools away from the recoil housing fans and all other moving parts when starting operating or repairing this machine ROUTINE AND PERIODIC MAINTENANCE NOTE NAMEPLATES Whenever routine maintenance is performed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those
10. ENGINE 5 W cc FAILURE 54454565860 DH N BROWN WAWHITE B LAMP 58 ggp T DLER ENGINE ALTERNATOR ROTOR PROTECTIO 1 PC BOARD gt SLIP RINGS Tw 50 610 sio ENGINE HOUR ae 62 TO IRON R AC AC 600B 6028 METER 99 n2 oS oom CENE eor ERAS _ 60 NS Ld IDLER IGNITION d Lie SOLENOID i ie 115 VOLT 230 VOLT 600A 2 5 SWITCH IL TEMP RECEPTACLE RECEPTACLE o 42 58A E P3 SENSOR n pee h 4 5 60 54 4 lt zo 47 Ery RHEOSTAT gt 6 jl HE a ume i oz lt 6 4 5 5 4 e SWITCH 9 9 60 55 i 5 4 1 ae ALTERNATOR 515 NE G CB2 AUXILIARY 7 FUEL POWER ND QN 916 SENE GAUGE ix SOLENOID WINDINGS sate oe MOTOR OIL PRESSURE 59 aqme 60B 1064 CONNECTOR G i 50 EP 11 51 Bn B 1 i o i fD 4 60 624 0 8 9 111543 21 CURRENT CR2 REED B D TRANSFORMER BELAY N LEAD BLOCK W A ALTERNATOR ize U W 7 1 JE N e NEGATIVE POSITIVE 5 5 amp CV WITH W F M Tr o REMOTE CONTROL OPTIONAL WIRE FEED MODULE OPTIONAL NTROL RECEPTACLE amp SWITCH gi8 ee B c cc E ium REMOTE CONTROL ON MACHINE REMOVE PLUG 10
11. TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 The PC board may be faulty The engine will not shut down Make sure the ignition switch is turned off and operating correct ly On older machines below serial number U1940718502 make sure Diode Kit S 21548 has been installed Check the fuel solenoid for proper operation When 12VDC is applied to the solenoid at leads 58 to 60 the fuel solenoid should be open When the 12VDC is removed the sole noid should close stopping fuel flow to the engine CAUTION 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 CLASSIC Il LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 8 E Return to Section TOC Return to Master TOC 7 5 11 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The engine cranks but will not start Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS Check for adequate fuel supply Press the engine prote
12. a pL 0 OUTPUT TERMINAL 115 8 230 RECEPTACLES 7 O GENERATOR 8 sooo pup TRANSFORMER S 2 RELAY ALTERNATOR STATOR 9 NOT PRESENT 4 5 ON LATER MODELS ENGINE IMECHANICAI GENERATOR m IGNITION Ls ARMATURE 5 3 2 SWITCH 8 INTERPOLE 225 COILS RESIDUAL STARTER MAGNETISM __ MOTOR FIELD SHUNT WINDINGS FIELD BATTERY RECTIFIER i GENERATOR FIELD CONTROL POSITIVE OUTPUT TERMINAL FIGURE E 1 CLASSIC Il BLOCK LOGIC DIAGRAM 0 5 CLASSIC II LINCOLN B 2 2 FIGURE E 2 BATTERY STARTER ENGINE ALTERNATOR AND PROTECTION CIRCUITS ON LATER MODELS PROTECTION AND IDLER CIRCUITS E ON ONE PC BOARD PROTECTION TREA RELAY SWITCH Return to Section TOC Return to Master TOC NEGATIVE O OUTPUT TERMINAL 115 amp 230VAC RECEPTACLES CURRENT E TRANSFORMER FUEL SOLENOID RELAY ALTERNATOR STATOR NOT PRESENT A e lt ON LATER MODELS ENGINE GENERATOR 5 ROTOR 2 m IGNITION ARMATURE 55 ALTERNATO 77 sue RINGS INTERPOLE tee COILS RESIDUAL MAGNETISM __ FIELD Return to Section TOC Return to Master TOC WINDINGS O o Fie 915 nl 212 ES 2 1 Return to Section
13. 2 Return to Section TOC Return to Master TOC 42 INSTALLATION MACHINE GROUNDING Because the Classic 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 See Figure A 2 to a suitable earth ground such as a metal pipe driven into the ground The US National Electrical Code lists a number of alternate means of grounding electrical equipment WARNING Do not ground the machine to a pipe that carries explosive or combustible material Some state local or other codes or unusual operating circumstances may require the machine frame to be grounded It is recommended that you determine the extent to which such requirements may apply to your particular situation and follow them explicitly When the Classic is mounted on a truck or a trailer the machine generator ground stud MUST be secure ly connected to the metal frame of the vehicle See Figure A 2 The ground stud is marked with the ground symbol For further protection against electric shock any elec trical equipment connected to the generator recepta cles must use a three blade grounded type plug or an Underwriter s Laboratories UL
14. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 515 gt oO 1 Return to Section TOC Return to Master TOC F 23 F 23 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE F 7 STROBE MARK LOCATION STROBE MARK TEST PROCEDURE Strobe Tach Method 1 2 Turn the engine welder OFF Unlatch lift and secure the right side door Note that there are latches at both ends of the door With a white or red marking pencil place a mark on one of the blower paddles or on the side of the flywheel See Figure 7 for loca tion Connect the strobe tach according to the manufacturer s instructions CLASSIC II LINCOLN B Start the engine and direct the strobe tach light on the blower paddle Synchronize it to the rotating mark With the machine at HIGH IDLE the tach should read between 1780 and 1810 RPM With the machine at LOW IDLE the tach should read between 1350 and 1400 RPM Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section TOC Return to Master TOC D g 5 24 24 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued If either of the readin
15. 59 53B 61 WB 602B o m TO IRON R AC 60 START FUSE SFE 14 9 pM 41 224 5 BM RECEPTACLE RECEPTACLE i o 42 SNIGH SENSOR 15 51 3 Y Bow ca 19 60 59 54B sed 350 4 5 gt M T ic gt 7 Y 18 9 ss d OIL PRESSURE m 50 ae 53 53A SENSOR B Ld SWITCH o 54 6 5 6 pe T m 8 2 55 5 4 4 9 ALTERNATOR 52 082 m W 3 AUXILIARY S 30AMP E ND C 8edr gp 2 GAUGE 8 FUEL WINDINGS STARTING 9 9 OIL PRESSURE 7c SOLENOID E GENERATOR G 50 60B pa 2 1 60 lt lt gt by CURRENT B CR2 REED D U TRANSFORMER RELAY ES LEAD BLOCK U A N ALTERNATOR ign U W 7 X 60D T E ZE NEGATIVE 9 POSITIVE CC olo REMOTE CONTROL OPTIONAL WIRE FEED MODULE OPTIONAL CONTROL amp SWITCH 2 REMOTE CONTROL ON MACHINE REMOVE PLUG P10 FROM CONNECTOR J5 oele R POTENTIOMETER EJE i SEE i RESISTORS 8 8 BELOW Y pu SEE INLINE PLUG o CONNECTORS 7 5 CREER c i SETENE ee CONTROL eee m PANEL BELOW 602
16. gt oO 1 Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div e S Coupling DC Fle Internal 5 5 910 oz gle 515 5 cc CLASSIC II LINCOLN B 31 31 TROUBLESHOOTING amp REPAIR ALTERNATOR ROTOR REMOVAL AND REPLACEMENT WARNING 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD 8 This procedure will aid the technician in the removal and replacement of the alternator rotor oz 8 8 MATERIALS NEEDED 2 5 9 3 8 wrench 1 2 wrench 5 16 nut driver 9 16 wrench 3 4 wrench 1 5 8 wrench Large slot head screwdriver S
17. NOTE Gas shielded welding requires a Magnum Gun Gasless welding requires an Innershield Gun Magnum Spool Gun K487 25 A lightweight semi automatic wire feeder for aluminum welding with argon gas Has built in remote wire speed control in the han dle Requires the K488 SG Control Module Includes 50 feet 15 2 meters of power cable CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 8 E Return to Section TOC Return to Master TOC g 5 4 ACCESSORIES CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS A WARNING ELECTRIC SHOCK can Kill Do not operate with panels open e Disconnect NEGATIVE BATTERY LEAD before servicing Do not touch electrically live parts MOVING PARTS 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 TO THE CLASSIC Il USING K867 UNIVERSAL ADAPTER SEE FIGURE C 1 1 Shutthe welder off 2 Connect the electrode cable from the LN 7 to the terminal of the welder Connect the work cable to the terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application NOTE Figure C 1 shows the electrode connected f
18. 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 The rotor locking nut should be torqued to 175 lb ft After the rotor locking nut is properly torqued bend the washer down over the locking nut Check rotor air gap 017 minimum is allowed Mount the brush holder assembly to the sta tor frame using two bolts washers and nuts Make sure brushes are positioned and seat ed properly on slip rings Install the alternator cover with the screw and washer at top and the screws at the two sides Mount the case front assembly onto the base and into position where it attaches to the fuel tank rails With the 3 4 wrench attach the copper strap to the negative output terminal Attach the cable retainer to the fuel tank rail Set the fuel tank into position on the rails and secure it with the four bolts washers and nuts 31 32 33 34 35 36 37 38 Attach the fuel return line at the top of the fuel tank Remove the plug from the fuel line and attach it to the fuel bowl Attach the case front with the screws at the bottom center and the right side where the output terminal assembly is mounted Further attach the case front to the machine frame with the three bolts lock washers and nuts three each side Attach the battery retainer clamp with the two nuts and split ring lock washers
19. tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Relier la terre le chassis du poste conformement au code de l lectricit
20. 2 E 5 TABLE 2 GENERATOR POWER APPLICATIONS ale 2138 S E Suggested Power Applications Running Watts Start up Watts d Air Compressor 3 4 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 ole Electric Motor 1 HP 1 000 2 500 4 000 Electric Range 1 element 1 500 sis Electric Skillet 1 250 9 Furnace Fan 1 3 HP 1 200 3 000 4 800 E Portable Grinder 4 1 2 600 p Portable Grinder 7 2 000 Halogen Work Light 500 1 4 500 Hand Drill 3 8 700 1500 Watt Heater 1 750 Hedge Trimmer 450 Light Bulb 100 Reciprocating Saw 900 Radial Arm Saw 2 600 99 Radio 50 T Refrigerator Freezer small 600 1 500 2 400 slg Slow Cooker 200 9 2 Submersible Pump 1 HP 1 000 2 500 4 000 8 Sump Pump 600 1 500 2 400 5 Toaster 1 100 9 c Weed Trimmer 500 Lincoln 100 or 125 Amp Wire Feeder Welder 4 000 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 Multiple loads can be used as long as the total load does not exceed 3 000 watts Be sure to start the largest loads first For example a 1 HP motor needs approximately 1 000 watts while running but may require 2 500 watts to start Some indu
21. 2 When the engine starts running observe the oil pressure If no pressure shows within 30 seconds stop the engine and consult the engine operating manual If the engine protection warning light comes on during cranking or after start up the IGNITION switch must be placed in the OFF position to reset the engine protec tion system CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC O o Fle 515 PEN gt 2 2 mlt 5 5 1 Return to Section TOC Return to Master TOC Return to Master TOC B 9 OPERATION 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 the engine for about five minutes and then stop the engine and recheck the oil If the level is down fill to the full mark again The engine controls were properly set at the factory and should require no adjusting when received At the end of each day s welding drain accumulated dirt and water from the sediment bowl under the fuel tank and from the fuel filter per instructions in the engine manufacturer s operating manual Refill the fuel tank to minimize moisture condensation in the t
22. 2 mlt 5 2 1 Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 1 Return to Section TOC Return to Master TOC F 21 F 21 TROUBLESHOOTING amp REPAIR IDLER SOLENOID TEST continued FIGURE F 6 SOLENOID HARNESS LEAD CONNECTIONS LEADS 56 57 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 and separate the two in line spade connectors that attach the solenoid leads to the wiring harness leads 56 and 57 See Figure F 6 and the Wiring Diagram 4 Using the external voltage supply apply 12VDC to the idler solenoid leads The sole noid should activate NOTE WHEN THE ENGINE IS NOT RUN NING THE SOLENOID MAY REQUIRE A SLIGHT MECHANICAL ASSISTANCE TO OPERATE CLASSIC II LINCOLN B The solenoid should deactivate when the 12VDC is removed 6 If the solenoid does not operate properly check for a mechanical restriction in the link age or a missing spring If the linkage is intact and the solenoid does not operate correctly when 12VDC is applied the solenoid may be faulty Replace When the test is complete and the problem repaired be sure to reconnect the two spade conn
23. 9 G GREEN U BLUE LOCAL OR REMOTE N BROWN W WHITE CONTROL SHOWN IN Da Y YELLOW CONTROL PANEL COMPONENTS REMOTE CONT SHOWN AS VIEWED FROM REAR POTENTIOMETER BOX LOCAL POSITION WITH MACHINE NOT RUNNING REMOVE JUMPER 42 TO 600 AT THE TERMINAL STRIP CONNECT THESE LEADS TO THE CORRESPONDING NUMBERS AT THE TERMINAL STRIP Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine E CLASSIC Il G 4 ELECTRICAL DIAGRAMS G4 Wiring Diagram Code 10070 Qjo FE
24. Attach the case top and door assembly using the 1 2 and 9 16 wrenches Install the exhaust pipe rain cap Replace any cable ties cut for disassembly Install the left case side Connect the negative battery cable Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B F 38 F 38 TROUBLESHOOTING amp REPAIR ALTERNATOR STATOR REMOVAL AND REPLACEMENT WARNING 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD O10 O e DESCRIPTION 8 2 This procedure will aid the technician in the removal and replacement of the alternator stator 512 2 2 MATERIALS NEEDED 2 2 3 8 nut driver 3 8 wrench 1 2 wrench Slot head screwdriver Pry bar 5 8 wrench 7 16 wrench E 515 PEN 9 gt 218 5 2 Return to Sectio
25. N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 5 COMMON CONNECTION WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY 777 FRAME CONNECTION THE EXACT COMPONENTS OR CIRCUITRY CONTROLS HAVING COMMON CODE EARTH GROUND CONNEC 1 THE LINCOLN ELECTRIC CO MeL ENGINE WELDERS ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 CLEVELAND OHIO U S A SUBJECT IDLER PCB SCHEMATIC ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE 4 TO AGREE SCALE NONE SHT AUSTRALIA CANADA FRANCE WITH PUBLISHED STANDARDS DR LEB DATE 2 10 93 SUP S D G 516477 NO M 16989 Return to Section TOC Return to Master TOC 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 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 LELECTHIC in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine CLASSIC G 9 ELECTRICAL DIAGRAMS G 9 Idler PC Board M13708 Components Return to Section TOC Return to Master TOC
26. conventional machine rectification is provided MECHANICA COUPLING mechanically by means of a commutator A commuta tor is a cylinder formed of copper segments insulated from each other and mounted on but insulated from the rotating shaft Each copper segment is connected to a corresponding armature winding Stationary car bon brushes held against the commutator surface con nect the armature windings to external terminals The commutator provides full wave rectification transform ing the voltage waveform between brushes and mak ing available a DC voltage to the external circuit DC CURRENT ARMATURE CLASSIC II LINCOLN B 6 NOTES CLASSIC II LINCOLN 5 E 6 901 0 901 901 J91Se N 01 901 J91Se N 01 DOL uonoes oj DOL uonoes DOL uonoes oj DOL uonoes 1 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING 8 REPAIR SECTION 5 3 Troubleshooting amp Repair Section Section F z How to Use Troubleshooting F 2 5 PC Board Troubleshooting Procedures F 3 9 Troubleshooting Guide F4 F 12 Test a de EEEE EEEE ES F 13 Alternator Rotor 65t ea eid F 13 Shunt Field Winding 5 F 17 Idler SolenOid TeSts M F 20 Engine Throttle Adjust
27. onds Retighten the locking nut Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 2 2 1 Return to Section TOC Return to Master TOC F 25 F 25 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE F 8 HIGH IDLE ADJUSTMENT 2 ADJUSTING SCREW LOCKING NUT FIGURE F 9 LOW IDLE ADJUSTMENT LOCKING NUT CLASSIC II LINCOLN B F 26 F 26 TROUBLESHOOTING amp REPAIR FLASHING THE FIELDS A WARNING Return to Section TOC Return to Master TOC 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This procedure will flash the fields of an exciter that has lost excitation MATERIALS NEEDED 12 volt automotive battery Two jumper wires with alligator clip on each end
28. 0 liters 1700 RPM High idle 1350 RPM Low idle RATED OUTPUT WELDER Duty Cycle Amps Volts at Rated Amperes 100 Duty Cycle 200 DC Constant Current 28V 60 Duty Cycle 250 DC Constant Current 40V 40 Duty Cycle 300 DC Constant Current 32V OUTPUT WELDER AND GENERATOR Welding Ranges Open Circuit Voltage Auxiliary Power 40 325 Amps DC 98 5 3 0 of 115 230 V 60Hz Power 26 Amps 115 V 13 Amps 230 V PHYSICAL DIMENSIONS Height i Depth Weight 49 94 in 60 in 1340 Ib 1040 mm 1524 mm 608 kg 1 CSA machines draw 15 amps from either half of the receptacle Non CSA machines can draw 20 amps from either half of the receptacle Total combined load of all receptacles cannot exceed 3 0 kVA CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Fle PEN 2 1 Return to Section TOC Return to Master TOC Return to Master TOC A 3 INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS WARNING Do 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 lists ELECTRIC SHOCK can kill e Do not touch electrically live parts or elect
29. 10 AUXI ER B 13 Accessories one conet deed Section C Maintenance Section D Safety PLECAUTIOINS D 2 Routine and Periodic 0 2 Major Component 0 8 Theory Of Operation eer Section E Troubleshooting and Repair Section F Electrical Diagrams nein dde entere donde Rede Sepe ABRE erus Section G Parts Manual eee LIE ELEM EIE P 219 CLASSIC II LINCOLN B Section 1 Section 1 TABLE OF CONTENTS INSTALLATION SECTION 5 a d Installation z g Technical Specifications A 2 2 9 Diesel Engine tea 2 Rated Output Welder 2 Output Welder and 2 Physical Dimensions A 2 Safety Precautlons iu ieu a th 3 Location and 3 9 sire A 3 E ph a MUNI dE A 4 9 TUNG 4 iae 4 High Altitude 4 2 9
30. 18 TROUBLESHOOTING amp REPAIR SHUNT FIELD WINDING TEST continued FIGURE F 4 PLUG P10 LOCATIONS Nm Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TEST PROCEDURE 1 Turn engine off 4 Remove plug P10 See Figure F 4 O10 Fle 515 5 1 2 Unlatch lift and secure the right side door 5 Locate the blue lead 3 and the Note that there are latches at both ends of brown lead N pin 5 in the harness plug the door See 3 Locate plug P10 See Figure F 4 Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B F 19 F 19 TROUBLESHOOTING amp REPAIR SHUNT FIELD WINDING TEST continued FIGURE F 5 SHUNT LEAD RESISTANCE CHECK Return to Section TOC Return to Master TOC PIN 3 eee 5 8 gt 2 2 213 d MN 6 Using the volt ohmmeter set on the low 9 If the plug and associated leads are okay scale X1 measure the resistance then the shunt field coils may be faulty between the blue and the brown leads Replace See Figure F 5 Normal resistance is 10 If the test does meet the resistance specifi approximately 57 ohms cations then the shunt coils are okay 7 Also measure the resistance from either lead blue or brown to ground Set the volt ohmmeter on the high scale X100 000 This resistance should b
31. 250 THERMOSTAT REMOTE CONTROL PANEL amp SWITCH ASSEMBLY COPPER CONNECT TO NEGATIVE COPPER TERMINAL UNLESS OTHERWISE SPECIFIED TOLERANGEn ge Sht WITH PUBLISHED STANDARDS ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS 202 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES IS 35 OF A DEGREE MATERIAL TOLERANCE TO AGREE TERMINAL PLUG FOR BRUSH HOLDER REMOTE CONTROL POTENTIOMETER 2 HEAVY LEAD Ojo o Fie c 515 gt 212 5 oO NEGATIVE CV OUTPUT TERMINAL GROUND TERM PIN CONFIGURATION WIDE SLOT ON ENGINE CONNECTOR THE LINCOLN ELECTRIC THIS SHEET CONTAINS PROPRIETARY INFORMATIQ OWNED BY THE LINCOLN ELECTRIC CO AND 15 NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF CONNECT ELECTRICAL SYMBOLS PER E1537 TO CASE LEAD COLOR CODE B BLACK R RED G GREEN U BLUE LOCAL OR REMOTE Pane components E REMOTE CONTRO SHOWN AS VEIWED FROM REAR WITH MACHINE NOT RUNNI G REMOVE JUMPER 42 TO POTEN OME IER 600 AT THE TERMINAL STRIP CONNECT THESE LEADS TO THE CORRESPONDING NUMBERS AT THE TERMINAL STRIP d SWITCH FOR Return to Section TOC Return to M
32. 5 5 HIGH IDLE NO LOAD FINE CURRENT CONTROL RHEOSTAT AND SELECTOR als SWITCH AT MAXIMUM 2 2 glg CH1 0 volts Return to Section TOC Return to Master TOC 50 volts 5 ms This is the typical DC output voltage generated from a properly operating machine Note that each vertical divi sion represents 50 volts and that each horizontal division represents 5 milliseconds in time Note Scope probes connected at machine output terminals O10 515 gt oO 1 SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div O10 2 Trigger nates Internal 5 5 olg gt 2 8 5 5 5 cc CLASSIC II LINCOLN B F 30 F 30 TROUBLESHOOTING amp REPAIR TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM 5 5 MACHINE LOADED SELECTOR SWITCH AT MAXIMUM POSITION CH1 0 volts Return to Section TOC Return to Master TOC 20 volts 5 ms MACHINE LOADED TO 250 AMPS AT 40 VDC This is the typical DC output voltage generated from a properly operating machine Note that each vertical divi sion represents 20 volts and that each horizontal division represents 5 milliseconds in time The machine was loaded with a resistance grid bank O10 515
33. Dept at 1 216 383 2531 or 1 800 833 9353 WELD Check the engine speed High idle speed should be 1800 RPM The Current Range selector switch may be faulty Check for proper operation Check the DC generator brushes for good commutation and alignment Contact the Lincoln Electric Service Dept at 1 216 383 2531 or 1 800 833 9353 WELD CAUTION 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 CLASSIC II LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 2 3 Return to Section TOC Return to Master TOC g 5 TROUBLESHOOTING amp REPAIR ALTERNATOR ROTOR TEST WARNING 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 If for any reason you do not understand the test procedures or are unable to perform the test r
34. MOTOR OIL PRESSURE 59 E ae GENERATOR H T 60B 10 CONNECTOR L 1 D 60E 2 lt Be D CURRENT CR2 REED 51 w TRANSFORMER RELAY N LEAD BL CK W ALTERNATOR Ut Wy 1 ale EE NEGATIVE POSITIVE CC CC 8 CV WITH W F M PTS o REMOTE CONTROL OPTIONAL WIRE FEED MODULE OPTIONAL REMOTE CONTROL RECEPTACLE amp SWITCH 8 8 UNE REMOTE CONTROL ON MACHINE REMOVE PLUG P10 FROM CONNECTOR 95 POTENTIOMETER CONNECT PLUG P5 ON W F M TO CONNECTOR J5 ON MACHINE 5 Em B x C 9 5 i SEE o i RESISTORS 515 i BELOW o R 3 4 INLINE PLUG c c i CONNECTORS 5 CN RU Jl isse 22 600 Yo i i BELOW 221 B W 48 LEAD 2 E CONNECT TO POS 8 NEG f POS i WIRE FEED PA j W OUTPUT TERMINALS E gt 1 1388 ei a i 82 gu HM ME EE Suna E MUS PANE SWITCH FOR LOCAL OR REMOTE CONTROL i E 1 cese ean ae ce ee o E ROREM i CONTRE CONNECT TO NEG aa E WTH MACHINE NOT RUNNING REMOVE PLUG ON DOR BRUSH HOLDER MACHINE FROM CONNECTOR J8
35. Pre operation Engine 4 4 4 Battery ee E Ee Ban ka A 4 5 5 9 DD A 5 E Electrical Output 6 9 Welding Cable Connections A 6 Cable Installation Polarity Control and Cable 5 2 5 A 6 Machine RO 7 5 E Auxiliary Power Receptacles Plugs and Hand held A 7 Circult Breakers 7 5 9 gt g E o CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e ci els ois 2 8 2 cc 1 Return to Section TOC Return to Master TOC INSTALLATION TECHNICAL SPECIFICATIONS CLASSIC INPUT DIESEL ENGINE Manufacturer Description Speed Displacement Ignition Capacities Deutz 3 1725 125 Electric Fuel 15 gal F3L 1011F Air cooled Full load 2049 cc 57 liters diesel Oil 6 3 qt 28 HP 1800 RPM 6
36. R13 R18 2 519400 1372 3 7K 1 4W R14 5 19400 1502 5 1 4W 515 R16 519400 5 110 511 1 4W 519 R17 S 19400 1001 K 1 4W iz R20 5 19400 3322 33 2K 1 4W 219 R21 519400 5111 5 11 1 4W X 515128 11 4 PIN QUAD ala 2 515018 13 6 PIN SS 2 CAPACITORS MFD VOLTS RESISTORS OHMS O Fie 99 5 nl 218 2 a 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 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 LELECTHIC in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine CLASSIC G 10 ELECTRICAL DIAGRAMS G 10 Idler PC Board 19902 Schematic UNUSED Return to Master TOC COMMON CONNECTION EARTH GROUND CONNECTION POWER SUPPLY SOURCE POINT Fh FRAME CONNECTION SUPPLY VOLTAGE NET CLASSIC WELDERS suBJEcr IDLER ENGINE SHUTDOWN SCHEMATIC Return to Section TOC 10V IDLER SWITCH 5 OTHERWISE SI IDLER 12 SE
37. THEN CONNECT 42 HEAVY LEAD CONNECTOR 38 ON MACHINE o MACHINE MUST NOT BE RUNNING lo 519 250 2 5 RED amp BLACK LEADS NOT CONNECTED ON THIS THERMOSTAT WHEN MAKING THESE CONNECTIONS MACHINE ASSEMBLY o 9 1 19 96 g ale CLEVELAND OHIO U S A L9920 NOTE This diagram is for reference only It may be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one the enclosure panels of your machine E CLASSIC Il G 7 ELECTRICAL DIAGRAMS e Wiring Diagram Code 10220 e O E c 2 2 2 oja 812 ELECTRICAL SYMBOLS CONTROL PANEL COMPONENTS olo PER E1987 SHOWN AS VIEWED FROM REAR tm LEAD COLOR CODE NEUTRAL BONDED TO FRAME a B BLACK NEUTRE RACCORDE AU GREEN U
38. TOC He o 8 E Return to Section TOC Return to Master TOC O N 9 2 tc TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The engine will not return to low idle when the welding and auxiliary loads are removed POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Make sure the ldler Control switch is set to the Auto position Make sure both welding and auxiliary loads are removed Check for mechanical restric tions in the idle and throttle link age TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Check the Idler Control switch and associated leads for loose or faulty connections See the Wiring Diagram Check the reed switch CR2 It may be stuck closed Replace if necessary Check for loose or faulty con nections at the PC board Make sure lead 60D is grounded correctly dre the Solenoid Test The PC board may be faulty Replace CAUTION 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 CLASSIC II LINCOLN B Return to Section TOC Return to Master TO
39. approved double insu lation system with a two blade plug Lincoln offers an accessory plug kit that has the right type of plugs See the section of this manual for details If you need ground fault protection for hand held equip ment refer to of this manual for the GFCI Receptacle kit AUXILIARY POWER RECEPTACLES PLUGS AND HAND HELD EQUIPMENT The AC auxiliary power supplied as a standard has a rating of 3 0 of 115 230V AC 60 hertz With the 3 0 kVA 115 230V AC auxiliary power one 115V duplex and one 230V grounding type receptacle are provided The circuit is protected with circuit break ers The rating of 3 0 kVA permits a maximum continuous current of 13 amps to be drawn from the 230 volt duplex receptacle Or a total of 26 amps can be drawn from the 115 volt duplex receptacle The 115 volt duplex receptacle has a configuration which permits 15 amps on CSA machines and 20 amps on non CSA machines The total combined load of all receptacles is not to exceed 3 0 kVA CIRCUIT BREAKERS Classic welders are equipped with circuit breakers on the 115 and the 230 volt receptacles for overload tection Under high heat a breaker may tend to trip at lower loads than it would normally Operation with high ambient temperatures may cause the breakers to trip at lower than normal loads CAUTION Never bypass the circuit breakers Without overload protection the Classic could ov
40. continued See Figure 13 for steps 16 17 17 Carefully lift the case front assembly up from the bottom and carefully slide the assembly up onto the fuel tank mounting rails Make sure all leads are clear Cut any necessary cable ties 16 With the 3 4 wrench remove the copper strap from the negative output terminal Clear the strap from cable ties Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FIGURE F 13 OUTPUT TERMINAL STRAP AND CASE FRONT REMOVAL O10 515 5 2 2 1 NEGATIVE OUTPUT TERMINAL COPPER STRAP ON REAR SIDE Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 2 3 Return to Section TOC g 5 Return to Master F 35 F 35 TROUBLESHOOTING amp REPAIR ALTERNATOR ROTOR REMOVAL AND REPLACEMENT continued See Figure F 14 for steps 18 21 20 With the 3 8 wrench loosen the two screws 18 With the 3 8 wrench loosen the two screws on the left side of the alternator cover 21 Remove the alternator top cover 19 With the 3 8 wrench remove the screw and lock washer from the top center of the alter nator cover FIGURE F 14 ALTERN
41. et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 LINCOLN B MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Lr PH i iv Installation ono E T Section Technical Specifications 2 Iuuen EE 3 Location and Veniliornis A 3 Pre operation Engine Service A 4 Electrical Output A 6 ERE Section B sr valium B 2 2 Recommended 3 Operational Features and B 3 Bini B 3 Welding Capability B 4 IB ocn S B 4 Controls and Settings eM equ ak REDI ETE Ra DERE B 5 Engine Operation PEEL 8 Welding Operation
42. for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Mar 95 LINCOLN B Return to Master Return to Master TOC 7 E Return to Master TOC SAFETY 7 WELDING SPARKS gt 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 Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut
43. greased To keep the contacts clean rotate the current control handle through its entire range frequently Good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld Put a drop of oil on the CURRENT RANGE SELEC TOR shaft at least once every month RECEPTACLES Keep the electrical receptacles in good condition Remove any dirt oil or other debris from their surfaces and holes CABLE CONNECTIONS Check the welding cable connections at the weld output terminals often Be sure that the connections are always firm IDLER MAINTENANCE 1 The solenoid plunger must work freely and bind Dust the plunger about once a year with graphite powder 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 CLASSIC II LINCOLN B FIGURE 0 3 MAJOR COMPONENT LOCATIONS 1 RIGHT CASE SIDE DOOR 2 BASE WITH BATTERY 3 ALTERNATOR BRUSHES 4 ALTERNATOR 5 GENERATOR 6 7 8 9 GENERATOR BRUSHES Return to Section TOC Return to Master TOC OUTPUT TERMINALS FUEL TANK CASE FRONT WITH CONTROL PANEL 10 LEFT CASE SIDE 11 CASE TOP 12 CASE BACK 13 DIESEL ENGINE 14 AIR CLEANER 15 IDLER CONTROL hs RES ed ESS MESS SS SS
44. linkage will cause an increase in the AC auxiliary voltage this voltage goes over 140 volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manual 7 Adjust wire feed speed at the SG Control Module NOTE For remote control a K775 remote control is required CAUTION When the welder is in local control the electrode is always HOT FIGURE C 5 CLASSIC II K492 K488 K487 SPOOL GUN CONNECTION DIAGRAM Wu m Classic Output Terminals are on 14 PIN AMPHENOL Opposite Side N __ WORK ELECTRODE CABLE TO K438 SG CONTROL CABLE HE b c GND K867 UNIVERSAL ADAPTER PLUG 5 1 3 Insulate Each age sG e Unused Lead CONTROL 7 25 Individually MODULE SPOOL GUN K492 INPUT CABLE 76 e 76 77 Splice Leads and Insulate K775 OPTIONAL REMOTE CONTROL CLASSIC II LINCOLN B Section D 1 Section D 1 TABLE OF CONTENTS F MAINTENANCE 8 Maintenance Section D Safe PRECAUTIONS E E D 2 Routine and Periodic D 2 Engine Metti etl 0 2 Chiangethe O
45. new fuel filter cartridge 4 Screw the new cartridge into position finger tight until the gasket is evenly seated Then turn it down another 1 2 turn Do not overtighten the new filter 5 Open the fuel stopcock Check the assembly for leaks Order Deutz fuel filter 8117 4482 from your local Deutz Service Center A fuel filter element without the water separator may be used in place of the standard ele ment Order Deutz 8117 4696 The fuel system on the Deutz engine is self priming You do not have to bleed the system AIR CLEANER The Deutz diesel engine is equipped with a dry type air filter Inspect the air cleaner daily more often in dusty conditions Never apply oil to the air cleaner Service the air cleaner as follows 1 Remove the dust cup from the bottom of the air cleaner housing Clean out any accumulated dust 2 Loosen the wing nut and remove the filter element 3 If dust is sticking to the dust collector element blow compressed air through it from the inside out Turn the element as you apply air Air pressure should be under 686 kPa 7 kgf cm 99 psi 4 Check the element for damage before reassem bling the air cleaner Replace the element if it appears damaged The air cleaner element part number is Donaldson 181050 or Nelson 70206N COOLING SYSTEM The Deutz diesel engine is air cooled Clean the engine cooling system periodically to prevent clogging the air passages on the cylinder heads and o
46. obtain 175 amps and a force ful arc set the CURRENT RANGE SELECTOR to 240 160 position and the FINE CURRENT ADJUSTMENT setting to get 175 amps Some arc instability may be experienced with EXX10 electrodes when trying to operate with long arc tech niques at settings at the lower end of the open circuit voltage range CAUTION DO NOT attempt to set the CURRENT RANGE SELECTOR between the five points designated on the nameplate These switches have a spring loaded cam which almost eliminates the possibility of setting this switch between the designated points FIGURE B 2 CURRENT CONTROLS CURRENT FINE CURRENT ADJUSTMENT RANGE SELECTOR 4 T0 CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Fle S PEN 2 2 mlt 5 2 cc 1 Return to Section TOC Return to Master TOC Return to Master TOC B 7 OPERATION FIGURE B 3 DIESEL ENGINE CONTROLS IDLER CONTROL TOGGLE SWITCH IGNITION TOGGLE SWITCH ENGINE PROTECTION WARNING LIGHT START PUSHBUTTON ENGINE HOUR METER AMMETER OIL PRESSURE GAUGE DIESEL ENGINE CONTROLS See Figure B 3 for the location of the following fea tures 1 IDLER CONTROL TOGGLE SWITCH Adjusts the r
47. of the rotor slip rings See Figure F 1 CLASSIC II LINCOLN B F 15 F 15 TROUBLESHOOTING amp REPAIR ALTERNATOR ROTOR TEST continued 9 Working from the left side of the machine measure the resistance across the rotor slip rings Return to Section TOC Return to Master TOC A Set the ohmmeter on the low scale X1 B Place one meter probe on one of the rotor slip rings Place the other probe on the other slip ring See Figure F 2 C Check the resistance across the slip rings It should read approximately 41 ohms Return to Section TOC Return to Master TOC FIGURE F 2 MEASURING ROTOR RESISTANCE O10 515 gt oO 1 Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B F 16 F 16 TROUBLESHOOTING amp REPAIR ALTERNATOR ROTOR TEST continued 10 Measure the rotor resistance to ground 11 Replace the brushes on the slip rings A Set the ohmmeter on the high scale reed eo X100 000 12 Reinstall the alternator cover Return to Section TOC Return to Master TOC B Place one probe on either of the rotor 13 Reinstall the left case side and close and slip rings Place the other probe on any latch the right side cover door good unpainted ground See Figure F 3 C Check the resistance It should read very high at least 0 5 megohm 500 000 ohms If the test does not meet the resistance sp
48. recep tacle duplex type with covers and installation instruc tions Each half of the receptacle is rated 15 amps but the maximum total current from the GFCI duplex is lim ited to 20 amps The GFCI receptacle replaces the factory installed 115 volt duplex receptacle CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 2 3 Return to Section TOC Return to Master TOC g 5 ACCESSORIES 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 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 Amptrols cables torches and mounting brackets must be purchased separately Control Cable K936 4 Control cable for connecting the K930 1 TIG Module to a Classic Arc Start Switch K814 Remote start switch for TIG module K930 1 NOTE TIG welding requires a Magnum TIG Gun appropriate Magnum Parts Kit and argon gas SEMIAUTOMATIC WELDING LN 25 Wire Feeder This portable wire feeder is capa ble of CC CV wire feed welding LN 7 Wire Feeder Semiautomatic constant speed wire feeder For CV operation only
49. so can result in damage to the internal charger com ponents Follow the instructions of the battery charger manufac turer for proper charger settings and charging time CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo 9 PEN 2 1 Return to Section TOC Return to Master TOC Return to Master TOC D 7 MAINTENANCE WELDER GENERATOR MAINTENANCE STORAGE Store the Classic 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 ALTERNATOR BRUSH REMOVAL AND REPLACE MENT It s normal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator overhaul is necessary Remove the brushes and clean the slip rings with fine emery paper To seat new slip ring brushes position the brushes in place Then slide one end of a piece of fine sandpaper between slip rings and brushes with the coarse side against the brushes With slight additional finger pres sure on top of the brushes pull the sandpaper around the circumference of the rings in the direction of rota tion only until brushes seat property Brushes must be seated 100 COMMUTATOR AND BRUSHES The generator brushes are properly adjusted when the welder is shipped They require no particular attention CA
50. stator lami nation CAUTION 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 CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC He o 8 E Return to Section TOC Return to Master TOC O 0 9 2 c tc F 5 F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The engine starts and runs at cor rect speed but there is no or very low welder output voltage The AC auxiliary output voltage is normal Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check for loose damaged or missing brushes in the welding generator Check the welding cables for loose or faulty connection RECOMMENDED COURSE OF ACTION Check the Fine Current Adjustment rheostat for resis tance and proper operation Normal resistance is 64 ohms Check associated wires for loose or faulty connections See the Wiring Diagram Shunt Field 2 Perform the Winding Test Check the continuity of the inter pole coils They should show continuity from the
51. the new battery last THE CORRECT POLARITY IS NEGATIVE 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 Keep the area well ventilated USING A BOOSTER Connect the positive lead to the battery first then connect the negative lead to the engine foot To prevent BATTERY BUCKLING tighten the nuts on the battery clamp until snug BATTERY ACID can burn eyes and skin Wear gloves and eye protection and be careful when working near a battery CLEANING THE BATTERY Keep the battery clean by wiping it with a damp cloth when dirty the terminals appear corroded discon nect the battery cables and wash the terminals with an ammonia solution or a solution of 1 4 pound 0 113 kg of baking soda and 1 quart 0 946 of water Be sure the battery vent plugs if equipped are tight so that none of the solution enters the cells After cleaning flush the outside of the battery the bat tery compartment and surrounding areas with clear water Coat the battery terminals lightly with petroleum jelly or a non conductive grease to retard corrosion Keep the battery clean and dry Moisture accumulation on the battery can lead to more rapid discharge and early bat
52. the stator end bracket assembly to the generator frame Line up the mating parts at the drill spot Tighten the four mounting bolts with the 5 8 wrench Check armature air gap Minimum gap is 035 Loosen the four mounting bolts adjust and re tighten if necessary Tighten the generator brush holder assem bly with the 7 16 wrench Connect the four heavy cables from the generator frame coils to the generator brush holders CLASSIC II LINCOLN B 24 25 26 27 28 29 Install the eight commutator brushes according to how you marked their posi tions at disassembly Attach the black lead to the positive termi nal of the field rectifier bridge Attach the red lead to the negative terminal Attach the white auxiliary power lead to the 115 VAC receptacle Attach the red auxiliary power lead to the circuit breaker Attach the black auxiliary power lead to the current transformer Thread the lead through the current transformer donut if you have a newer machine Connect the two yellow leads to the field bridge and to the field fuse holder Connect the white and yellow wires at the in line connectors Install the commutator wrap around the bottom alternator cover the battery and the alternator brush holder assembly Install the alternator rotor according to the reassembly directions in the Rotor Removal and Replacement cedure Before installing the case top and sides replace any cable tie
53. under carriage to ensure stability side to side and front to back This includes when being moved and when standing by itself for operation or service 4 Typical conditions of use such as travel speed roughness of the surfaces where the undercarriage will be used environmental conditions likely main tenance 5 Conformance with federal state and local laws Consult applicable federal state and local laws about specific requirements for use on public high ways CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 2 3 Return to Section TOC Return to Master TOC D g 5 INSTALLATION ELECTRICAL OUTPUT CONNECTIONS See Figure A 1 for the location of the 115 and 230 volt receptacles weld output terminals and ground stud WELDING CABLE CONNECTIONS CABLE INSTALLATION 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 terminals located below the fuel tank mounting rail See size recommendations below For positive polarity connect the electrode cable to the ter minal marked Positive For Negative polarity con nect the electrode cable to the Negative terminal These connections should be checked periodically and tightened if n
54. which are no longer clear Refer to the parts list for the replacement item number ENGINE MAINTENANCE CAUTION To prevent the engine from accidentally starting dis connect the positive battery cable before servicing the engine See Table D 1 for a summary of maintenance intervals for the items listed below Follow either the hourly or the calendar intervals whichever come first More fre quent service may be required depending on your spe cific application and operating conditions hours of operation or daily BE SURE MAINTAIN THE OIL LEVEL Change the oil the first time after 50 hours of opera tion Then under normal operating conditions change the oil as specified in Table D 1 If the engine is oper ated under heavy load or in high ambient tempera tures change the oil more frequently OIL Check the oil level after every 10 CHANGE THE OIL Change the oil while the engine is still warm as follows 1 Drain the oil from the drain plug located on the engine bottom as shown 2 Replace the plug and tighten it securely Remove the oil fill cap and add oil until the level reaches the upper dash full mark on the dipstick Use high quality detergent oil of API service class CC CD CE oil viscosity grade 10W30 Always check the level with the dipstick before adding more oil 4 Reinstall the oil fill cap and the dipstick CLASSIC II LINCOLN B Return to Section TOC Return to Master TO
55. 12 5 2 1 Return to Section TOC Return to Master TOC Return to Master TOC E 3 E 3 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 SERIES IMECHANICAL COUPLING LATER MODELS ENGINE IGNITION SWITCH ALTERNATOR ENGINE GENERATOR ARMATURE AND FRAME ALTERNATOR STATOR AND ROTOR EXCITATION 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 to the armature shaft which is mechanically coupled to the engine The rotat ing magnet rotor induces a voltage in the stationary windings of the alternator stator AUXILIARY AND FIELD FEEDBACK COILS There are two isolated windings incorporated in the sta tor lamination assembly One of these windings is tapped and provides 115VAC and 230VAC of auxiliary power to the appropriate receptacles The other 115VAC isolated winding is rectified to a DC voltage and is used to supply field feedback voltage to the GENERATOR ARMATURE INTERPOLE COILS WINDINGS SELECTOR SWITCH NEGATIVE C OUTPUT TERMINAL 115 amp 230VAC RECEPTACLE
56. 4W R23 R28 R29 R41 4 519400 1002 10 1 4W R27 1 519400 6812 68 IK 174W R30 1 519400 3321 3 32K 1 4 R31 R33 2 819420 6881 68 1 1 4W O o R32 R37 2 819420 1801 174W Fie R34 1 518380 1 THERMI STOR 5 R35 1 519400 2212 22 1K 1 4 R36 R42 2 519400 1003 100K 174W 518 R39 1 619400 1821 1 82K 174W 1 5194 1 211 1 21 1 4 o R43 1 519400 7681 7 68 1 4 9 9 1 3640 15 15 X2 2 515018 13 16 PIN SS x3 1 515018 15 14 59 5 5 5 1 15128 10 VOLTAGE REF THIS DEVICE IS SUBJECT DAMAGE BY STATIC ELECTRICITY SEE E2454 BEFORE HANDLING CAPACITORS MFD VOLTS INDUCTANCE HENRYS O10 Fie 515 gt 2 2 5 5 2 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 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 ELECTRIC in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine CLASSIC Il
57. 6 BLUE AND BROWN LEADS o 2 E Return to Master TOC PROCEDURE S 8 1 the engine OFF 7 Label the five cables that are connected to the selector switch Otherwise you will need to 2 2 2 Perform the Rotor Removal see the Wiring Diagram during reassembly 218 procedure 8 With the 1 2 wrench remove the five cables 813 3 Perform the Alternator Stator Removal connected to the selector switch procedure 9 Carefully clear all remaining leads and set the 4 Cut all necessary cable ties front panel assembly to the left side of the 5 Disconnect the blue and the brown wires at machine On later models remove leads 62 the in line connectors See Figure F 21 and and 58 from the circuit breaker located on the Wiring Diagram the output terminal assembly 6 With the 3 4 wrench remove the cable from the positive output terminal Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 2 3 Return to Section TOC Return to Master TOC g 5 F 45 F 45 TROUBLESHOOTING amp REPAIR GENERATOR FRAME REMOVAL AND REPLACEMENT continued FIGURE F 22 FRAME MOUNTING DETAILS See
58. ATOR COVER REMOVAL LOOSEN 5 SCREWS ALTERNATOR COVER BRUSHES CLASSIC II LINCOLN B F 36 F 36 TROUBLESHOOTING amp REPAIR o Pe ALTERNATOR ROTOR REMOVAL 5 5 AND REPLACEMENT continued 0 See Figure 15 for steps 22 24 24 With the 1 5 8 socket wrench remove the n rotor locking nut washer and sleeve collar 22 With the 7 16 wrench remove the two bolts i 2 nuts and washers mounting the brush hold sleeve collar pave 10 be E mbly tothe stator frame removed with a gear puller Be careful not to ang damage the rotor slip ring assembly 23 Bend the flat washer away from the rotor Remove the rotor by pulling it free of the locking nut generator shaft 5 FIGURE F 15 ROTOR REMOVAL E Return to Master TOC ae BENT CAE WASHER SS 50 mlt NUT COLLAR HOLDER ASSEMBLY Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC O10 515 gt oO 1 Return to Master TOC F 37 F 37 INSTALLATION ALTERNATOR ROTOR REMOVAL AND REPLACEMENT continued Replacement 25 26 27 28 29 30 Carefully mount the rotor onto the generator shaft Install a new sleeve collar part num
59. C md o 2 3 Return to Section TOC Return to Master TOC D g 5 ACCESSORIES OPTIONS ACCESSORIES The following options accessories are available for your Classic from your local Lincoln Distributor Undercarriage Under 10 MPH K768 For in plant or yard towing of the Classic 11 Not intended for high way towing Undercarriage K913 1 Two wheeled undercarriage for in plant and yard towing Includes fender and light kit three optional hitch choices For highway use con sult applicable federal state and local laws Power Plug Kit K802 C Provides four 20 amp 115 volt plugs and one 50 amp dual voltage 115 230V full plug NOTE For CSA machines and machines with receptacles use Power Plug Kit K802 R Power Plug Kit K802 D Provides four 15 amp 115 volt plugs and one 50 amp dual voltage 115 230V full plug For non CSA machines CV Adapter Below Code 10050 K384 Provides constant voltage output for semiautomatic welding Ether Start Kit K887 1 Automatic ether start kit pro vides cold weather starting assistance in temperatures below 10 F 12 2 C Requires an ether tank that must be purchased locally NOTE Ether starting can contribute to shortened engine life Avoid unnecessary or indiscriminate use Linc Thaw Control Unit L2964 5 Includes met
60. C Return to Section TOC O10 Fle 515 gt 2 2 cc 1 Return to Section TOC Return to Master TOC Return to Master TOC D 3 MAINTENANCE FIGURE D 1 OIL DRAIN AND REFILL 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 Seo Table 0 recommended maintenance intervals Order Deutz oil filter 8117 4416 or 4117 4417 from your local Deutz service center Change the oil filter as follows 1 Drain the oil from the engine and allow the oil filter to drain 2 Remove the old filter spin it off and discard it Wipe off the filter mounting surface and adapter 3 Apply a thin coat of new oil to the rubber gasket on the new oil filter 4 Spinthe new filter onto the mounting adapter finger tight until the gasket is evenly seated Then turn it down another 1 2 turn Do not overtighten the new filter DIPSTICK FUEL FILTER OILFILTER OIL DRAIN PLUG OILFILL CAP DIPSTICK LEVELS 5 Refill the engine with the proper amount and type of oil as described in the hende above Start the engine and check for leaks around the filter element Correct any leaks usu ally by retig
61. C Return to Section TOC Return to Master TOC o 8 E Return to Section TOC Return to Master TOC 7 5 F 9 F 9 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The engine will NOT go to high speed when a load is applied to the welding output terminals engine does go to high speed when a load is applied to the AC auxiliary power receptacles The engine will NOT go to high speed when a load is applied to the AC auxiliary receptacles engine does go to high speed when a load is applied to the welding out put terminals Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS 1 Check welding cables for loose 1 Check the reed switch CR2 for or faulty connections proper operation The reed switch should close when there is current flow in the welding cir cuit Locate the red lead connected to the PC board While leaving the red lead connected jumper the red lead to frame ground If the engine goes to high speed the fault is in the reed switch or associated leads If the engine does NOT go to high speed in step 2 the Idler PC board may be faulty Check the auxiliary power plug 1 Check the leads associated with and associated
62. C TIMER NONE lo lac REED SW lt p 2 100 Vdd gt MONO IN 15 4 OSCINH 14 2N4401 OUT 1 DECODE 1 1 5 lour2 C2 8 BY PASS SCALE CLOCK INH ELECTRICAL SYMBOLS PER E1537 CLEVELAND OHIO U S A CAPACITOR RESISTORS GENERAL INFORMATION DIODES FILE L9901_1BA THE LINCOLN ELECTRIC CO JR Vss e 45368 Return to Section TOC Return to Master TOC THE LINCOLN ELECTRIC CO TO FRAME GND THRU MOUNTI THE LINCOLN ELECTRIC CO 013 100 15V CRI NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NUMBER REF ENGINE PROTECTION 5 6 Ji R30 SET Vdd gt 1 4 3 4 ENG PROTECT LAMP D5 332 RESET MONO IN 15 OIL PRESS 7 4 N1 yo OSCINH F 4 Jour DECODE 13 2 i GND Ke 1 5 1 77 8 BY PASS 1 e CLOCK INH gt o gt HOUR METER lt A A J
63. CHED PC BOARDS TO VERIFY PROB LEM will help avoid denial of legitimate PC board warranty claims CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 8 E Return to Section TOC Return to Master TOC O 0 9 2 tc TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The engine starts and runs at cor rect speed but there is no or very low welder output voltage There is no AC auxiliary output voltage POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check the 15 amp fuse located on the inside of the front control panel If the welder output is zero volts the fields need to be flashed Fields in this section Check for loose or missing brushes in the exciter alternator and welding generator See Flashing the TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Check the flashing diode and associated leads connected between the generator brushes and the exciter alternator brush es Check the field diode bridge and associated leads and con nections Diagram 3 Perform the Alternator Rotor See the Wiring 4 Check for opens or shorted turns in the alternator stator windings The coils must NOT be grounded to the
64. COLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 2 3 Return to Section TOC Return to Master TOC g 5 F 47 TROUBLESHOOTING amp REPAIR GENERATOR ARMATURE REMOVAL AND REPLACEMENT continued FIGURE 23 BLOWER PADDLE REMOVAL LE OF PROCEDURE Turn the engine OFF Perform the Alternator Rotor Removal pro cedure Perform the Al ternator Stator Removal pro cedure Perform the Generator Frame Removal pro cedure 5 Using the rope sling support the armature Make sure the engine is supported with the wood or steel blocks With the 5 8 wrench remove the eight bolts and lock washers holding the blower paddles and the armature to the engine flywheel See Figure F 23 With the armature supported and balanced in the rope sling carefully rotate the armature 1 8 turn in either direction to release Caution The armature is now free to be removed from the engine Lot ROPE SLING BLOWER PADDLE ARMATURE MOUNTING BOLTS 8 Replacement 9 Support the armature with the rope sling Mount the armature to the engine rotating it 1 8 of a turn in either direction to achieve proper attachment Before removing the rope sling be careful to support the arma ture with the wood or steel blocks und
65. FROM CONNECTOR J5 goa CONNECT PLUG P5 ON W F M TO CONNECTOR J5 ON MACHINE aT 215 BELOW R RESISTORS y X INLINE PLUG 52 2 5 5 oc DX 7 o c aem r CONNECTORS P5 E BU 2 gt 600 YO 1 ae 1 3 gt 4 42 1 H p W 8 LEAD NE i CONNECT TO POS NEG O POS WIRE FEED 4 W OUTPUT TERMINALS i ERE H CONNECTS E F i P8 A l CASE AJ NEGATIVE CV MODULE hi p OUTPUT TERMINAL 2 HEAVY LEAD i o PANEL i SWITCH FOR LOCAL OR REMOTE CONTROL 58 05 Ss 1 1 4 CONTROL CONNECT TO NEG Nome ES Fle WITH MACHINE NOT RUNNING REMOVE PLUG Po ON BRUSH HOLDER MACHINE FROM CONNECTOR 48 THEN CONNECT 42 HEAVY LEAD id TNT MM i 212 Auc 250 MACHINE MUST NOT BE RUNNING amp BLACK LEADS NOT CONNECTED ON THIS THERMOSTAT 2 MACHINE LINCOLN ASEMS y WHEN MAKING THESE CONNECTIONS 8518 1 19 96 218 CLEVELAND OHIO U S A L9919 cc NOTE This diagram is for reference only may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one o
66. Figure 22 for steps 10 13 10 11 12 13 With the 3 4 wrench remove the frame mounting bolts nuts and spacers from the feet of the generator frame With the rope sling around the generator frame carefully lift the frame and engine assembly a small distance Slide the wood or steel block under the engine adapter plate With the 9 16 wrench remove the nine bolts mounting the engine to the generator frame Using the rope sling and pry bars carefully lift and wiggle the generator frame away from the engine and armature assembly Be careful to support the generator frame as you remove it Replacement 14 Support the generator frame with the rope sling Mount the generator frame to the engine and alternator assembly Before removing the rope sling be careful to sup port the generator frame with the wood or steel block under the engine adapter plate With the 9 16 wrench install the nine bolts that attach the generator frame to the engine A 19 CLASSIC II LINCOLN B ROPE SLING ENGINE GENERATOR MOUNTING HOLES With the 3 4 wrench install the frame mounting bolts nuts and spacers to the feet of the generator frame Connect leads 462 and 58 to the circuit breaker on the output terminal assembly newer model machines Connect the five cables to the selector switch according to how you labeled them during disassembly See the Wiring Diagram if necessary Co
67. GND GND INPUT CABLE 75 75 76 _e _ 76 TE K775 OPTIONAL Splice Leads REMOTE CONTROL and Insulate CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC md o 2 E Return to Section TOC Return to Master TOC g 5 ACCESSORIES CONNECTION OF THE LN 7 TO THE CLASSIC USING K584 INPUT CABLE ASSEMBLY SEE FIGURE C 2 1 Shut the welder off 2 Connect the electrode cable from the LN 7 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 NOTE Figure C 2 shows the electrode connected for positive polarity To change polarity shut the welder off and reverse the electrode and work cables at the Classic output terminals 3 Connect the input cable from the K584 XX Input Cable Assembly to the 14 pin amphenol on the K864 adapter and the input cable plug on the LN T 4 Connect the K864 adapter to the 14 pin amphenol on the Classic Il 5 Place the IDLER switch in the HIGH position CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage this voltage goes over 140 v
68. LE pere 48 LEAD 5 gt CONNECT TO POS amp NEG O POS WIRE FEED 42 W OUTPUT TERMINALS gt 1 22 CONNECT L L CASE EE NEGATIVE MODULE i OUTPUT TERMINAL SWITCH FOR LOCAL OR REMOTE CONTROL 1 olo SHOWN IN LOCAL POSITION i 4 LL SHOWN IN LOCAL POS ITION REN E CONNECT TO NEG REPRE 2 10 WITH MACHINE NOT RUNNING REMOVE PLUG ON NBE ELE EUN BRUSH HOLDER MACHINE FROM CONNECTOR 48 THEN CONNECT 2 HEAVY LEAD HE 518 no 200 MACHINE MUST NOT BE RUNNING 9 RED amp BLACK LEADS NOT CONNECTED THIS THERMOSTAT 3 2 MACHINE LINCOLN SMS WHEN MAKING THESE CONNECTIONS 2 2 218 CLEVELAND OHIO U S A amp NOTE This diagram is for reference only It may be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one the enclosure panels of your machine E CLASSIC Il G 6 ELECTRICAL DIAGRAMS G 6 Wiring Diagram Code 10219
69. M 123 133 1 90 2 30 2 2 2 6 1780 1810 Fle 515 o gt 2 2 mt 5 5 1 Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B Return to Master Return to Master TOC 7 E Return to Master TOC ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams Section a Re tiet ra dU Section G Wiring Diagram Code 9805 G 2 Wiring Diagram Code 10000 G 3 Wiring Diagram Code 10070 G 4 Wiring Diagram Code 10071 rtt noe RE bn tug 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 sss nennen nennen nns G 9 Idler PC Board 19902 G 10 Idler PC Board 19902 Components G 11 CLASSIC II LINCOLN B G 1 NOTES CLASSIC II LINCOLN 5 901 0 901 901 J91Se N 01 901 J91Se N 01 DOL uonoes oj DOL uonoes DOL uonoes oj DOL uonoes G 2 ELECTRICAL DIAGRA
70. MS G 2 Wiring Diagram Code 9805 TO WELDING CRY Bs D ALTERNATOR ROTOR cu SLIP RINGS B 610 _ ALTERNATOR TERMINAL SLIP RING NEAREST STRIP TO IRON Return to Section TOC Return to Master TOC FUEL SOLENO SUP S D G WIRING DIAGRAM 115 VOLT 1 RECEPTACLE F SOLES i IGNITION amp SELECTOR SWITCH L IDLER gt 602A SWITCH SWITCH OIL TEMPERATURE SENSOR ALTERNATOR WINDINGS CLASSIC I WITH CV ADAPTER EQUIP SUBJECT CHK DATE 7 9 91 SCALE NONE OIL PRESSURE SENSOR CLEVELAND OHIO U S A THE LINCOLN ELECTRIC CO Return to Section TOC Return to Master TOC CURRENT TRANSFORMER 5432 U 230 VOLT BE WELDER RECEPTACLE LEAD BLOCK N o N 509 U o U 508 l POSITIVE CV amp VV OUTPUT VV OUTPUT POS TERMINAL REMOTE CONTROL OPTIONAL SA
71. Master TOC Return to Section TOC Fle 515 PEN 5 2 2 1 Return to Section TOC Return to Master TOC Return to Master TOC B 4 OPERATION WELDING CAPABILITY The Classic Il is rated 250 amps 30 volts constant cur rent at 6096 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 LIMITATIONS The Classic ll is not recommended for any process es besides those that are normally performed using DC stick welding SMAW and DC TIG welding Specific limitations on using the Classic Il for these processes are described in the Welding Operation section of this manual Constant voltage welding is available with the optional wire feed module CLASSIC II LINCOLN B B 5 B 5 OPERATION CONTROLS AND SETTINGS The welder generator controls are located on the the case front Welding output terminals and ground Output Control Panel of the machine case front Diesel stud are located on the machine right side under the engine idler control and start stop controls are also door See Figure B 1 and the explanations that follow FIGURE B 1 OUTPUT CONTROLS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 2 3 Return to Section TOC Return to Master TOC
72. POSITIVE CC 515 REMOTE CONTROL OPTIONAL WIRE FEED MODULE OPTIONAL 512 REMOTE CONTROL RECEPTACLE amp SWITCH D Aa S EEN 1 REMOTE CONTROL ON MACHINE REMOVE PLUG P10 FROM CONNECTOR J5 Biz i SEE ox i RESISTORS M liae c Eg i BELOW o R i _______ INLINE PLUG sis Ee Sree i i CONNECTORS 1 o i SW i C N 221900 Yo BELOW 2 i W MESE pnm p CONNECT TO POS 8 NEG O POS WIRE FEED Pa 46 W OUTPUT TERMINALS gt 1 Bie ee SSE Oo ee 65 L P8 4 T CASE NEGATIVE CV MODULE i i m OUTPUT TERMINAL i m PANEL SWITCH FOR LOCAL OR REMOTE CONTROL SHOWN LOCAL POSITION sl CONNECT TO NEG WITH MACHINE NOT RUNNING REMOVE PLUG ON BRUSH HOLDER 55005555 olo MACHINE FROM CONNECTOR J8 THEN CONNECT 2 HEAVY LEAD ee CONNECTOR ON MACHINE MACHINE MUST NOT BE RUNNING 250 RED amp BLACK LEADS NOT CONNECTED ON THIS 515 MACHINE N COLN THERMOSTAT WHEN MAKING THESE CONNECTIONS 0 olo CLEVELAND OHIO U S A L9012 A Z NOTE This diagra
73. Return to Master Return to Master TOC HE o 8 3 Return to Master TOC View Safety Info View Safety Info gt gt Q gt SERVICE MANUAL View Safety Info CLASSIC 11 1996 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 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 LINCOLN amp World s Leader in Welding and Cutting Products ELECTRIC 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 SAFETY A WARNING 5 CALIFORNIA PROPOSITION 65 WARNINGS d Diesel engine exhaust and some of its constituents The engine exhaust from this product contains z are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm a The Ab
74. S BRUSHES amp COMMUTATOR RESIDUAL 777 MAGNETISM __ FIELD RECTIFIER GENERATOR FIELD CONTROL POSITIVE OUTPUT TERMINAL rotor field rheostat control to the field shunt windings in the main generator frame It also supplies voltage through the generator INTERPOLE AND SERIES COILS The generator armature rotates within the magnetic field created by the shunt field windings A DC voltage is induced in the armature and is transferred through the armature commutator and brushes to the series and interpole coils The interpole coils which are con nected in series with the positive output terminal are located so as to counteract any magnetic influences that could cause mechanical distortion in the rotating armature The series coils are designed to oppose or buck the DC voltage that is generated in the arma ture NOTE Unshaded areas of Block Logic Diagram are the subject of discussion CLASSIC Il LINCOLN B E 4 E 4 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 SELECTOR SWITCH Return to Section TOC Return to Master TOC NEGATIVE C OUTPUT TERMINAL 115 amp 230VAC RECEPTACLES 77 PRESSURE SENSOR CURRENT TRANSFORMER SERIES NOT PRESENT ON LATER MODELS
75. SSORIES E CONNECTION OF THE LN 25 TO THE 3 Attach the single lead from the LN 25 control box 8 CLASSIC ACROSS THE to the work using the spring clip on the end of the lead This is only control lead it carries no 2 2 SEE FIGURE welding current 218 Sle e collie welder oft 4 Place the IDLER switch in the HIGH position 2 Connect the electrode cable from the LN 25 to the t f It t the LN 25 terminal of the welder Connect the work cable to the terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application NOTE Figure C 4 shows the electrode connect ed for positive polarity To change polari ty shut the welder off and reverse the electrode and work cables at the Classic output terminals Reverse the LN 25 polarity switch FIGURE C 4 CLASSIC II LN 25 ACROSS THE ARC CONNECTION DIAGRAM o 2 E Return to Master TOC O10 E o 14 PIN c T Classic Il Output AMPHENOL o o Terminals are on 9 Opposite Side 5 LN 25 WIRE FEEDER WITH K444 2 REMOTE 9 9 VOLTAGECONTROL OPTION 5 ale ELECTRODE CABLE WORK CLIP WORK LEAD TO WORK Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Sect
76. TOC Return to Master TOC BATTERY H GENERAL DESCRIPTION The Classic 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 115 or 230VAC receptacles The Classic II is manufactured with all copper windings FIELD RECTIFIER GENERATOR FIELD CONTROL POSITIVE OUTPUT TERMINAL BATTERY STARTER ENGINE ALTERNATOR AND PROTECTION CIRCUITS The 12VDC battery powers the starter motor and through the ignition switch the engine protection cir cuitry In the event of a low oil pressure or a high oil temperature condition the engine protection system shuts the engine off The protection relay monitors the oil pressure sensor and the oil temperature sensor either sensor faults the protection relay deactivates the fuel solenoid and the engine shuts down The engine alternator supplies charging current for the battery circuit If the alternator would cease to func tion correctly due to a broken fan belt or other mal function the CR1 relay would activate causing the pro tection relay to close the fuel solenoid and shut off the engine NOTE Unshaded areas of Block Logic Diagram are the subject of discussion CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC O o Fie 915 nl 2
77. UTION DO NOT SHIFT THE BRUSHES adjust the rocker setting Shifting of the brushes may result in Change in machine output Commutator damage Excessive brush wear Periodically inspect the commutator slip rings and brushes by removing the covers DO NOT remove these covers while the machine is running Commutators and brushes require little attention However if they are black or appear uneven have them cleaned by experienced maintenance personnel using a commutator stone Never use emery cloth or paper for this purpose Replace brushes when they wear within 1 4 of the pig tail A complete set of replacement brushes should be kept on hand Lincoln brushes have a curved face to fit the commutator Have experienced maintenance personnel seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact is made across the full face of the brushes After stoning blow out the dust with low pressure air Arcing or excessive exciter brush wear indicates a pos sible misaligned shaft Have an authorized Lincoln Electric Field Service facility check and realign the shaft WARNING Uncovered rotating equipment be dangerous Use care so your hands hair clothing or tools do not catch in the rotating parts Protect yourself from particles that may be thrown out by the rotating armature when stoning the commutator CURRENT RANGE SELECTOR CONTACTS The contacts should not be
78. Wiring Diagram Return to Section TOC Return to Master TOC Fle S PEN 2 2 mlt 5 2 1 Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B 27 27 TROUBLESHOOTING amp REPAIR FLASHING THE FIELDS continued Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 2 3 g 5 FIGURE 10 FLASHING THE FIELDS 12 VOLT BATTERY PROCEDURE Turn engine welder OFF Unlatch lift and secure the right side door Note that there are latches at both ends of the door Remove the cover from the exciter See Figure F 10 Turn the FINE CURRENT ADJUSTMENT control rheostat to 100 Using one of the leads with alligator clips connect the negative terminal of the 12 volt automotive battery to the negative brush holder This is the brushholder nearest the rotor lamination See Figure F 11 and the Wiring Diagram DO NOT remove brush holder NEGATIVE BRUSH HOLDER POSITIVE 4 BRUSH HOLDER With the engine OFF use the other lead with alligator clips and touch the positive battery terminal to the positive brushholder Then disconnect the leads to remove the battery from the circuit Replace the exciter cover Start the welder generator voltage should build up If voltage does n
79. 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 SPARK ARRESTER Diesel engine mufflers may emit sparks when the engine is running Some federal state or local laws require spark arresters in locations where unarrested sparks could present a fire hazard Standard mufflers like the one included with the Classic do not act as spark arresters When local laws require it a spark arrester must be installed on the machine and properly maintained An optional spark arrester kit is available for your Classic See the Accessories section of this manual for more informa tion CAUTION An incorrect spark arrester may lead to damage to the engine or reduce performance UNDERCARRIAGES If you use a non Lincoln undercarriage you must assume responsibility that the method of attachment and usage does not result in a safety hazard nor dam age the welding equipment Some of the factors to be considered are as follows 1 Design capacity of the undercarriage vs the weight of the Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework 3 Proper placement of the equipment on the
80. affolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 CLASSIC II Also see item 1 b ARC RAYS can burn 4 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 weldi
81. 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunc tions Simply follow the three step procedure list ed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into three main categories Output Problems Function Problems Engine Problems and Welding Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub ject component is eit
82. ank Also running out of fuel tends to draw dirt into the fuel system Check the crankcase oil level In diesel engines if the fuel supply is cut off or runs out while the fuel pump is operating air may be entrapped in the fuel distribution system If this happens bleed ing of the fuel system should not be required since the Deutz F3L 1011F engine is equipped with a self prim ing feature 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 O F If the engine is frequently started below 10 F you may want to install the optional ether starter kit Installation and operating instructions are included in the kit Use ether starting only when required because excessive use shortens engine life It is important to follow the engine manufacturer s rec ommendations for oil and fuel to obtain satisfactory cold weather performance Consult the engine manu al and the IMaintenance bection of this manual BREAK IN PERIOD Any engine will use a small amount of oil during its break in period For the diesel engine on the Classic Il break in is about 200 running hours Check the oil twice a day during break in Change the oil and oil filter cartridge after the first 50 hours of oper ation Also change the fuel filter cartridge F
83. aster TOC CURRENT TRANSFORMER PEE U CR2 REED 230 VOLT EE WELDER RECEPTACLE LEAD BLOCK N o N 509 U o U 508 POSITIVE CV amp VV OUTPUT NEGATIVE TERMINAL VV OUTPUT TERMINAL REMOTE CONTROL OPTIONAL 21 CONTROL PANEL amp SWITCH eo ESISTORS ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS 402 ON 3 PLACE DECIMALS IS 002 ON ALL ANGLES 15 45 OF A DEGREE MATERIAL TOLERANCE TO AGREE WITH PUBLISHED STANDARDS CONNECT NEGATIVE BRUSH HOLDER UNLESS OTHERWISE SPECIFIED TOLERANCE Sht No PLUG FOR TERMINA REMOTE CONTROL 2 HEAVY LEAD POTENTIOMETER Ojo o Fie c 515 gt 212 5 oO NEGATIVE CV OUTPUT TERMINAL GROUND TERM CONFIGURATION WIDE SLOT ON ENGINE 64 i CONNECTOR GROUND TERM 7 _ 6 WIDE SLOT ELECTRICAL SYMBOLS PER E1537 THE LINCOLN ELECTRIC CO THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO AND 15 NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF CONNECT TO CASE LEAD COLOR CODE 7 B BLACK R RED SWITCH FOR
84. aster TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine E CLASSIC Il G 3 ELECTRICAL DIAGRAMS G3 Wiring Diagram Code 10000 59A CR1 TO WELDING B D BOTTOM VIEW F ALTERNATOR ROTOR GENERATOR SHOWN 9 SLIP RINGS 610 ALTERNATOR 9071 Return to Section TOC Return to Master TOC TERMINAL SLIP RING NEAREST B 58D Ri TO IRON 50 Q 8 4 FUEL 60B SOLENOID SUP S D G WIRING DIAGRAM 58 ENGINE 7 PROTECTION 115 VOLT RECEPTACLE und 56 SEI Nd IGNITION L FUSE SFE 14 SELECTOR SWTCH 4 f Sion NONC 5 B OIL TEMPERATURE 5 2 SENSOR ALTERNATOR RY WINDINGS CLASSIC II WITH CV ADAPTER REF 18594 EQUIP SUBJECT TYPE CHK JJ DATE 2 14 92 54 SCALE NONE OIL PRESSURE SENSOR THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A 5 6 Return to Section Return to M
85. ater Such practices pose safety hazards and cause improp er operation and corrosion of parts STORING 1 Store the machine in a cool dry place when it is not in use Protect it from dust and dirt Keep it where it can t be accidentally damaged from construction activities moving vehicles and other hazards 2 Drain the engine oil and refill with fresh 10W30 oil Run the engine for about five minutes to circulate oil to all the parts See the eme Ra of this manual for details on changing oil 3 Remove the battery recharge it and adjust the electrolyte level Store the battery in a dry dark place 4 See your engine operation manual for further infor mation on fuel and engine preservation CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC He o 2 Return to Section TOC Return to Master TOC g 5 INSTALLATION STACKING Classic Il machines CANNOT be stacked TILTING 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 angle be sure to check the oil regularly and keep the oil level at the FULL mark as i
86. atic shielding bag and place it directly into the equipment Don t set the PC Board on or near paper plastic or cloth which could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag e If the PC Board uses protective shorting jumpers don t remove them until installation is complete e 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 4 Test the machine to determine if the failure symp tom has been corrected by the replacement PC board NOTE Allow the machine to heat up so that all electri cal components can reach their operating tem perature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and termi nal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWIT
87. ction Reset button Note On later models without a Reset but ton turn the ignition switch OFF and then back ON Check the fuse in the engine protection relay Note Not present on later models On later models check the fuel solenoid circuit breaker located near the welding output termi nals Reset if tripped RECOMMENDED COURSE OF ACTION Check the ignition switch for proper operation Check the associated leads for loose or faulty connections See the Wiring Diagram Check the fuel solenoid Make sure it is opening when 12VDC is applied to leads 58 to 60 The engine protection relay may be faulty Note On later models the Idler Engine Protection PC board may be faulty The engine fuel injectors may need service The engine starts but shuts down after a short period of time Check for adequate fuel supply Check engine oil level Check engine alternator belt The oil pressure or oil tempera ture sensor may be causing the engine protection relay PC Board on later models to shut off the fuel solenoid Make sure oil pressure and temperature are correct before replacing sensors The engine alternator may be faulty causing the relay PC Board on later models to activate which signals the engine protection relay to shut off the fuel solenoid The protection relay may be faulty Note On later models the Engine Protec
88. ctive motors may require as much as 4 times running watts to start O o 515 PEN 9 gt 818 5 3 CLASSIC II LINCOLN B Section C 1 Section C 1 TABLE OF CONTENTS O ACCESSORIES mI M M Section C Options ACCeSSOTIGS cete atte d ae eee C 2 RAN TR E C 3 2 9 Semiautomatic FCAW Welding c cccccecesceeseeeeeeeeeeeeeecaeceaeeeseaeeeeeeeeeeeentees C 3 Connection of Lincoln Electric Wire 9 C 4 Connection of the LN 7 using K867 Universal C 4 Connection of the LN 7 using K584 Input Cable 5 Connection of the LN 25 using K867 Universal C 6 Connection of the LN 25 Across the Arc 7 Connection of the K488 SG Control Module and K487 Magnum Spool C 8 5 9 gt 8 E 2 o O 5 9 gt g E 2 o ra O 5 9 gt g E 2 o CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TO
89. e B 8 Starting the Engine oaia dec de de ed ie B 8 Stopping the ENGINE 9 Gold Weather Starting icai eerie B 9 Breakin a 9 T Welding Operation needs set ni hel p B 10 e General IMPOR ALON 10 5 IDI Operatii Get B 10 9 gt Classic DC Constant Current Stick or TIG B 11 je Classic 1 DC Wire Feed Welding Constant Voltage B 12 2 Ailia POWOT NRI B 13 Using Auxiliary Power and Welding at the Same B 13 5 9 gt g E CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC md 9 o 8 E Return to Section TOC Return to Master TOC 5 OPERATING INSTRUCTIONS Read and understand this entire section before operat ing your Classic Il 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 detailed engine starting operatin
90. e total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables 1 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les CLASSIC II zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux
91. e at least 500 000 12 Close and latch the right side door ohms 11 Replace plug P10 making sure the leads and plug are secure O10 Fle 515 5 1 8 If the test does meet the resistance specifications then check the harness plug and inline connectors for loose connec tions or shorted leads Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B 20 20 TROUBLESHOOTING amp REPAIR IDLER SOLENOID TEST WARNING 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the idler solenoid is capable of functioning when it is energized with 12VDC Return to Section TOC Return to Master TOC MATERIALS NEEDED External 12VDC supply Wiring Diagram Fle S PEN 2
92. e commuta ing the stator end bracket tor Note the position of the brushes for reassembly 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 It is not necessary to remove the brush holder jumper cables See Figure F 19 Label leads and posi tions for re assembly CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 2 3 Return to Section TOC Return to Master TOC g 5 42 17 18 19 42 TROUBLESHOOTING amp REPAIR ALTERNATOR STATOR REMOVAL AND REPLACEMENT continued FIGURE 20 DRILL SPOT LOCATIONS STATOR ENDBRACKET MOUNTING BOLT 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 20 With the 7 16 wrench loosen do remove the generator brush holder clamping bolt Note the drill spot for reassembly See Figure F 20 Carefully pry the stator end bracket assembly away from the generator frame NOTE The generator brush holder assem bly will also be removed Replacement 20 21 22 23 Mount
93. ecessary CAUTION Loose connections will cause the output terminals to overheat The terminals may eventually melt Do not cross the welding cables at the output terminal connection Keep the cables isolated and separate from one another When welding at a considerable distance from the welder be sure you use ample size welding cables Table A 1 lists recommended cable sizes and lengths for rated current and duty cycle Length refers to the distance from the welder to the work and back to the welder 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 See the Accessories section of this manual for more information FIGURE A 1 CLASSIC OUTPUT CONNECTIONS 230 VOLT RECEPTACLE 115 VOLT RECEPTACLE WELD OUTPUT TERMINALS 2 GROUND STUD LOCATION CABLE STRAIN RELIEF BRACKET AUN TABLE A 1 RECOMMENDED COPPER WELDING CABLE SIZE AND LENGTH TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable sizes for combined length of electrode plus work cable Amps Duty Cycle Up to 200 ft 200 to 250 ft 200 10096 1 1 0 250 6096 1 1 0 300 4096 1 0 2 0 CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o
94. ecifications then the rotor may be faulty Replace the rotor FIGURE F 3 MEASURING ROTOR RESISTANCE TO GROUND Return to Section TOC Return to Master TOC O10 Fle 515 5 1 Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B 17 17 TROUBLESHOOTING amp REPAIR SHUNT FIELD WINDING TEST WARNING 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if the shunt field coils are shorted open or grounded MATERIALS NEEDED Volt Ohmmeter Wiring Diagram Return to Section TOC Return to Master TOC Fle 515 PEN 9 gt 218 mlt 5 2 1 Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B 18
95. ectors to leads 56 and 57 on the wiring harness Close and latch the right side door F 22 F 22 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST A WARNING 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION If the machine output is low or high this test will determine whether the engine is operating at the correct speed RPM during both HIGH and LOW idle conditions Directions for adjust ing the throttle to the correct RPM are given Return to Section TOC Return to Master TOC MATERIALS NEEDED Slot head screw driver 7 16 wrench 10mm wrench Strobe tach frequency counter oscilloscope white or red marking pencil Fle 515 PEN 9 gt 218 mlt 5 2 1 Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B
96. ed with the wire feeder that gives the best arc characteristics for the range E 2 Select the appropriate electrode selected See Control of Welding Current n this section of the manual 3 Start the diesel engine See Engine this section of the manual 7 Strike an arc and begin welding 515 TABLE B 1 5 RANGE SETTINGS FOR WIRE SIZE SPEED 0 gle S Diameter inches Wire Speed Range Appropriate Current Range t o inches minute tc C 035 80 110 75 to 120 Amps 045 70 130 120 to 170 Amps 068 40 90 125 to 210 Amps EE 5 8 mio olg 512 gle ala 2 2 2 5 5 mio olg 512 218 EIE 5 5 9 cm CLASSIC II LINCOLN B 13 AUXILIARY POWER A WARNING Be sure that any electrical equipment plugged into the generator AC power receptacles can withstand a 10 voltage and a 3 frequency variation Return to Section TOC Return to Master TOC The AC auxiliary power supplied as a standard has a rating of 3 0 kVA of 115 230V AC power 60 hertz One 115 duplex and one 230V grounding type recep tacle are provided The circuit is protected with circuit breakers The rating of 3 0 kVA permits a maximum continuous current of 13 amps to be drawn from the 230 volt duplex receptacle Or a total of 26 amps can be drawn from the 115 volt duplex receptacle The 115 volt duplex recep
97. electrode and work cables If the electrode cable is on your right Do not put your hands near the engine fan Do not attempt to side the work cable should also be on your right side override the governor or idler by pushing on the throttle con trol rods while the engine is running 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance 2 4 5 Do not work next to welding power source work disconnect the spark plug wires distributor cap or magneto wire as appropriate Return to Master TOC CLASSIC II LINCOLN B Return to Master TOC Return to Master TOC 7 E Return to Master TOC SAFETY 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 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or sc
98. epairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine if there is a shorted open or grounded winding in the alter nator rotor MATERIALS NEEDED Volt Ohmmeter 3 8 Nut driver or socket wrench Wiring Diagram CLASSIC II LINCOLN B F 13 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 1 Return to Section TOC Return to Master TOC F 14 F 14 TROUBLESHOOTING amp REPAIR ALTERNATOR ROTOR TEST continued FIGURE 1 ALTERNATOR COVER REMOVAL LOOSEN 5 SCREWS ALTERNATOR COVER BRUSHES TEST PROCEDURE 1 Turn engine off 5 With the 3 8 socket wrench remove the screw and lock washer from the top center 2 With the 3 8 socket wrench remove the of the alternator cover See Figure F 1 left case side 6 With the 3 8 socket wrench loosen the 3 Unlatch lift and secure the right side door two screws on the right side of the alterna Note that there are latches at both ends of tor cover the door 7 Remove the alternator top cover Be 4 With the 3 8 nut driver or socket wrench ful to clear the leads loosen the two screws on the left side of the alternator cover See Figure F 1 8 Locate and lift the brushes off
99. er and fuses to protect the welder when thawing frozen water pipes WARNING THAWING 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 Wire Feed Module Above Code 10050 K623 1 Provides constant voltage output for semiautomatic welding Includes remote for CV mode and internal Cold Tip Contactor for the LN 7 and LN 23P Accessory Kit K703 Includes the following Thirty five feet 10 5 meters of 2 AWG electrode cable Thirty feet 9 1 meters of 2 AWG work cable Headshield with No 12 filter GC300 work clamp Cooltong 300 insulated electrode holder The cables are rated at 250 amps 40 duty cycle Spark Arrester Kit K899 1 A field installed kit for the Classic diesel engine muffler exhaust pipe Includes a heavy gauge steel approved spark arrester mounting clamp and adapter Remote Control 100 Feet Below Code 10050 K888 2 Includes a control box with 100 ft 7 5 meters of 4 conductor cable Allows output to be con trolled remotely Remote Control Kit Above Code 10050 924 1 Includes a control box with 100 ft 7 5 meters of 4 conductor cable Allows output to be controlled remotely GFCI Receptacle Kit K896 2 Includes a UL approved 115 volt ground fault circuit interrupter
100. er the engine With the 5 8 wrench install the eight bolts and lock washers that attach the blower paddles and the armature to the engine flywheel 10 Perform the replacement procedures according to each of the following Generator Frame Removal and Replacement Alternator Stator Removal and Replacement Alternator Rotor Removal and Replacement Before installing the machine case top and sides be sure to replace any cable ties cut during dis assembly CLASSIC II LINCOLN B 48 48 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest a machine If itis rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics f you repair or replace any electrical components ENGINE OUTPUT Mode No Load RPM Load RPM Low Idle 1350 1400 NA High Idle 1780 1810 1650 1740 Return to Section TOC Return to Master TOC WELDER DC OUTPUT Current Control Current Selector Open Circuit Load Volts Load Amps Rheostat Switch Voltage Maximum Maximum 91 98 5 38 45 300 Return to Section TOC Return to Master TOC AC AUXILIARY POWER RECEPTACLE OUTPUT 230 Volt Receptacle 115 Volt Receptacle Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps Voltage Voltage 240 254 210 225 13 8 118 128 103 112 26 0 FIELD AMPS AND VOLTS Current Rheostat at Maximum Exciter DC Volts Shunt Field Amps Alt Rotor Amps RP
101. erheat and or cause damage to the equipment being used FIGURE A 2 GROUND STUD LOCATION 0722 12 1 Ground Stud CLASSIC II LINCOLN B 8 NOTES CLASSIC II LINCOLN 5 901 0 901 901 J91Se N 01 901 J91Se N 01 DOL uonoes oj DOL uonoes DOL uonoes oj DOL uonoes 1 Section 1 TABLE OF CONTENTS OPERATION SECTION 8 etna NM MI MI IM Mm Section B 5 Safety 6 2225 2 General Description kd 2 2 Recommended 3 e B 3 mn 3 Operational Features and B 3 T CALI OS B 3 Welding Capability a aaa iiaa B 4 T Binder B 4 e Controls and 5 5 Welder Generator 5 5 Control of Welding B 6 Diesel Engine Controls 7 E RT n B 8 Before Starting the Engin
102. est grounding procedure CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 8 E Return to Section TOC Return to Master TOC g 5 CONTROL 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 Open circuit voltage is also controled by the FINE CURRENT ADJUSTMENT permitting control of the arc character istics A high open circuit voltage setting provides the soft buffering arc with best resistance to pop outs pre ferred for most welding To get this characteristic set the CURRENT RANGE SELECTOR to the lowest set ting that still provides the current you need and set the FINE CURRENT ADJUSTMENT near maximum For example to obtain 175 amps and a soft arc set the CURRENT RANGE SELECTOR to the 190 120 posi tion and then adjust the FINE CURRENT ADJUST MENT for 175 amps When a forceful digging arc is required usually for vertical and overhead welding use a higher CURRENT RANGE SELECTOR setting and lower open circuit voltage For example to
103. f the enclosure panels of your machine E CLASSIC Il G 8 ELECTRICAL DIAGRAMS G 8 Idler PC Board M13708 Schematic NOT USED ES xi C YEL 8213 e 1 Return to Section TOC Return to Master TOC TO SOLENOID 1 WHITE B212 TO REED SW RED T13157 14 Return to Section TOC Return to Master TOC VDD 15V 022 RESET MONO IN 27V 5W IN 1 OSC INH OUT 1 DECODE e OUT2 D 8 BY PASS C CLOCK INH B i Vss 45368 B210 8211 O e e e BLUE P C BOARD IS CONNECTED DIRECTLY TO FRAME GND THRU MOUNTING SCREW olo o 515 0 gt 212 pile oO M16989 2DE GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 ROM CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED 5 70 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 0 8 DIODES 1 4000 UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET NOTES C POWER SUPPLY SOURCE POINT
104. g and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet clothing e e Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dan gerous 3 Keep your head out of fumes 40 Use ventilation or exhaust to remove fumes from breathing zone d WELDING SPARKS can cause Se fire or explosion Keep flammable material away Do not weld on containers that have held combustibles RAYS can burn Wear eye ear and body protection NY WARNING ENGINE EXHAUST can kill Use in open well ventilated areas vent exhaust to the outside 9 TN Do not stack anything on or near the engine MOVING PARTS can injure Do not operate this equipment with any of its doors open or guards off Stop the engine before servicing it AX Keep away from moving parts Only qualified personnel should install use or ser vice this equipment GENERAL DESCRIPTION The Classic Il is a heavy duty engine driven DC arc welding power source capable of providing constant current output for stick welding or DC TIG welding The Classic 11 is wound with all copper coils and is config ured in a new shorter case with no exciter stickout and setup for one side service With the addition of the optional Wire Feed Module the Classic II will pr
105. g regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s
106. gh any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician Keep all equipment safety guards covers before welding and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known Q 0 E All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure 1 6 some cases it may be necessary to remove safety them with tape when possible guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 2 Never coil the electrode lead around your body Always use the greatest care when working near moving parts 2 d 3 Do not place your body between the
107. gs 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 Turn the threaded screw counter clock wise to increase the HIGH IDLE speed Adjust the speed until the tach reads between 1780 and 1810 RPM Retighten the locking nut Adjust LOW IDLE First make sure there is no load on the machine Set the IDLE switch to AUTO and wait for the engine to change to low idle speed Use the 7 16 wrench to loosen the solenoid lever arm locking nut See Figure F 9 Adjust the collar to change the amount of throw in the lever arm until the tach reads between 1350 and 1400 RPM Retighten the locking nut Frequency Counter Method 1 Plug the frequency counter into one of the 115 VAC auxiliary receptacles Start the engine and check the frequency counter At HIGH IDLE 1800 RPM the counter should read 60 Hz At LOW IDLE 1400 RPM the counter should read 47 Hz Note that these are median measurements hertz readings may vary slightly above or below 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 8 for location of the adjusting screw and lock ing nut Turn the threaded screw counter clockwise to increase the HIGH IDLE speed Adjust the speed until the frequency reads 60 Hz Retighten the lock
108. her good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points components terminal strips etc can be found on the referenced elec trical_wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of iContents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC o 515 o PEN 9 gt 218 cic 5 5 a Return to Section TOC Return to Master TOC Return to Master TOC F 3 F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the machine OFF before working on equipment not touch electrically hot parts Some
109. htening the filter but only enough to stop leaks before placing the Classic back in service 6 If there no leaks stop the engine and recheck the oil level If necessary add oil to bring the level up to the upper dash mark but do not overfill FUEL At the end of each day s use refill the fuel tank to minimize moisture conden sation and dirt contamination in the fuel line Do not overfill leave room for the fuel to expand Refer to your engine operation manual for recom mended grade of fuel CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC E 515 PEN 9 gt 218 5 2 Return to Section TOC Return to Master TOC Return to Master TOC D 4 MAINTENANCE FUEL FILTER 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 follows 1 Close the fuel stopcock 2 Loosen the fuel filter cartridge see Figure D 1 with a removal tool and spin the cartridge off Catch any escaping fuel in an appropriate container 3 Clean the sealing surface of the filter carrier Apply a light film of oil or diesel fuel to the rubber gasket of the
110. il tee be e D 2 Change the eterne hear EE Red D 3 D 3 EC E A D 4 Alr CIO AMG Misi D 4 T COOLING aies D 4 e Current Range Selector Contacts 2 D 7 5 0 4 Tightening the Fan Belt D 4 Engine Maintenance D 5 Battery Maintenance sicura ovid Uta pud US eO MERE Su TUN dM D 6 tc Cleaning the Battery it re esa eia ep D 6 Checking Specific Gravity D 6 Checking Electrolyte D 6 Charging the Battery tertie D 6 Welder Generator Maintenance D 7 Sirm afl Mea 0 7 E T 0 7 8 Brush Removal and 0 7 Commutator and Brushes ir ert ete teta esu D 7 PROCS PLACIGS ies D 7 Cable Connections 2 6 capot qa dcus D 7 Idler Maintenarnce encore t decedere rectc f eee ee D 7 Major Component Locations dsrscs aaa aaa ba pata a aka
111. il cooler and overheating the engine Consult the Engine Operation Manual It is important to locate the welder to provide an unrestricted flow of clean cool air BEARINGS The Classic is equipped with double shielded ball bearings having sufficient grease to last indefinitely under normal service Where the welder is used constantly or in excessively dirty locations it may be necessary to add one half ounce of grease per year A pad of grease one inch wide one inch long and one inch high weighs approximately one half ounce Over greasing is far worse than insufficient greasing When greasing the bearings keep all dirt out of the area Wipe the fittings completely clean and use clean equipment More bearing failures are caused by dirt introduced during greasing than from insufficient grease TIGHTENING THE FAN BELT Fan Belts tend to loosen after the first 50 hours of operation If the fan belts are loose the engine can overheat and the bat tery can lose its charge Check belt tightness by press ing on the belt midway between the pulleys The cool ing blower belt should deflect no more than 10 to 15 mm 0 28 to 0 35 in See Figure D 2 To adjust the cooling blower belt loosen bolts 1 and 2 then push idler pulley 3 outward until the correct belt tension is achieved Retighten bolts 1 and 2 FIGURE D 2 TIGHTENING THE COOLING BLOWER BELT CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Retur
112. ine control include a two position IGNITION ON OFF toggle switch a START pushbutton and a two position IDLER switch that selects engine speed for welding or auxiliary power applications See Oneraon n the Operation section of this manual for details about starting run ning stopping and breaking in the diesel engine DESIGN FEATURES Constant current DC Stick welding SMAW process capability with output range from 40 325 DC amps Constant current DC TIG Welding with output across the entire range of settings Work and Electrode welding cable mounting termi nals Separate ground stud for safe connection of case to earth ground Duplex 230 volt auxiliary power receptacle Duplex 115 volt auxiliary power receptacles Integrated generator output overload protection through two 20 amp circuit breakers CSA versions Electric starting Battery Charging Ammeter Engine Oil Pressure Gauge Engine Hour Meter for determining periodic mainte nance Top of the line 28 5 HP Deutz diesel engine Top mounted 15 gallon 57 0 litter fuel tank with convenient top fill All copper alternator windings and high quality insu lation for dependable long life Automatic engine shutdown protection for low oil pressure Automatic engine idler goes to low idle approximate ly 15 seconds after welding for greater fuel economy includes high idle switch CLASSIC II LINCOLN B Return to Section TOC Return to
113. ing nut CLASSIC II LINCOLN B Adjust LOW IDLE First make sure there is no load on the machine Set the IDLE switch to AUTO and wait for the engine to change to low idle speed Use the 7 16 wrench to loosen the solenoid lever arm locking nut See Figure 9 Adjust the col lar to change the amount of throw in the lever arm until the frequency reads 47 Hz Retighten the locking nut Oscilloscope Method 1 Connect the oscilloscope to the 115 VAC receptacle according to the manufacturer s instructions At HIGH IDLE 1800 RPM the waveform should exhibit a period of 16 6 milliseconds At LOW IDLE 1400 RPM the should S a period of 21 ne NORMAL VAC SUPPLY HIGH IDLE NO LOAD jn this section of the manual If either of these periods is incorrect adjust the throttle as follows Adjust HIGH IDLE Use the 10mm wrench loosen the locking nut See F for location of the adjusting screw and lock ing nut Turn the threaded screw counter clockwise to increase the HIGH IDLE speed Adjust the speed until the period is 16 6 mil liseconds Retighten the locking nut Adjust LOW IDLE First make sure there is no load on the machine Set the IDLE switch to AUTO and wait for the engine to change to low idle speed Use the 7 16 wrench to loosen the solenoid lever arm locking nut 52 the col lar to change the amount of throw in the lever arm until the period is 21 4 millisec
114. ion TOC olo Fle PEN 2 1 Return to Section TOC Return to Master TOC Return to Master TOC C 8 ACCESSORIES CONNECTION OF THE K488 SG CONTROL MODULE AND K487 MAGNUM SPOOL GUN TO THE CLASSIC SEE FIGURE C 5 1 Shut the welder off 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 NOTE Figure C 5 shows the electrode connect ed for positive polarity To change polari ty shut the welder off and reverse the electrode and work cables at the Classic output terminals 3 Connect the K867 Universal adapter to the K492 input cable as shown in Figure C 5 Connect the other end of the adapter to the 14 pin amphenol on the Classic Il 4 Connect the K492 Input Cable to the SG Control Module 5 Set the slide switch on the SG Control Module to the Lincoln position CAUTION Be sure this switch is set to the Lincoln contact clo sure position before attempting to operate the SG Control Module Incorrect switch position could result in damage to the SG Control Module and or the CLASSIC II 6 Place the IDLER switch on the Classic Il in the HIGH position CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle
115. irty or poorly seated DOC generator brushes 3 The armature commutator may need cleaned Check for loose or faulty weld ing cables TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Check the Fine Current Adjust ment rheostat for resistance and proper operation Normal resistance is 64 ohms Check associated wires for loose or faulty connections Wiring Diagram Perform the Shunt Field Wind See the Check the Current Range Selector Switch and contacts for proper operation While the machine is loaded check the interpole and series coils for signs of arcing This condition would point to shorted turns in the arcing coil The main armature may be faulty Check for grounds CAUTION If for any reason you do understand the test procedures or 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 CLASSIC II LINCOLN B 7 F 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Return to Section TOC Return to Master TOC The engine starts and runs at the 1 Check the AC auxiliary output 1 Check for loose or faulty con correct speed but the
116. is is an added precaution When full the oil level should be up to but not over the FULL mark on the dipstick If it is not full add enough oil to fill it to the full mark DO NOT overfill NOTE This unit is equipped with an Engine Protection Package internal kill switch will shut down the engine if the oil pressure drops below a minimum oper ating specification or if the oil temperature reaches an excessive level For more oil fill and service information see the Maintenance section of this manual FUEL Fill the fuel tank with clean diesel fuel only The Classic has 15 gallon 57 liter fuel tank with a top fill and fuel gauge mounted on the control panel See the and Maintenance sections of this manual for more details about fuel BATTERY CONNECTIONS The Classic is shipped with the negative battery cable disconnected Before you operate the machine make sure the IGNITION switch is in the OFF position and attach the disconnected cable securely to the battery terminal If the battery is discharged and won t start the engine see the battery charging instructions in the Maintenance section CLASSIC II LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo Fle 515 PEN 2 2 mlt 5 2 1 Return to Section TOC Return to Master TOC Return to Master TOC A 5 INSTALLATION MUFFLER This welder is supplied with an
117. leads for loose the current transformer for loose or faulty connections or faulty connections See the 2 The load may be too small The waning Diagram load must be above 150 watts Check the current transformer for opens in the windings The PC board may be faulty CAUTION 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 CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 8 E Return to Section TOC Return to Master TOC O 4 0 9 2 tc F 10 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The engine will NOT go to high speed when either a welding load or an auxiliary load is connected to the Classic The machine has normal output and engine speed when the Idler switch is in the High position POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Check the welding cables and auxiliary load leads for loose or faulty connections Check for mechanical restric tions or missing parts in the idler and throttle linkage Springs etc
118. m is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside of the enclosure panels of your machine E CLASSIC Il G 5 ELECTRICAL DIAGRAMS G 5 Wiring Diagram Code 10071 ELECTRICAL SYMBOLS 2 t PER E1537 SHOWN AS VIEWED FROM 4181 CONNECTOR LEAD COLOR CODE NEUTRAL BONDED TO FRAME 812 317 NEUTRE RACCORDE AU o 9 B BLACK R RED 216 G GREEN U BLUE Ww cle 115 N BROWN W WHITE B 2 5 Y YELLOW ilz ENGINE NOTES ALTERNATOR ROTOR a ENGINE PROTECTION N A EARLIER MODELS DO NOT SLIP RINGS RELAY HAVE THIS DIODE K HOUR 99 610 m MM 7 T
119. mall gear puller olo E 515 PEN 9 gt 218 5 2 Return to Section Return to Master TOC CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 2 3 g 5 32 32 TROUBLESHOOTING amp REPAIR ALTERNATOR ROTOR REMOVAL AND REPLACEMENT continued PROCEDURE Turn the engine off Unlatch lift and secure the right side door There are latches on both sides With the 1 2 wrench disconnect the negative battery cable With 3 8 socket wrench remove the left case side With the 1 2 wrench remove the exhaust pipe rain cap With the 1 2 and 9 16 wrenches remove the four nuts and bolts securing the case top and door assembly Remove the case top and door assembly See Figure F 11 for steps 7 10 7 With the 1 2 wrench remove the battery terminal cables Remove negative cable first Then remove the two nuts and split ring lock washers holding the battery retain er clamp Remove battery With the 1 2 wrench remove the six bolts nuts and lock washers holding the case front to the frame three on each side With the 5 16 nut driver remove the two sheet metal screws from the right side of the case front These screws hold the out
120. ment F 22 Flashing the Feldes eie OR F 26 Oscilloscope WaVeforITIs ecco eu e UR de a ea DR Fake F 28 gt Normal Open Circuit Voltage Waveform 115VAC Supply F 28 Normal Open Circuit DC Weld Voltage F 29 5 Typical DC Weld Output Voltage Waveform sss F 30 o Replacement Procedures 4 2 1 nnne 31 Alternator Rotor Removal and F 31 E Alternator Stator Removal and Replacement sse F 38 E Generator Frame Removal and F 43 Generator Armature Removal and F 46 Retest iu ecrire Per dad che pc ree dg te LU re etre lg p ee aen F 48 5 8 9 gt g E 2 2 ra 5 9 gt g E 2 o CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC He o 2 E Return to Section TOC Return to Master TOC D g 5 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service
121. n Return to Master TOC CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section TOC Return to Master TOC D 5 39 TROUBLESHOOTING amp REPAIR ALTERNATOR STATOR REMOVAL AND REPLACEMENT continued FIGURE F 16 COMMUTATOR WRAP AROUND REMOVAL PROCEDURE Turn the engine OFF Perform the Alternator Rotor Removal procedure With the 3 8 nut driver remove the two leads from the alternator brush holder assembly Note lead placement Set brush holder aside With the 3 8 wrench remove the bottom alternator cover With the slot head screwdriver remove the commutator wrap around See Figure 16 Disconnect the yellow and white wires at the in line connectors See the Wiring Diagram and Figure F 17 Disconnect the two yellow leads One is located at the field bridge and the other at the field fuse holder See Figure F 17 and CLASSIC II LINCOLN B COMMUTATOR WRAP AROUND ALTERNATOR BRUSH HOLDER ASSEMBLY REMOVED 10 11 12 Remove the black auxiliary power lead from the current transformer On newer machines the black lead will be threaded through the current transformer donut and connected to the circuit brea See ker the Wiring Diagram a
122. n to Section TOC Return to Master TOC 9 o 2 3 Return to Section TOC Return to Master TOC g 5 TABLE D 1 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 Change engine oil Change oil filter Change fuel filter Check fan belt Every 50 Hours Check fuel lines and clamps Every 100 Hours Check battery electrolyte level and connections Refer to your Deutz engine Owner s Manual for periodic maintenance at 100 hours and beyond CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC md o 2 3 Return to Section TOC Return to Master TOC 5 BATTERY MAINTENANCE WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery Follow the instructions printed on the battery To prevent EXPLOSION when INSTALLING A NEW BATTERY Disconnect the negative cable from the old battery first and connect to
123. nd Remove the red auxiliary power lead from the circuit breaker Diagram See the Wiring Remove the white auxiliary power lead from the 115VAC receptacle Cut any nec essary cable ties Remove the red lead from the negative ter of the field rectifier bridge See Remove the black lead from the positive terminal of the field rectifier bridge Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 2 2 1 Return to Section TOC Return to Master TOC F 40 F 40 TROUBLESHOOTING amp REPAIR ALTERNATOR STATOR REMOVAL AND REPLACEMENT continued FIGURE F 17 LEAD DISCONNECTION POINTS YELLOW AND WHITE WIRE IN LINE CONNECTORS BEHIND CASE FRONT VY FIGURE F 18 LEAD DISCONNECTION CIRCUIT BREAKER RECEPTACLES AND FIELD BRIDGE RECTIFIER 230 VAC RECEPTACLE 115 VAC RECEPTACLE nd BREAKER FIELD BRIDGE RECTIFIER CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 2 2 1 Return to Section TOC Return to Master TOC F 41 F 41 TROUBLESHOOTING amp REPAIR ALTERNATOR STATOR REMOVAL AND REPLACEMENT continued 14 Clear the leads in preparation for remov 15 Lift the eight brushes from th
124. ne high speed is controlled by the governor 2 In the AUTO position the idler operates as fol lows a When welding or drawing power for lights or tools approximately 100 150 watts minimum from the receptacles the engine operates at full speed b When welding ceases or the power load is turned off a preset time delay of about 15 sec onds starts This time delay cannot be adjust ed c If the welding or power load is not re started before the end of the time delay the idler reduces the engine to low idle speed CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 2 3 Return to Section TOC Return to Master TOC D g 5 TO USE THE CLASSIC FOR DC CONSTANT 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 cables at the welder s output terminals See Figure B 4 Replace and tighten the flange nuts securely Be sure the connections are tight Select the appropriate electrode Attach the work clamp securely to the work you are welding Insert the electrode int
125. ng Headshield and filter lens should conform to ANSI 287 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used
126. nnect the blue and brown wires at their in line connectors Perform the replacement procedures according to each of the following Alternator Stator Removal and Replacement Alternator Rotor Removal and Replacement Before installing the machine case top and sides be sure to replace any cable ties cut during disassembly 46 46 TROUBLESHOOTING amp REPAIR GENERATOR ARMATURE REMOVAL AND REPLACEMENT WARNING 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD PE sis DESCRIPTION 3 E This procedure will aid the technician in the removal and replacement of the main armature 2 2 EIE MATERIALS NEEDED 5 8 wrench Rope sling Wood or steel blocks Fle 515 PEN 9 gt 218 mlt 5 2 1 Return to Section TOC Return to Master TOC CLASSIC II LIN
127. o the electrode holder Start the Diesel Engine See Engine Operation n this section of the manual Set the Idler Switch to AUTO T Set the CURRENT RANGE SELECTOR to a set ting equal to or slightly higher than the desired welding current Set the FINE CURRENT ADJUSTMENT to the set ting that gives the best arc characteristics for the range selected See Control of Welding Current in this section of the manual Strike an arc and begin welding After you finish welding 1 Stop the engine See Engine Operation in this section of the manual Allow the electrode and work to cool completely Remove the work clamp from the work Remove any remaining piece of electrode from the electrode holder FIGURE B 4 WELDING CIRCUIT CONNECTIONS FOR STICK WELDING OUTPUT TERMINALS ELECTRODE CABLE ELECTRODE HOLDER ELECTRODE WORK PIECE WORK CLAMP WORK CABLE 2 2 9 CLASSIC II LINCOLN B e TO USE THE CLASSIC II FOR DC WIRE 4 Setthe Switch to AUTO 5 5 FEED WELDING CONSTANT VOLTAGE 5 Set the CURRENT RANGE SELECTOR to a set 8 WITH WIRE FEED MODULE ting appropriate for your wire size and speed See 1 Connect the LN 25 or LN 7 Wire Feeder with wire Table B 1 for recommended settings feed module Follow the installation instructions 6 Set the VOLTAGE ADJUSTMENT to the setting 5 3 provid
128. olts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manual 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 CLASSIC II LN 7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM 14 PIN Classic 11 Output Terminals are on Opposite Side TO WORK ELECTRODE CABLE TO LN 7 AMPHENOL K864 ADAPTER LN 7 CONTROL 14 PIN BOX K584 L INPUT CABLE 6 PIN AMPHENOL K857 REMOTE CONTROL CLASSIC II LINCOLN B 6 6 INSTALLATION CONNECTION OF THE LN 25 TO THE 4 Connect the K433 to the LN 25 Mount the K433 CLASSIC USING K867 UNIVERSAL to the welder according to instructions included ADAPTER SEE FIGURE C 3 5 Place the IDLER switch the HIGH position 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 CAUTION NOTE Welding cable must be sized for current and duty cycle of application Return to Section TOC Return to Master TOC Any increase of the high idle engine RPM by changing the governor setting or overriding the throt
129. on when the engine is running you may damage the engine flywheel gear or starter motor ENGINE HOUR METER Records engine running time Use the meter to determine when to perform required maintenance AMMETER Shows whether the charging circuit is performing its job of charging the battery when the engine is running The meter will register discharge during starting but then the needle should return to a position slightly toward positive during running The needle will hold position in the center when the engine stops OIL PRESSURE GAUGE Indicates engine oil pressure If no oil pressure shows on the gauge within 30 seconds after startup the engine should be stopped by placing the IGNITION switch in the OFF position LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 2 E Return to Section TOC Return to Master TOC D g 5 A WARNING DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS The maximum allowable high idle speed for the Classic Il 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 included in the Deutz engine instruction manual tha
130. or more details see Pe rere Meee of this manual CAUTION During break in subject the Classic II to only moderate loads Avoid long periods running at idle Before stop ping the engine remove all loads and allow the engine to cool several minutes CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 2 3 Return to Section TOC Return to Master TOC D g 5 10 WELDING OPERATION GENERAL INFORMATION The Classic 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 ADJUSTMENT on the output control panel to the set tings that are best for your selected welding process IDLER OPERATION Start the engine with the IDLER switch in the HIGH position Allow it to run at high idle speed for several minutes to warm the engine See Technical 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 engi
131. or positive polarity To change polarity shut the welder off and reverse the elec trode and work cables at the Classic Il output terminals 3 Connect the K867 Universal Adapter to the K291 or K404 input cable and the 14 pin amphenol of the Classic as indicated in Figure C 1 Make the proper connections for local or remote control according to Figure C 1 4 Connect the K291 or K404 input cable to the LN 7 5 Place the IDLER switch in the HIGH position CAUTION Any increase of the high idle engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the AC auxiliary voltage this voltage goes over 140 volts wire feeder control circuits may be damaged The engine governor set ting is preset at the factory do not adjust above RPM specifications listed in this manual 6 Adjust wire feed speed and voltage at the LN 7 NOTE For remote control a K775 remote control is required See Figure C 1 CAUTION When the welder is in local control the electrode is always HOT FIGURE C 1 CLASSIC II LN 7 WITH K867 ADAPTER CONNECTION DIAGRAM Classic Il Output Terminals are on Opposite Side CV TO WORK K867 UNIVERSAL ADAPTER PLUG ELECTRODE CABLE TO LN 7 Unused Lead SPARE 82 Insulate Each LN 7 CONTROL BOX Individually 32 2 2 2 4 4 21 21 291 OR K404
132. or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c CLASSIC II CYLINDER may explode i if damaged 7 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operatin
133. ot build up there are a num ber of possible causes such as loose or missing brushes open leads or poor con nections at the field diode bridge or between the exciter alternator brushes and the gener he PROBLEMS in Troubleshooting Guide located in this section of the manual for recommended action Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC E 515 PEN 812 218 5 2 Return to Section TOC Return to Master TOC F 28 F 28 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY HIGH IDLE NO LOAD FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM 16 6 ms 0 volts 50 volts 5 ms This is the typical auxiliary output voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal division rep resents 5 milliseconds in time Note Scope probes connected at machine 115VAC receptacle SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Trigger Internal CLASSIC II LINCOLN B F 29 F 29 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
134. ove For Diesel Engines The Above For Gasoline Engines WELDING CAN HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society Box 351040 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 t T FOR ENGINE 8 7 us 1 h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment 2 y f hot 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines open well ventilated areas or vent the engine exhaust fumes outdoors Return to Master TOC ELECTRIC AND 9 MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld S may be dangerous ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric current flowing throu
135. ovide constant voltage output for running the LN 7 or LN 25 This unit uses the Deutz F3L 1011F three cylinder industrial air cooled diesel engine CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section TOC Return to Master TOC g 5 3 RECOMMENDED APPLICATIONS WELDER The Classic provides excellent constant current DC welding output for stick SMAW welding and for DC TIG welding It also offers constant voltage output for DC semiautomatic wire feed welding For more detail on using the machine as a welder see the Operation section of this manual GENERATOR The Classic is also capable of providing 3 0 kVA of 115 230 volts of 60 Hertz AC auxiliary power OPERATIONAL FEATURES AND CONTROLS The Classic was designed for simplicity Therefore it has very few operating controls Two switches are used for welding operations A five position CURRENT RANGE SELECTOR switch selects current output for constant current stick or TIG applications and constant voltage wire feed applications with optional Wire Feed Module see the Accessories section A FINE CURRENT ADJUSTMENT switch for fine adjustment of current from minimum to maximum within each range Controls for the diesel eng
136. positive brusholders to the positive out put terminal and should NOT be grounded to the generator frame Check the continuity of the series coils They should show continuity from the negative brusholders through the Current Range selector switch to the negative output terminal and should NOT be grounded Also check the Selector Switch for proper operation 5 The main armature may be faulty Check for grounds and or shorts CAUTION 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 CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC He o 8 E Return to Section TOC Return to Master TOC O 7 9 2 tc F 6 F 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The welding output varies abnor mally The auxiliary output remains constant The engine is operating correctly POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS May be a normal condition The machine will normally lose some output as the components get heated Check for loose worn d
137. put terminal assembly to the case front With the 3 8 wrench remove the screw from the bottom center of the case front holding the front to the frame FIGURE 11 CASE FRONT REMOVAL PREPARATION TERMINAL CABLES BATTERY REMOVE RETAINER olo FASTENERS FASTENERS 5 5 o 9 5 2 X CLASSIC II LINCOLN B F 33 F 33 TROUBLESHOOTING amp REPAIR ALTERNATOR ROTOR REMOVAL AND REPLACEMENT continued Return to Section TOC Return to Master TOC See Figure 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 13 Using pliers remove the fuel return line from the top of the fuel tank 14 Slightly lift the fuel tank and remove the cable retainer A large screwdriver will be required to pry the cable retainer from the fuel tank rail bolts and washers that mount the fuel tank to the rails 15 Carefully remove the fuel tank Return to Section TOC Return to Master TOC FIGURE F 12 FUEL TANK REMOVAL FUEL TANK MOUNTING HARDWARE O10 515 gt oO 1 FUEL BOWL olo 2 8 5 5 9 8 3a cm CLASSIC II LINCOLN B 34 34 TROUBLESHOOTING amp REPAIR ALTERNATOR ROTOR REMOVAL AND REPLACEMENT
138. re is no AC circuit breakers Reset if nections between the recepta auxiliary output voltage The DC tripped cles the circuit breakers the welding generator is functioning Check the 115VAC current transformer and the correctly 230VAC receptacles and plugs exciter alternator stator See the Wiring Diagram for loose or faulty connections Check the 115VAC and 230VAC windings in the alterna tor stator for shorted turns or grounds Check the continuity of the windings See the Wiring Diagram The engine starts and runs normal Contact your local Authorized Check the flashing diode ly The machine takes a long time Field Service Facility located on the DC generator to build up and produce output brush holder The diode may voltage The AC auxiliary voltage be shorted or installed incor varies when the Fine Current rectly Control Rheostat is adjusted Return to Section TOC Return to Master TOC Fle els nl 2 2 2 1 CAUTION If for any reason you do not understand the test procedures or 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 Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master
139. recommendations Mar 95 LINCOLN B Return to Master Return to Master TOC 7 E Return to Master TOC SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes 6 S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre l
140. rodes with your skin or wet clothing e Insulate yourself from the work and ground e Always wear dry gloves insulating ENGINE EXHAUST can kill e Use in open well ventilated areas or vent exhaust to the out side Do not stack anything on or near the engine MOVING PARTS can injure Do not operate this equipment with any of its doors open or guards off Stop the engine before servicing it Keep away from moving parts See additional safety information at the front of this manual Only qualified personnel should install use or ser vice this equipment LOCATION AND VENTILATION Always operate the Classic Il with the doors closed 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 Whenever you use the Classic 11 be sure that clean cooling air can flow through the machine s diesel engine and the generator Avoid dusty dirty areas Also keep the machine away from heat sources Do not place the back end of the generator anywhere near hot engine exhaust from another machine And of course make sure that engine exhaust is ventilated to an open outside area The Classic may be used outdoors Do not set the machine in puddles or otherwise submerge it in w
141. s cut for disas sembly 43 43 TROUBLESHOOTING amp REPAIR GENERATOR FRAME REMOVAL AND REPLACEMENT WARNING 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD O10 EE DESCRIPTION oz This procedure will aid the technician in the removal and replacement of the DC generator 88 frame EIE 2 2 o cc MATERIALS NEEDED 3 4 wrench Rope sling 1 2 wrench 5 8 wrench Wood or steel blocks Pry bars Fle 515 PEN 9 gt 218 mlt 5 2 1 Return to Section TOC Return to Master TOC CLASSIC II LINCOLN B 44 44 TROUBLESHOOTING amp REPAIR GENERATOR FRAME REMOVAL AND REPLACEMENT continued FIGURE 21 GENERATOR LEAD AND CABLE CONNECTIONS Return to Section TOC Return to Master TOC SELECTOR SWITCH CABLES
142. t is shipped with your Classic 11 BEFORE STARTING THE ENGINE Check and fill the engine oil level 1 Be sure the machine is on a level TA surface 2 Remove the engine oil dipstick and wipe it with a clean cloth Reinsert the dipstick_and check the level on the dipstick See Figure D 1 in the Maintenance section of this manual 3 Add oil if necessary to bring the level up to the full mark Do not overfill 4 Replace the dipstick Check and fill the engine fuel tank A WARNING Do not add fuel near an open flame welding arc or when the engine is run ning Stop the engine and allow itto cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been elimi nated 1 Remove the fuel tank cap 2 Fill the tank to allow approximately 1 4 inch 5 mm of tank space for fuel expansion DO NOT FILL THE TANK TO THE POINT OF OVERFLOW 3 Replace the fuel tank cap and tighten securely NOTE USE DIESEL FUEL ONLY Purchase diesel fuel in quantities that will be used within 30 days to assure freshness STARTING THE ENGINE NOTE Remove all loads connected to the AC power receptacles before starting the diesel engine 1 Place the IDLER switch in the HIGH position the IGNITION switch in the ON position and then press the START button
143. t would be in its normal level condition Also fuel capacity will be a little less at an angle LIFTING The Classic weighs 1340 1b 608 kg A lift bail is provided for lifting with a hoist WARNING FALLING EQUIPMENT can cause injury Do not lift this machine using lift bail if it is equipped with a heavy accessory Such as a trailer 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 PRE OPERATION ENGINE SERVICE Read and understand the information about the diesel engine in the Operation and Maintenance sections of this manual before you operate the Classic Il WARNING Keep hands away from the engine muffler or HOT engine parts Stop the engine when fueling Do not smoke when fueling Remove the fuel cap slowly to release pressure Do not overfill the fuel tank Wipe up spilled fuel and allow the fumes to clear before starting the engine Keep sparks and flame away from the fuel tank OIL The Classic is shipped with the engine T Z filled with SAE 10W 30 class CC DO This should be fine for most ambient operating temperature conditions See the engine operation manual for specific recommenda tions CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE Th
144. tacle has a configuration which permits 15 amps on CSA machines and 20 amps on non CSA machines to be drawn from either half The total com a load of all receptacles is not to exceed 3 0 kVA AET use Table B 2 Generator Power Applications to determine the wattage requirements of the most common types of loads you can power with the Classic Il Be sure to read the notes at the bottom of the table Return to Section TOC Return to Master TOC An optional power plug kit is available When this kit is specified the customer is supplied with a plug for each receptacle See the of this man ual An optional GFCI 115 volt receptacle kit is also avail able Note that the use of this GFCI kit reduces avail able current to 15 Amps from each half of the duplex receptacle and to a total of 20 Amps of available 115 volt power See the Accessories section of this manual To use the generator as an auxiliary power supply 1 Start the diesel engine See Engine Operation in this section of the manual 2 Setthe IDLER switch to AUTO Set the CURRENT RANGE SELECTOR to MAX See 3 Plugthe load s into the appropriate 115 volt or 230 volt power receptacle O o 515 9 gt 218 cic 5 2 a Return to Section TOC Return to Master TOC A LINCOLN amp O10
145. tery failure CHECKING SPECIFIC GRAVITY Check each battery cell with a hydrometer fully charged battery will have a specific gravity of 1 260 Charge the battery if the reading is below 1 215 NOTE Correct the specific gravity reading by adding four gravity points 0 004 for every five degrees the electrolyte temperature is above 80 degrees F 27 degrees C Subtract four gravity points 004 for every five degrees the electrolyte temperature is below 80 degrees F 27 degrees C CHECKING ELECTROLYTE LEVEL If battery cells are low fill them to the neck of the filler hole with distilled water and recharge If one cell is low check for leaks CHARGING THE BATTERY The Classic is equipped with a wet charged battery The charging current is automatically regulated when the battery is low after starting the engine to a trickle current when the battery is fully charged When you charge jump replace or otherwise connect battery cables to the battery be sure the polarity is cor rect Improper polarity can damage the charging cir cuit The Classic charging system is NEGATIVE GROUND The positive battery terminal has a red terminal cover If you need to charge the battery with an external charger disconnect the negative cable first then the positive cable before you attach the charger leads After the battery is charged reconnect the positive bat tery cable first and the negative cable last Failure to do
146. times machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect board using standard practices to avoid static elec trical damage and electrical shock Read the warn ing inside the static resistant bag and perform the following procedures PC Board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg IWAN ATTENTION Static Sensitive ohm resistive cord connected to a Devices grounded part of the equipment Handle only at frame Static Safe e If you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent sta tic build up Be sure not to touch any electrically live parts at the same time Workstations Reusable Container Do Not Destroy Tools which come in contact with the PC Board must be either conductive anti static or static dissipative Remove the PC Board from the st
147. tion PC board may be faulty The engine fuel injectors may need service CAUTION 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 CLASSIC II LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC md 9 o 8 E Return to Section TOC Return to Master TOC O E o 9 2 12 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The welding arc is loud and spat ters excessively The welding arc frequently pops out Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS The current setting may be too high for the electrode and process The polarity may be wrong for the electrode and process The Fine Current Control Rheostat may be set too low for the process and electrode Check the welding cables for loose or faulty connections RECOMMENDED COURSE OF ACTION Check the engine speed High idle speed should be 1800 RPM Check the DC generator brush es for good commutation and alignment Contact the Lincoln Electric Service
148. tle linkage NOTE Figure shows the electrode connected for will cause an increase in the AC auxiliary voltage If positive polarity To change polarity shut the this voltage goes over 140 volts wire feeder control welder off and reverse the electrode and work circuits may be damaged The engine governor set cables at the Classic output terminals ting is preset at the factory do not adjust above Reverse the LN 25 polarity switch RPM specifications listed in this manual 3 Connect the K867 Universal adapter to the K432 L cable and the 14 pin amphenol of the Classic II as 6 Adjust wire f It t the LN 25 indicated in Figure C 3 djust wire feed speed and voltage at the 5 Return to Master TOC FIGURE C 3 CLASSIC II LN 25 CONNECTION DIAGRAM Return to Section TOC ___ 4 PIN ae Insulate Each Classic Output 2 Unused Lead K433 Terminals are on 41 Individually Opposite Side 21 31 31 32 32 Bin O CV gt K432 L CABLE K867 UNIVERSAL 515 o PEN 9 gt 218 5 5 a ADAPTER PLUG 75 75 76 76 We 77 77 LN 25 WIRE FEEDER WORK WITH K431 OPTION Splice Leads and Insulate ELECTRODE CABLE O10 Fle 912 Ola nl 218 EIE 212 CLASSIC LINCOLN B ACCE
149. unning 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 Welding The engine accelerates to high speed when the electrode touches the work and strikes a welding arc The engine returns to low idle approx imately 15 seconds after welding stops as long as no auxiliary power is being drawn Auxiliary Power The engine accelerates to high speed when power is drawn at the receptacles for lights or tools The engine returns to low idle approximately 15 seconds after demand for auxiliary power stops IGNITION CONTROL TOGGLE SWITCH Has two positions ON and OFF When the switch is in the ON position the diesel engine can be started by pressing the START pushbutton When the switch is placed in the OFF position the engine stops ENGINE PROTECTION WARNING LIGHT Lights when the engine protection system an internal kill switch has shut down the engine The system activates in response to low oil pressure or high oil temperature If the light comes on during startup cranking or after the engine starts the IGNITION switch must be placed in the OFF position to reset the engine protection system CLASSIC II START PUSHBUTTON Press this button to start the diesel engine The IGNITION switch must be in the ON position NOTE If you press the START pushbutt
150. wer is being used the current is passed through the current trans former This signals the idler PC board to release the idler solenoid When welding ceases or the auxiliary load is removed a preset time delay of about 15 seconds starts After approximately 15 seconds the idler PC board activates the idler solenoid and the machine will return to a low speed condition NOTE Unshaded areas of Block Logic Diagram are the subject of discussion CLASSIC II LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fle 515 5 1 Return to Section TOC Return to Master TOC E 5 E 5 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 The armature coil sides are placed at opposite points on the rotating shaft with the conductors parallel to the shaft The armature assembly is normally turned at a constant speed by a source of mechanical power con nected to the shaft Rotation of the armature through the magnetic field produced by the stationary field winding induces a coil voltage in the armature winding The voltage induced in an individual armature coil is an alternating AC voltage which must be rectified In a

Lincoln Electric CLASSICII SVM125-A User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents