SVM125-A
October 1996
TM
CLASSIC II
For use with machine code numbers 9805 to 10220
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation .
. . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
SERVICE MANUAL
World’s Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
Sales and Service through subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
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ii
ii
SAFETY
ARC RAYS can burn.
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.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
4.c. 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.
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
scaffolds; 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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5.b. 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.
3.g. Never dip the electrode in water for cooling.
3.h. 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.
5.c. Shielding gases used 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
5.d. 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.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
CLASSIC II
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iii
iii
SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. 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.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. 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.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut 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).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. 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.
FOR ELECTRICALLY
powered equipment.
6.g. 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.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
CLASSIC II
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iv
iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés 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
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93
CLASSIC II
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v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Technical Specifications..............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation..............................................................................................................A-3
Pre-operation Engine Service .....................................................................................................A-4
Operation...............................................................................................................................Section B
General Description ....................................................................................................................B-2
Operational Features and Controls.............................................................................................B-3
Accessories ..........................................................................................................................Section C
Maintenance..........................................................................................................................Section D
Routine and Periodic Maintenance.............................................................................................D-2
Major Component Locations.......................................................................................................D-8
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair................................................................................................Section F
Electrical Diagrams..............................................................................................................Section G
Parts Manual ................................................................................................................................P-219
CLASSIC II
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Section A-1
Installation
Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Technical Specifications..............................................................................................................A-2
Rated Output – Welder.........................................................................................................A-2
Output – Welder and Generator...........................................................................................A-2
Physical Dimensions.............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation..............................................................................................................A-3
Storing .................................................................................................................................A-3
Stacking................................................................................................................................A-4
High Altitude Operation.........................................................................................................A-4
Pre-operation Engine Service .....................................................................................................A-4
Fuel.......................................................................................................................................A-4
Battery Connections .............................................................................................................A-4
Spark Arrester.......................................................................................................................A-5
Undercarriages .....................................................................................................................A-5
Cable Installation, Polarity Control, and Cable Sizes..............................................A-6
Auxiliary Power Receptacles, Plugs, and Hand-held Equipment.........................................A-7
Circuit Breakers ....................................................................................................................A-7
CLASSIC II
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - CLASSIC II
INPUT - DIESEL ENGINE
Manufacturer Description
Speed
Displacement
Ignition
Capacities
Deutz
F3L-1011F
3 cyl.,
Air-cooled
diesel
28 HP @
1700 RPM
1725 RPM
Full load
125 cu. in.
(2049 cc)
Electric
Fuel: 15 gal.
(57 liters)
Oil: 6.3 qt.
(6.0 liters)
1800 RPM
High idle
1350 RPM
Low idle
RATED OUTPUT - WELDER
Duty Cycle
Amps
Volts at Rated Amperes
100% Duty Cycle
60% Duty Cycle
40% Duty Cycle
200 DC Constant Current
250 DC Constant Current
300 DC Constant Current
28V
40V
32V
OUTPUT - WELDER AND GENERATOR
Welding Ranges Max. Open Circuit Voltage
Auxiliary Power(1)
40-325 Amps DC
98.5
3.0 kVA of 115/230 V, 60Hz Power
26 Amps @ 115 V
13 Amps @ 230 V
PHYSICAL DIMENSIONS
Height
Width
Depth
Weight
49.94 in.
1040 mm
24 in.
610 mm
60 in.
1524 mm
1340 lb.
608 kg
1
CSA machines can draw 15 amps from either half of the receptacle. Non-CSA machines can draw 20 amps from either half of the
receptacle. Total combined load of all receptacles cannot exceed 3.0 kVA.
CLASSIC II
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A-3
A-3
INSTALLATION
Read this entire installation section before you
start installation.
LOCATION AND VENTILATION
Always operate the Classic II 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.
SAFETY PRECAUTIONS
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,
operating, and maintenance instructions; and parts
lists.
Whenever you use the Classic II, 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.
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrodes with your
skin or wet clothing.
The Classic II may be used outdoors. Do not set the
machine in puddles or otherwise submerge it in water.
Such practices pose safety hazards and cause improp-
er operation and corrosion of parts.
• Insulate yourself from the work
and ground.
• Always wear dry insulating
gloves.
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.
ENGINE EXHAUST can kill.
• Use in open, well ventilated
areas or vent exhaust to the out-
side.
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 Maintenance section of
this manual for details on changing oil.
• Do not stack anything on or near
the engine.
3. Remove the battery, recharge it, and adjust the
electrolyte level. Store the battery in a dry, dark
place.
MOVING PARTS can injure.
• Do not operate this equipment
with any of its doors open or
guards off.
4. See your engine operation manual for further infor-
mation on fuel and engine preservation.
• 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.
CLASSIC II
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A-4
A-4
INSTALLATION
STACKING
WARNING
Classic II machines CANNOT be stacked.
Keep hands away from the engine muffler or HOT
engine parts.
• Stop the engine when fueling.
TILTING
• Do not smoke when fueling.
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.
• 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.
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 it would be in its normal
level condition. Also, fuel capacity will be a little less at
an angle.
• Keep sparks and flame away from the fuel tank.
OIL
The Classic II is shipped with the engine
filled with SAE 10W-30 oil (API class
CC/DO). This should be fine for most
LIFTING
ambient operating temperature conditions. See the
engine operation manual for specific recommenda-
tions. CHECK THE OIL LEVEL BEFORE YOU
START THE ENGINE. This 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.
The Classic II weighs 1340 lb./608 kg. A lift bail is
provided for lifting with a hoist.
WARNING
NOTE: This unit is equipped with an Engine Protection
Package. An 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.
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.
For more oil fill and service information, see the
Maintenance section of this manual.
Lift only with equipment of adequate lifting capacity. Be
sure machine is stable when lifting.
FUEL
Fill the fuel tank with clean, diesel fuel only.
The Classic II has a 15 gallon (57 liter) fuel
tank with a top fill and fuel gauge mounted
on the control panel. See the Operation
and Maintenance sections of this manual for more
details about fuel.
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.
BATTERY CONNECTIONS
PRE-OPERATION ENGINE SERVICE
The Classic II 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.
Read and understand the information about the diesel
engine in the Operation and Maintenance sections of
this manual before you operate the Classic II.
CLASSIC II
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A-5
A-5
INSTALLATION
UNDERCARRIAGES
MUFFLER
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:
This welder is supplied with an adjustable rain cap for
the muffler. Install the rain cap using the clamp provid-
ed with the outlet facing away from the direction in
which this unit will be transported. This will minimize
the amount of water and debris that could enter the
muffler during transportation.
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.
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.
3. Proper placement of the equipment on the 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.
Standard mufflers (like the one included with the
Classic II) 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 II. See the
Accessories section of this manual for more informa-
tion.
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.
CAUTION
An incorrect spark arrester may lead to damage to the
engine or reduce performance.
CLASSIC II
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A-6
A-6
INSTALLATION
ELECTRICAL OUTPUT
CONNECTIONS
CAUTION
• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.
See Figure A.1 for the location of the 115 and 230 volt
receptacles, weld output terminals, and ground stud.
• Do not cross the welding cables at the output terminal
connection. Keep the cables isolated and separate
from one another.
WELDING CABLE CONNECTIONS
CABLE INSTALLATION, POLARITY CONTROL,
AND CABLE SIZES
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.
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 necessary.
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 II OUTPUT CONNECTIONS
1
2
4
3
5
1. 230 VOLT RECEPTACLE
2. 115 VOLT RECEPTACLE
3. WELD OUTPUT TERMINALS (2)
4. GROUND STUD (LOCATION)
5. CABLE STRAIN RELIEF BRACKET
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
200
Duty Cycle
100%
Up to 200 ft.
200 to 250 ft.
1
1
1/0
1/0
2/0
250
60%
300
40%
1/0
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A-7
A-7
INSTALLATION
MACHINE GROUNDING
AUXILIARY POWER RECEPTACLES,
PLUGS, AND HAND-HELD EQUIPMENT
Because the Classic II creates its own
power from its diesel-engine driven gener-
ator, you do not need to connect the
machine frame to an earth ground.
The AC auxiliary power, supplied as a standard, has a
rating of 3.0 kVA 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.
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.
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.
WARNING
Do not ground the machine to a pipe that carries
explosive or combustible material.
CIRCUIT BREAKERS
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.
Classic II welders are equipped with
circuit breakers on the 115 and the
230 volt receptacles for overload pro-
tection. Under high heat a breaker
may tend to trip at lower loads than it would normally.
When the Classic II 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.
Operation with high ambient temperatures may cause
the breakers to trip at lower than normal loads.
CAUTION
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) 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 Accessories section of this manual for details.
Never bypass the circuit breakers. Without overload
protection, the Classic II could overheat and/or cause
damage to the equipment being used.
FIGURE A.2 - GROUND STUD LOCATION
If you need ground fault protection for hand-held equip-
ment, refer to the Accessories section of this manual
for the GFCI Receptacle kit.
1
1. Ground Stud
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A-8
A-8
NOTES
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Section B-1
Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
General Description ....................................................................................................................B-2
Operational Features and Controls.............................................................................................B-3
Welder/Generator Controls...................................................................................................B-5
Control of Welding Current...................................................................................................B-6
Diesel Engine Controls:........................................................................................................B-7
Starting the Engine...............................................................................................................B-8
Break-in Period.....................................................................................................................B-9
General Information............................................................................................................B-10
Idler Operation....................................................................................................................B-10
Classic II DC Wire Feed Welding (Constant Voltage)........................................................B-12
Using Auxiliary Power and Welding at the Same Time......................................................B-13
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B-2
B-2
OPERATION
WARNING
OPERATING INSTRUCTIONS
Read and understand this entire section before operat-
ing your Classic II.
ENGINE EXHAUST can kill.
SAFETY INSTRUCTIONS
WARNING
• Use in open, well ventilated areas or
vent exhaust to the outside.
• Do not stack anything on or near the
engine.
Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.
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.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet clothing.
Only qualified personnel should install, use, or ser-
vice this equipment.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
GENERAL DESCRIPTION
The Classic II is a heavy duty engine driven DC arc
welding power source capable of providing constant
current output for stick welding or DC TIG welding. The
Classic II 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 provide
constant voltage output for running the LN-7 or LN-25.
FUMES AND GASES can be dan-
gerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
This unit uses the Deutz F3L-1011F three-cylinder,
industrial air cooled diesel engine.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
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B-3
B-3
OPERATION
RECOMMENDED APPLICATIONS
DESIGN FEATURES
• Constant current DC Stick welding (SMAW) process
capability with output range from 40 - 325 DC amps.
WELDER
The Classic II 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 details
on using the machine as a welder, see Welding
Operation in the Operation section of this manual.
• 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.
GENERATOR
The Classic II is also capable of providing 3.0 kVA of
115/230 volts of 60 Hertz AC auxiliary power.
• 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).
OPERATIONAL FEATURES AND
CONTROLS
• Electric starting.
• Battery Charging Ammeter.
• Engine Oil Pressure Gauge.
The Classic II was designed for simplicity. Therefore,
it has very few operating controls. Two switches are
used for welding operations:
• Engine Hour Meter for determining periodic mainte-
nance.
• 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)
• 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.
• A FINE CURRENT ADJUSTMENT switch for fine
adjustment of current from minimum to maximum
within each range
• Automatic engine shutdown protection for low oil
pressure.
Controls for the diesel engine 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 Engine Operation in the Operation
section of this manual for details about starting, run-
ning, stopping, and breaking in the diesel engine.
• Automatic engine idler goes to low idle approximate-
ly 15 seconds after welding for greater fuel economy;
includes high idle switch.
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B-4
B-4
OPERATION
WELDING CAPABILITY
LIMITATIONS
The Classic II is rated 250 amps, 30 volts constant cur-
rent DC at 60% duty cycle based on a ten minute time
period. Longer duty cycles at lower output currents are
possible.
• The Classic II 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 II for these
processes are described in the Welding Operation
section of this manual. Constant voltage welding is
available with the optional wire feed module.
The current is continuously variable from 40 to 325
amps DC.
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B-5
B-5
OPERATION
CONTROLS AND SETTINGS
the case front. Welding output terminals and ground
stud are located on the machine right side, under the
door. See Figure B.1 and the explanations that follow.
The welder/generator controls are located on the
Output Control Panel of the machine case front. Diesel
engine idler control and start/stop controls are also on
FIGURE B.1 – OUTPUT CONTROLS
1
2
3
4
5
6
7
1. CURRENT RANGE SELECTOR
2. FINE CURRENT ADJUSTMENT
3. 230 VOLT RECEPTACLE
4. 115 VOLT RECEPTACLE
5. WELD OUTPUT TERMINAL (–)
6. WELD OUTPUT TERMINAL (+)
7. GROUND STUD
WELDER/GENERATOR CONTROLS
See Figure B.1 for the location of the following fea-
tures:
4. 115 VOLT DUPLEX RECEPTACLE: Connection
point for supplying 115 volt power to operate one or
two electrical devices.
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 for
more information.
5. WELD OUTPUT TERMINAL (–) WITH FLANGE
NUT: Provides the connection point for either the
electrode holder or the work cable.
6. WELD OUTPUT TERMINAL (+) WITH FLANGE
NUT: Provides the connection point for either the
electrode holder or the work cable.
2. FINE CURRENT ADJUSTMENT: Allows fine
adjustment of current within the selected output
range. See Control of Welding Current for more
information.
7. GROUND STUD: Provides a connection point for
connecting the machine case to earth ground for
the safest grounding procedure.
3. 230 VOLT DUPLEX RECEPTACLE: Connection
point for supplying 230 volt power to operate one or
two electrical devices.
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B-6
B-6
OPERATION
CONTROL OF WELDING CURRENT
CAUTION
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 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.
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 controlled by the FINE CURRENT
ADJUSTMENT, permitting control of the arc character-
istics.
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
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.
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 RANGE
SELECTION
130-80
FINE CURRENT
ADJUSTMENT
190-120
60
50
240-160
70
80
90
40
30
20
220
MAX.
90
MIN.
100
10
FINE CURRENT
ADJUSTMENT
CURRENT
RANGE
SELECTOR
Classic
ENGINE
PROTECTION
START
IDLER
IGNITION
REMOTE
CONTROL
230 VOLT AC
115 VOLTAC
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B-7
B-7
OPERATION
FIGURE B.3 – DIESEL ENGINE CONTROLS
CURRENT RANGE
SELECTION
130-80
FINE CURRENT
ADJUSTMENT
190-120
60
50
240-160
70
80
90
40
30
20
220
MAX.
90
MIN.
100
10
1. IDLER CONTROL TOGGLE SWITCH
2. IGNITION TOGGLE SWITCH
3. ENGINE PROTECTION WARNING LIGHT
4. START PUSHBUTTON
Classic
ENGINE
PROTECTION
START
IDLER
IGNITION
REMOTE
230 VOLT AC
115 VOLTAC
CONTROL
5. ENGINE HOUR METER
6. AMMETER
7. OIL PRESSURE GAUGE
4
5
1
2
3
6
7
DIESEL ENGINE CONTROLS
See Figure B.3 for the location of the following fea-
tures:
1. IDLER CONTROL TOGGLE SWITCH: Adjusts the
running speed of the engine. The switch has two
positions, "HIGH" and "AUTO." In "HIGH," the
engine runs continuously at high idle. In "AUTO,"
the idler control works as follows:
4. START PUSHBUTTON: Press this button to start
the diesel engine. The IGNITION switch must be
in the ON position.
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.
NOTE: If you press the START pushbutton when
the engine is running, you may damage the engine
flywheel gear or starter motor.
5. ENGINE HOUR METER: Records engine running
time. Use the meter to determine when to
perform required maintenance.
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.
6. 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.
2. 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.
7. 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.
3. 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.
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B-8
B-8
OPERATION
Check and fill the engine fuel tank:
ENGINE OPERATION
WARNING
WARNING
Do not add fuel near an open flame,
welding arc or when the engine is run-
ning. Stop the engine and allow it to
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.
DO NOT RUN THE ENGINE AT EXCESSIVE
SPEEDS. The maximum allowable high idle speed for
the Classic II is 1800 RPM, no load. Do NOT increase
the idle speed on the engine. Severe personal injury
and damage to the machine can result if it is operated
at speeds above the maximum rated speed.
Read and understand all safety instructions included in
the Deutz engine instruction manual that is shipped
with your Classic II.
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.
BEFORE STARTING THE ENGINE
Check and fill the engine oil level:
3. Replace the fuel tank cap and tighten securely.
1. Be sure the machine is on a level
surface.
NOTE: USE DIESEL FUEL ONLY. Purchase diesel
fuel in quantities that will be used within 30 days, to
assure freshness.
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.
STARTING THE ENGINE
NOTE: Remove all loads connected to the AC power
receptacles before starting the diesel engine.
4. Replace the dipstick.
1. Place the IDLER switch in the "HIGH" position, the
IGNITION switch in the ON position and then press
the START button.
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.
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B-9
B-9
OPERATION
STOPPING THE ENGINE
COLD WEATHER STARTING
1. Remove all welding and generator power loads
and let the engine cool by running it for several
minutes at low idle.
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 0oF.
2. Place the IGNITION switch in the OFF position.
If the engine is frequently started below 10oF, 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.
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.
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 Maintenance section of this manual.
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
tank. Also, running out of fuel tends to draw dirt into the
fuel system. Check the crankcase oil level.
BREAK-IN PERIOD
Any engine will use a small amount of oil during its
break-in period. For the diesel engine on the Classic
II, 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. For more
details, see the Maintenance section of this manual.
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.
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.
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B-10
B-10
OPERATION
WELDING OPERATION
GENERAL INFORMATION
2. In the "AUTO" position, the idler operates as fol-
lows:
The Classic II can deliver from 40 to 325 amps of con-
stant current for DC stick welding or DC semiautomat-
ic wire feed welding (with wire feed module). DC TIG
welding is possible across the entire range from 40 to
325 amps. Output can be adjusted by setting the CUR-
RENT RANGE SELECTOR and the FINE CURRENT
ADJUSTMENT on the output control panel to the set-
tings that are best for your selected welding process.
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.
IDLER OPERATION
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.
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
engine high speed is controlled by the governor.
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B-11
B-11
OPERATION
7. Set the CURRENT RANGE SELECTOR to a set-
ting equal to or slightly higher than the desired
welding current.
TO USE THE CLASSIC II FOR DC
CONSTANT CURRENT STICK OR TIG
WELDING:
8. 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.
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.
9. Strike an arc and begin welding.
After you finish welding:
1. Stop the engine. See Engine Operation in this
section of the manual.
2. Select the appropriate electrode.
2. Allow the electrode and work to cool completely.
3. Remove the work clamp from the work.
3. Attach the work clamp securely to the work you are
welding.
4. Remove any remaining piece of electrode from the
electrode holder.
4. Insert the electrode into the electrode holder.
5. Start the Diesel Engine. See Engine Operation in
this section of the manual.
6. Set the Idler Switch to "AUTO."
FIGURE B.4 – WELDING CIRCUIT CONNECTIONS FOR STICK WELDING
1. OUTPUT TERMINALS
2. ELECTRODE CABLE
3. ELECTRODE HOLDER
4. ELECTRODE
5. WORK PIECE
6. WORK CLAMP
7. WORK CABLE
80
1
2
4 3
5
7
6
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B-12
B-12
OPERATION
4. Set the Idler Switch to "AUTO."
TO USE THE CLASSIC II FOR DC WIRE
FEED WELDING (CONSTANT VOLTAGE)
WITH WIRE FEED MODULE:
5. Set the CURRENT RANGE SELECTOR to a set-
ting appropriate for your wire size and speed. See
Table B.1 for recommended settings.
1. Connect the LN-25 or LN-7 Wire Feeder (with wire
feed module). Follow the installation instructions
provided with the wire feeder.
6. Set the VOLTAGE ADJUSTMENT to the setting
that gives the best arc characteristics for the range
selected. See Control of Welding Current in this
section of the manual.
2. Select the appropriate electrode.
3. Start the diesel engine. See Engine Operation in
7. Strike an arc and begin welding.
this section of the manual.
TABLE B.1
RANGE SETTINGS FOR WIRE SIZE/SPEED
Diameter (inches)
Wire Speed Range
(inches/minute)
Appropriate Current Range
.035
.045
.068
80-110
70-130
40-90
75 to 120 Amps
120 to 170 Amps
125 to 210 Amps
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B-13
B-13
OPERATION
AUXILIARY POWER
WARNING
Be sure that any electrical equipment plugged into the
generator AC power receptacles can withstand a ±10%
voltage and a ±3% frequency variation.
The AC auxiliary power, supplied as a standard, has a
rating of 3.0 kVA of 115/230V AC power (60 hertz).
One 115V duplex and one 230V grounding type recep-
tacle are provided. 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 receptacle 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-
bined load of all receptacles is not to exceed 3.0 kVA.
You can 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 II. Be sure to read the notes at the bottom
of the table.
An optional power plug kit is available. When this kit is
specified, the customer is supplied with a plug for each
receptacle. See the Accessories section 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. Set the IDLER switch to AUTO. Set the CURRENT
RANGE SELECTOR to "MAX." See Figure B.1.
3. Plug the load(s) into the appropriate 115 volt or 230
volt power receptacle.
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B-14
B-14
OPERATION
TABLE B.2 – GENERATOR POWER APPLICATIONS
Suggested Power Applications
*Air Compressor - 3/4 HP
Running Watts
*Start-up Watts
1,250
600
3,100 - 5,000
1,500 - 2,400
*Airless Sprayer - 1/3 HP
Chain Saw
1,200
1,200
1,000
500
Circular Saw
Coffee Maker
*Deep Freezer
750 - 2,000
*Electric Motor - 1 HP
Electric Range (1 element)
Electric Skillet
1,000
1,500
1,250
1,200
600
2,500 - 4,000
*Furnace Fan - 1/3 HP
Portable Grinder (4 1/2”)
Portable Grinder (7”)
Halogen Work Light
Hand Drill - 1/4”
3,000 - 4,800
2,000
500
500
Hand Drill - 3/8”
700
1500 Watt Heater
Hedge Trimmer
1,750
450
Light Bulb
100
Reciprocating Saw
Radial Arm Saw
900
2,600
50
Radio
*Refrigerator/Freezer (small)
Slow Cooker
600
1,500 - 2,400
200
*Submersible Pump - 1 HP
*Sump Pump
1,000
600
2,500 - 4,000
1,500 - 2,400
Toaster
1,100
500
Weed Trimmer
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 inductive motors may require as much as 4 times running watts to start.
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Section C-1
Section C-1
TABLE OF CONTENTS
- ACCESSORIES -
Accessories...........................................................................................................................Section C
Connection of the LN-7 using K867 Universal Adapter........................................................C-4
Connection of the LN-7 using K584 Input Cable Assembly.................................................C-5
Connection of the LN-25 using K867 Universal Adapter......................................................C-6
Connection of the LN-25 “Across the Arc” ...........................................................................C-7
Connection of the K488 SG Control Module and K487 Magnum Spool Gun......................C-8
CLASSIC II
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C-2
C-2
ACCESSORIES
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.
OPTIONS/ACCESSORIES
The following options/accessories are available for
your Classic II from your local Lincoln Distributor.
Undercarriage - Under 10 MPH (K768) - For in-plant
or yard towing of the Classic II. Not intended for high-
way towing.
Accessory Kit (K703) - Includes the following:
• Thirty-five feet (10.5 meters) of #2 AWG electrode
cable
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.
• Thirty feet (9.1 meters) of #2 AWG work cable
• Headshield with No. 12 filter.
• GC300 work clamp
• Cooltong™ 300 insulated electrode holder
Power Plug Kit (K802-C) - Provides four 20 amp, 115
volt plugs and one 50 amp, dual voltage (115/230V),
full kVA plug. NOTE: For CSA machines and machines
with GFCI receptacles, use Power Plug Kit K802-R.)
The cables are rated at 250 amps, 40% duty cycle.
Spark Arrester Kit (K899-1) - A field-installed kit for
the Classic II diesel engine muffler exhaust pipe.
Includes a heavy-gauge steel, approved spark arrester,
mounting clamp and adapter.
Power Plug Kit (K802-D) - Provides four 15 amp, 115
volt plugs and one 50 amp, dual voltage (115/230V),
full kVA plug. (For non-CSA machines.)
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.
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 10oF (-12.2oC). Requires an ether tank that must
be purchased locally.
Remote Control Kit - Above Code 10050 - (K924-1)
- Includes a control box with 100 ft. (7.5 meters) of 4-
conductor cable. Allows output to be controlled
remotely.
NOTE: Ether starting can contribute to shortened
engine life. Avoid unnecessary or indiscriminate use.
GFCI Receptacle Kit (K896-2) - Includes a UL
approved 115 volt ground fault circuit interrupter 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.
Linc Thaw™ Control Unit (L2964-5) - Includes meter
and fuses to protect the welder when thawing frozen
water pipes.
WARNING
PIPE THAWING can result in fire, explosion, damage
to pipes, wiring, and the welder as well as other unsafe
or hazardous conditions. Do not use a welder to thaw
pipes before reviewing Lincoln Bulletin E695.1 (dated
October 1987 or later).
CLASSIC II
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C-3
C-3
ACCESSORIES
TIG WELDING
SEMIAUTOMATIC WELDING
TIG Module (K930-1) - The TIG Module is an acces-
sory that provides high frequency and shielding gas
control for DC GTAW (TIG) welding applications. It
provides contactor control of constant current welding
power sources having an internal contactor.
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.
NOTE: Gas-shielded welding requires a Magnum Gun.
Gasless welding requires an Innershield Gun.
The K930-1 TIG Module is supplied without acces-
sories. Arc Start switches, Amptrols, cables, torches
and mounting brackets must be purchased separately.
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.
Control Cable (K936-4) - Control cable for connecting
the K930-1 TIG Module to a Classic II.
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.
CLASSIC II
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C-4
C-4
ACCESSORIES
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS
WARNING
3. Connect the K867 Universal Adapter to the K291 or
K404 input cable and the 14 pin amphenol of the
Classic II as indicated in Figure C.1. Make the
proper connections for local or remote control
according to Figure C.1.
ELECTRIC SHOCK can kill.
• Do not operate with panels open.
• Disconnect NEGATIVE (-) BATTERY
LEAD before servicing.
4. Connect the K291 or K404 input cable to the LN-7.
5. Place the IDLER switch in the “HIGH” position.
• Do not touch electrically live parts.
CAUTION
MOVING PARTS can injure.
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. If
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.
• 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 II USING K867 UNIVERSAL
ADAPTER (SEE FIGURE C.1.)
6. Adjust wire feed speed and voltage at the LN-7.
NOTE: For remote control, a K775 remote control is
1. Shut the welder off.
required. See Figure C.1.
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.
CAUTION
When the welder is in local control, the electrode is
always “HOT.”
NOTE: Welding cable must be sized for current
and duty cycle of application.
NOTE: Figure C.1 shows the electrode connected
for positive polarity. To change polarity,
shut the welder off and reverse the elec-
trode and work cables at the Classic II
output terminals.
FIGURE C.1
CLASSIC II/LN-7 WITH K867 ADAPTER CONNECTION DIAGRAM
SPARE
82
Insulate Each
LN-7
14 PIN
81
Unused Lead
AMPHENOL
CONTROL
BOX
Classic II Output
Terminals are on
Opposite Side
42
41
Individually
31
31
+
32
2
4
21
GND
32
2
4
CV-
K291 OR K404
INPUT CABLE
21
GND
GREEN
75
76
77
TO
WORK
K867 UNIVERSAL
ADAPTER PLUG
75
76
77
ELECTRODE CABLE
TO LN-7
K775 OPTIONAL
REMOTE CONTROL
Splice Leads
and Insulate
CLASSIC II
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C-5
C-5
ACCESSORIES
CONNECTION OF THE LN-7 TO THE
CLASSIC II USING K584 INPUT CABLE
ASSEMBLY (SEE FIGURE C.2.)
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. If
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.
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 II output terminals .
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.
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-
7.
CAUTION
When the welder is in local control, the electrode is
always "HOT."
4. Connect the K864 adapter to the 14 pin amphenol
on the Classic II.
5. Place the IDLER switch in the "HIGH" position.
FIGURE C.2
CLASSIC II/LN-7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM
LN-7
CONTROL
BOX
14 PIN
AMPHENOL
14 PIN
AMPHENOL
Classic II Output
Terminals are on
K584-"L" INPUT CABLE
Opposite Side
+
CV-
6 PIN
AMPHENOL
K864
ADAPTER
TO
WORK
K857
REMOTE CONTROL
ELECTRODE CABLE
TO LN-7
CLASSIC II
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C-6
C-6
INSTALLATION
4. Connect the K433 to the LN-25. Mount the K433
to the welder according to instructions included
with the K433 kit.
CONNECTION OF THE LN-25 TO THE
CLASSIC II USING K867 UNIVERSAL
ADAPTER (SEE FIGURE C.3.)
5. Place the IDLER switch in the "HIGH" position.
1. Shut the welder off.
2. Connect the electrode cable from the LN-25 to the
“+” terminal of the welder. Connect the work cable
to the “CV-” terminal of the welder.
CAUTION
NOTE: Welding cable must be sized for current and
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. If
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.
duty cycle of application.
NOTE: Figure C.3 shows the electrode connected for
positive polarity. To change polarity, shut the
welder off and reverse the electrode and work
cables at the Classic II output terminals.
Reverse the LN-25 polarity switch.
3. Connect the K867 Universal adapter to the K432-L
cable and the 14 pin amphenol of the Classic II as
indicated in Figure C.3.
6. Adjust wire feed speed and voltage at the LN-25.
FIGURE C.3
CLASSIC II/LN-25 CONNECTION DIAGRAM
SPARE
82
81
42
41
Insulate Each
14 PIN
AMPHENOL
Unused Lead
K433
Classic II Output
Terminals are on
Opposite Side
Individually
21
+
31
32
2
31
32
2
K432-"L" CABLE
CV-
4
4
GND
GND
K867 UNIVERSAL
ADAPTER PLUG
75
76
77
75
76
77
TO
WORK
LN-25 WIRE FEEDER
WITH K431 OPTION
Splice Leads and Insulate
ELECTRODE CABLE
CLASSIC II
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C-7
C-7
ACCESSORIES
3. Attach the single lead from the LN-25 control box
to the work using the spring clip on the end of the
lead. This is only a control lead — it carries no
welding current.
CONNECTION OF THE LN-25 TO THE
CLASSIC II “ACROSS THE ARC”
(SEE FIGURE C.4.)
1. Shut the welder off.
4. Place the IDLER switch in the “HIGH” position.
5. Adjust wire feed speed and voltage at the LN-25.
2. Connect the electrode cable from the LN-25 to the
“+” terminal of the welder. Connect the work cable
to the “CV–” terminal of the welder.
NOTE: Welding cable must be sized for current
and duty cycle of application.
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 II
output terminals. Reverse the LN-25
polarity switch.
FIGURE C.4
CLASSIC II/LN-25 ACROSS THE ARC CONNECTION DIAGRAM
14 PIN
AMPHENOL
Classic II Output
Terminals are on
Opposite Side
+
LN-25 WIRE FEEDER
WITH K444-2 REMOTE
VOLTAGECONTROL OPTION
CV-
ELECTRODE CABLE
TO
WORK
WORK CLIP
LEAD TO WORK
CLASSIC II
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C-8
C-8
ACCESSORIES
6. Place the IDLER switch on the Classic II in the
“HIGH” position.
CONNECTION OF THE K488 SG CONTROL
MODULE AND K487 MAGNUM SPOOL GUN
TO THE CLASSIC II (SEE FIGURE C.5.)
CAUTION
1. Shut the welder off.
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. If
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.
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 II
output terminals.
7. Adjust wire feed speed at the SG Control Module.
NOTE: For remote control, a K775 remote control
is required.
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 II.
CAUTION
4. Connect the K492 Input Cable to the SG Control
Module.
When the welder is in local control, the electrode is
always “HOT.”
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.
FIGURE C.5
CLASSIC II/K492/K488/K487 SPOOL GUN CONNECTION DIAGRAM
SPARE
82
81
42
41
21
Insulate Each
Unused Lead
Individually
14 PIN
AMPHENOL
K488 SG
CONTROL
MODULE
Classic II Output
Terminals are on
Opposite Side
K487-25
SPOOL
GUN
+
31
32
2
31
32
2
CV-
K492
4
4
INPUT CABLE
GND
GND
GREEN
75
76
77
TO
WORK
K867 UNIVERSAL
ADAPTER PLUG
75
76
77
ELECTRODE CABLE TO
K438 SG CONTROL CABLE
K775 OPTIONAL
REMOTE CONTROL
Splice Leads
and Insulate
CLASSIC II
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Section D-1
Section D-1
TABLE OF CONTENTS
-MAINTENANCE-
Maintenance .........................................................................................................................Section D
Routine and Periodic Maintenance.............................................................................................D-2
Change the Oil ........................................................................................................D-2
Fuel..........................................................................................................................D-3
Air Cleaner...............................................................................................................D-4
Current Range Selector Contacts ...........................................................................D-7
Tightening the Fan Belt ...........................................................................................D-4
Cleaning the Battery................................................................................................D-6
Checking Electrolyte Level......................................................................................D-6
Charging the Battery ...............................................................................................D-6
Storage....................................................................................................................D-7
Brush Removal and Replacement...........................................................................D-7
Commutator and Brushes .......................................................................................D-7
Receptacles.............................................................................................................D-7
Cable Connections ..................................................................................................D-7
Idler Maintenance...........................................................................................................D-7
Major Component Locations.......................................................................................................D-8
CLASSIC II
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D-2
D-2
MAINTENANCE
ENGINE MAINTENANCE
SAFETY PRECAUTIONS
WARNING
CAUTION
To prevent the engine from accidentally starting, dis-
connect the positive battery cable before servicing the
engine.
• Have qualified personnel do all maintenance and
troubleshooting work.
• Turn the engine off before working inside the
machine.
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.
• Remove covers or guards only when necessary to
perform maintenance and replace them when the
maintenance requiring their removal is complete.
• If covers or guards are missing from the machine,
get replacements from a Lincoln Distributor. See the
Exploded View and Parts List at the back of this
manual.
OIL: Check the oil level after every 10
hours of operation or daily. BE SURE
TO 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.
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
II.
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.
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 in Figure D.1.
2. Replace the plug and tighten it securely.
ROUTINE AND PERIODIC
MAINTENANCE
3. 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.
NOTE: NAMEPLATES
Whenever routine maintenance is performed on this
machine - or at least yearly - inspect all nameplates
and labels for legibility. Replace those which are no
longer clear. Refer to the parts list for the replacement
item number.
4. Reinstall the oil fill cap and the dipstick.
CLASSIC II
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D-3
D-3
MAINTENANCE
FIGURE D.1 – OIL DRAIN AND REFILL
5
6
{
1
1. DIPSTICK
2. FUEL FILTER
3. OIL FILTER
2
4. OIL DRAIN PLUG
5. OIL FILL CAP
6. DIPSTICK LEVELS
3
4
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. See Table D.1 for
recommended maintenance intervals. Order Deutz oil
filter #117-4416 or #117-4417 from your local Deutz
service center.
5. Refill the engine with the proper amount and type
of oil as described in the Change the Oil section,
above. Start the engine and check for leaks
around the filter element. Correct any leaks (usu-
ally by retightening the filter, but only enough to
stop leaks) before placing the Classic II back in
service.
6. If there are 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.
Change the oil filter as follows:
1 . Drain the oil from the engine and allow the oil filter
to drain.
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.
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
Refer to your engine operation manual for recom-
mended grade of fuel.
4. Spin the 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.
CLASSIC II
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D-4
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:
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 oil 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.
1. Close the fuel stopcock.
BEARINGS: The Classic II 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.
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 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.
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.
5. Open the fuel stopcock. Check the assembly for
leaks.
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.
Order Deutz fuel filter #117-4482 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 #117-4696.
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:
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.
1. Remove the dust cup from the bottom of the air
cleaner housing. Clean out any accumulated dust.
FIGURE D.2 – TIGHTENING THE COOLING
BLOWER BELT
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/cm2, 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.
CLASSIC II
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D-5
D-5
MAINTENANCE
TABLE D.1
DEUTZ ENGINE MAINTENANCE SCHEDULE
FREQUENCY
MAINTENANCE REQUIRED
Daily or Before
Starting Engine
• Fill fuel tank.
• Check oil level.
• Check air cleaner for dirty, loose, or damaged parts.
• Check air intake and cooling areas, clean as necessary.
First 50 Hours
Every 50 Hours
• Change engine oil.
• Change oil filter.
• Change fuel filter.
• Check fan belt.
• 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
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D-6
D-6
MAINTENANCE
CHECKING SPECIFIC GRAVITY
BATTERY MAINTENANCE
WARNING
Check each battery cell with a hydrometer. A 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).
GASES FROM BATTERY can explode.
• Keep sparks, flame, and cigarettes away
from battery.
BATTERY ACID can burn eyes and skin.
• Wear gloves and eye protection and be
careful when working near a battery.
Follow the instructions printed on the
battery.
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.
To prevent EXPLOSION when:
• INSTALLING A NEW BATTERY - Disconnect the
negative cable from the old battery first and connect
to the new battery last.
CHARGING THE BATTERY
The Classic II 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.
• THE CORRECT POLARITY IS NEGATIVE
GROUND - Damage to the engine alternator and
the printed circuit board can result from incorrect
connection.
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 II charging system is NEGATIVE
GROUND. The positive (+) battery terminal has a red
terminal cover.
• 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.
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 so can result in damage to the internal charger com-
ponents.
• 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.
Follow the instructions of the battery charger manufac-
turer for proper charger settings and charging time.
CLEANING THE BATTERY
Keep the battery clean by wiping it with a damp cloth
when dirty. If 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 l) 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 battery failure.
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D-7
D-7
MAINTENANCE
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.
WELDER/GENERATOR
MAINTENANCE
STORAGE: Store the Classic II in clean, dry, protect-
ed areas.
CLEANING: Blow out the generator and controls peri-
odically with low pressure air. Do this at least once a
week in particularly dirty areas.
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.
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%.
WARNING
Uncovered rotating equipment can 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 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.
COMMUTATOR AND BRUSHES: The generator
brushes are properly adjusted when the welder is
shipped. They require no particular attention.
CAUTION
Put a drop of oil on the CURRENT RANGE SELEC-
TOR shaft at least once every month.
DO NOT SHIFT THE BRUSHES or adjust the rocker
setting.
RECEPTACLES: Keep the electrical receptacles in
good condition. Remove any dirt, oil, or other debris
from their surfaces and holes.
Shifting of the brushes may result in:
• Change in machine output
• Commutator damage
• Excessive brush wear
CABLE CONNECTIONS: Check the welding cable
connections at the weld output terminals often. Be
sure that the connections are always firm.
Periodically inspect the commutator, slip rings, and
brushes by removing the covers. DO NOT remove
these covers while the machine is running.
IDLER MAINTENANCE
1. The solenoid plunger must work freely and not
bind. Dust the plunger about once a year with
graphite powder.
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.
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.
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D-8
D-8
MAINTENANCE
FIGURE D.3 - MAJOR COMPONENT LOCATIONS
1. RIGHT CASE SIDE (DOOR)
2. BASE (WITH BATTERY)
3. ALTERNATOR BRUSHES
4. ALTERNATOR
11
5. GENERATOR
12
6. GENERATOR BRUSHES
7. OUTPUT TERMINALS
8. FUEL TANK
9. CASE FRONT WITH CONTROL PANEL
10. LEFT CASE SIDE
11. CASE TOP
12. CASE BACK
13. DIESEL ENGINE
14. AIR CLEANER
15. IDLER CONTROL
10
9
13
8
14
7
5
15
6
4
3
2
1
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Section E-1
Section E-1
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
Theory of Operation .............................................................................................................Section E
General Description...............................................................................................................E-2
Battery, Starter, Engine Alternator, and Protection Circuits...................................................E-2
Engine, Generator Armature and Frame, Alternator Stator and Rotor..................................E-3
Excitation (Flashing)........................................................................................................E-3
Auxiliary and Field Feedback Coils.................................................................................E-3
Interpole and Series Coil.................................................................................................E-3
Current Range Selector ..................................................................................................E-4
Fine Current Adjustment ................................................................................................E-4
Engine Idler Circuit..........................................................................................................E-4
DC Generator Machines........................................................................................................E-5
ON LATER MODELS
PROTECTION AND IDLER CIRCUITS
ARE ON ONE PC BOARD
PROTECTION
RELAY
SELECTOR
SWITCH
REED
RELAY
CR2
IDLER
BOARD
NEGATIVE
OUTPUT
TERMINAL
115 & 230VAC
RECEPTACLES
IDLER
SOLENOID
OIL
OIL
PRESSURE
SENSOR
GENERATOR
FRAME
TEMPERATURE
SENSOR
CURRENT
TRANSFORMER
FUEL
SOLENOID
SERIES
COILS
RELAY
CR1
ALTERNATOR STATOR
ROTOR
(NOT PRESENT
ON LATER MODELS)
GENERATOR
MECHANICAL
COUPLING
ENGINE
ARMATURE
SHAFT
IGNITION
SWITCH
ARMATURE
ENGINE
ALTERNATOR
SLIP
RINGS
INTERPOLE
COILS
RESIDUAL
MAGNETISM
FLASHING
STARTER
MOTOR
FIELD
SHUNT
WINDINGS
FIELD
BATTERY
RECTIFIER
GENERATOR
FIELD CONTROL
POSITIVE
OUTPUT
TERMINAL
FIGURE E.1 – CLASSIC II BLOCK LOGIC DIAGRAM
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 – BATTERY, STARTER, ENGINE ALTERNATOR, AND PROTECTION CIRCUITS
ON LATER MODELS
PROTECTION AND IDLER CIRCUITS
ARE ON ONE PC BOARD
PROTECTION
RELAY
SELECTOR
SWITCH
REED
RELAY
CR2
IDLER
BOARD
NEGATIVE
OUTPUT
TERMINAL
115 & 230VAC
RECEPTACLES
IDLER
SOLENOID
OIL
OIL
PRESSURE
SENSOR
GENERATOR
FRAME
TEMPERATURE
SENSOR
CURRENT
TRANSFORMER
FUEL
SOLENOID
SERIES
COILS
RELAY
CR1
ALTERNATOR STATOR
ROTOR
(NOT PRESENT
ON LATER MODELS)
GENERATOR
MECHANICAL
COUPLING
ENGINE
ARMATURE
SHAFT
IGNITION
SWITCH
ARMATURE
ENGINE
ALTERNATOR
SLIP
RINGS
INTERPOLE
COILS
RESIDUAL
MAGNETISM
FLASHING
STARTER
MOTOR
FIELD
SHUNT
WINDINGS
FIELD
BATTERY
RECTIFIER
GENERATOR
FIELD CONTROL
POSITIVE
OUTPUT
TERMINAL
GENERAL DESCRIPTION
BATTERY, STARTER, ENGINE,
ALTERNATOR, AND PROTECTION
CIRCUITS
The Classic II is a heavy duty, engine driven DC arc
welding power source capable of providing constant
current output for stick welding or DC TIG welding.
Also, a total of 3000 watts of auxiliary power is avail-
able at the 115 or 230VAC receptacles. The Classic II
is manufactured with all copper windings.
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. If
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.
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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
SELECTOR
SWITCH
REED
RELAY
CR2
IDLER
BOARD
NEGATIVE
OUTPUT
TERMINAL
115 & 230VAC
RECEPTACLES
IDLER
SOLENOID
OIL
OIL
PRESSURE
SENSOR
GENERATOR
FRAME
TEMPERATURE
SENSOR
CURRENT
TRANSFORMER
FUEL
SOLENOID
SERIES
COILS
RELAY
CR1
ALTERNATOR STATOR
ROTOR
(NOT PRESENT
ON LATER MODELS)
GENERATOR
MECHANICAL
COUPLING
ENGINE
ARMATURE
SHAFT
IGNITION
SWITCH
ARMATURE
ENGINE
ALTERNATOR
SLIP
RINGS
INTERPOLE
COILS
RESIDUAL
MAGNETISM
FLASHING
STARTER
MOTOR
FIELD
SHUNT
WINDINGS
FIELD
BATTERY
RECTIFIER
GENERATOR
FIELD CONTROL
POSITIVE
OUTPUT
TERMINAL
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.
rotor. It also supplies voltage, through the generator
field rheostat control, to the field shunt windings in the
main generator frame.
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.
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
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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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
REED
RELAY
CR2
IDLER
BOARD
NEGATIVE
OUTPUT
TERMINAL
115 & 230VAC
RECEPTACLES
IDLER
SOLENOID
OIL
OIL
PRESSURE
SENSOR
GENERATOR
FRAME
TEMPERATURE
SENSOR
CURRENT
TRANSFORMER
FUEL
SOLENOID
SERIES
COILS
RELAY
CR1
ALTERNATOR STATOR
ROTOR
(NOT PRESENT
ON LATER MODELS)
GENERATOR
MECHANICAL
COUPLING
ENGINE
ARMATURE
SHAFT
IGNITION
SWITCH
ARMATURE
ENGINE
ALTERNATOR
SLIP
RINGS
INTERPOLE
COILS
RESIDUAL
MAGNETISM
FLASHING
STARTER
MOTOR
FIELD
SHUNT
WINDINGS
FIELD
BATTERY
RECTIFIER
GENERATOR
FIELD CONTROL
POSITIVE
OUTPUT
TERMINAL
ENGINE IDLER CIRCUIT
ENGINE, GENERATOR ARMATURE
AND FRAME, ALTERNATOR STA-
TOR AND ROTOR (CONTINUED)
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 power is being
used, the current is passed through the current trans-
former. This signals the idler PC board to release the
idler solenoid.
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.
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.
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.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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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.
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.
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
conventional machine, rectification is provided
C
U
F
R
I
R
E
E
L
N
D
T
SHUNT FIELD WINDINGS
DC CURRENT
MAGNETIC FIELD
BRUSH
GENERATOR
ARMATURE
SHAFT
MECHANICAL
COUPLING
ARMATURE
BRUSH
MAGNETIC FIELD
DC CURRENT
WINDINGS
SHUNT FIELD
C
U
R
R
E
N
T
F
I
E
L
D
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E-6
E-6
NOTES
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Section F-1
Section F-1
TABLE OF CONTENTS
TROUBLESHOOTING & REPAIR SECTION
Troubleshooting & Repair Section ................................................................................Section F
How to Use Troubleshooting Guide.......................................................................................F-2
PC Board Troubleshooting Procedures .................................................................................F-3
Troubleshooting Guide .................................................................................................F4 - F-12
Test Procedures...................................................................................................................F-13
Alternator Rotor Test......................................................................................................F-13
Shunt Field Winding Test...............................................................................................F-17
Idler Solenoid Test.........................................................................................................F-20
Engine Throttle Adjustment Test....................................................................................F-22
Flashing the Fields ........................................................................................................F-26
Oscilloscope Waveforms......................................................................................................F-28
Normal Open Circuit Voltage Waveform (115VAC Supply)...........................................F-28
Normal Open Circuit DC Weld Voltage Waveform........................................................F-29
Typical DC Weld Output Voltage Waveform..................................................................F-30
Replacement Procedures ....................................................................................................F-31
Alternator Rotor Removal and Replacement ................................................................F-31
Alternator Stator Removal and Replacement................................................................F-38
Generator Frame Removal and Replacement ..............................................................F-43
Generator Armature Removal and Replacement..........................................................F-46
Retest After Repair...............................................................................................................F-48
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F-2
F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
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 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 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 either 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.
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.
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
Contents to locate the appropriate diagram.
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.
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.
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F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
• Remove the PC Board from the static-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.
WARNING
ELECTRIC SHOCK can kill.
Have an electrician install and service
this equipment. Turn the machine OFF
before working on equipment. Do not
touch electrically hot parts.
• If the PC Board uses protective shorting jumpers,
don’t remove them until installation is complete.
• If you return a PC Board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop-
er failure analysis.
Sometimes 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:
4. Test the machine to determine if the failure symp-
tom has been corrected by the replacement PC
board.
1. Determine to the best of your technical ability that
the PC board is the most likely component causing
the failure symptom.
NOTE: Allow the machine to heat up so that all electri-
cal components can reach their operating tem-
perature.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
5. Remove the replacement PC board and substitute
it with the original PC board to recreate the original
problem.
3. If the problem persists, replace the suspect PC
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:
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.
PC Board can be damaged by
static electricity.
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.
• Remove your body’s static charge
before opening the static-shielding
bag. Wear an anti-static wrist
strap. For safety, use a 1 Meg
ohm resistive cord connected to a
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
grounded part of the equipment
frame.
6. Always indicate that this procedure was followed
when warranty reports are to be submitted.
• 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.
NOTE: Following this procedure and writing on the
Workstations
warranty
report,
“INSTALLED
AND
SWITCHED PC BOARDS TO VERIFY PROB-
LEM,” will help avoid denial of legitimate PC
board warranty claims.
Reusable
Container
Do Not Destroy
• Tools which come in contact with the PC Board must
be either conductive, anti-static or static-dissipative.
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F-4
F-4
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
OUTPUT PROBLEMS
The engine starts and runs at cor- 1. Check the 15 amp fuse located 1. Check the “flashing” diode and
rect speed, but there is no, or very
low, welder output voltage. There
is no AC auxiliary output voltage.
on the inside of the front control
panel.
associated leads connected
between the generator brushes
and the exciter alternator brush-
es.
2. If the welder output is zero volts,
the fields may need to be
flashed. See Flashing the 2. Check the field diode bridge
Fields in this section.
and associated leads and con-
nections.
Diagram.
See the Wiring
3. Check for loose or missing
brushes in the exciter alternator
and welding generator.
3. Perform the Alternator Rotor
Test.
4. Check for “opens” or shorted
turns in the alternator stator
windings. The coils must NOT
be grounded to the 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.
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F-5
F-5
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The engine starts and runs at cor- 1. Check for loose, damaged or 1. Check the Fine Current
rect speed, but there is no, or very
low, welder output voltage. The AC
auxiliary output voltage is normal.
missing brushes in the welding
generator.
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.
2. Check the welding cables for
loose or faulty connection.
2. Perform the Shunt Field
Winding Test.
3. Check the continuity of the inter-
pole coils. They should show
continuity from the positive
brusholders to the positive out-
put terminal and should NOT be
grounded to the generator
frame.
4. 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.
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F-6
F-6
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
OUTPUT PROBLEMS
The welding output varies abnor- 1. May be a normal condition. The 1. Check the Fine Current Adjust-
mally. The auxiliary output remains
constant. The engine is operating
correctly.
machine will normally lose
some output as the components
get heated.
ment rheostat for resistance
and proper operation. Normal
resistance is 64 ohms. Check
associated wires for loose or
faulty connections. See the
Wiring Diagram.
2. Check for loose, worn, dirty, or
poorly seated DC generator
brushes.
2. Perform the Shunt Field Wind-
3. The armature commutator may
need cleaned.
ing Test.
3. Check the Current Range
Selector Switch and contacts
for proper operation.
4. Check for loose or faulty weld-
ing cables.
4. 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.
5. The main armature may be
faulty. Check for grounds.
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
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F-7
F-7
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The engine starts and runs at the 1. Check the AC auxiliary output 1. Check for loose or faulty con-
correct speed, but there is no AC
auxiliary output voltage. The DC
welding generator is functioning
correctly.
circuit breakers. Reset if
tripped.
nections between the recepta-
cles, the circuit breakers, the
current transformer and the
exciter alternator stator. See
the Wiring Diagram.
2. Check the 115VAC and
230VAC receptacles and plugs
for loose or faulty connections.
2. 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- 1. Contact your local Authorized 1. Check the “flashing” diode
ly. The machine takes a long time
to “build-up” and produce output
voltage. The AC auxiliary voltage
varies when the Fine Current
Control Rheostat is adjusted.
Field Service Facility.
located on the DC generator
brush holder. The diode may
be “shorted” or installed incor-
rectly.
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
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F-8
F-8
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
FUNCTION PROBLEMS
The engine will not return to low 1. Make sure the Idler Control 1. Check the Idler Control switch
idle when the welding and auxiliary
loads are removed.
switch is set to the Auto position.
and associated leads for loose
or faulty connections. See the
Wiring Diagram.
2. Make sure both welding and
auxiliary loads are removed.
2. Check the reed switch CR2. It
may be stuck closed. Replace if
necessary.
3. Check for mechanical restric-
tions in the idle and throttle link-
age.
3. Check for loose or faulty con-
nections at the Idler PC board.
4. Make sure lead #60D is
grounded correctly.
5. Perform the Idler Solenoid
Test.
6. The Idler 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
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F-9
F-9
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
The engine will NOT go to high 1. Check welding cables for loose 1. Check the reed switch (CR2) for
speed when a load is applied to the
welding output terminals. The
engine does go to high speed when
a load is applied to the AC auxiliary
power receptacles.
or faulty connections.
proper operation. The reed
switch should close when there
is current flow in the welding cir-
cuit.
2. Locate the red lead connected
to the Idler 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.
3. If the engine does NOT go to
high speed (in step 2), the Idler
PC board may be faulty.
The engine will NOT go to high 1. Check the auxiliary power plug 1. Check the leads associated with
speed when a load is applied to the
AC auxiliary receptacles. The
engine does go to high speed when
a load is applied to the welding out-
put terminals.
and associated leads for loose
or faulty connections.
the current transformer for loose
or faulty connections. See the
Wiring Diagram.
2. The load may be too small. The
load must be above 150 watts.
2. Check the current transformer
for “opens” in the windings.
3. The Idler 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
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F-10
F-10
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
FUNCTION PROBLEMS
The engine will NOT go to high 1. Check the welding cables and 1. The Idler PC board may be
speed when either a welding load
or an auxiliary load is connected to
the Classic II. The machine has
normal output and engine speed
when the Idler switch is in the “High
position.
auxiliary load leads for loose or
faulty connections.
faulty.
2. Check for mechanical restric-
tions or missing parts in the idler
and throttle linkage (Springs,
etc.).
The engine will not shut down.
1. Make sure the ignition switch is 1. Check the fuel solenoid for
turned off and operating correct-
ly.
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.
2. On older machines (below serial
number U1940718502), make
sure Diode Kit S-21548 has
been installed.
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
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F-11
F-11
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
ENGINE PROBLEMS
The engine “cranks” but will not 1. Check for adequate fuel supply. 1. Check the ignition switch for
start.
proper operation. Check the
associated leads for loose or
faulty connections. See the
Wiring Diagram.
2. Press the engine protection
“Reset” button. Note: On later
models without a “Reset” but-
ton, turn the ignition switch
“OFF” and then back “ON.”
2. Check the fuel solenoid. Make
sure it is opening when 12VDC
is applied to leads #58(+) to
#60(-).
3. Check the fuse in the engine
protection relay. Note: Not
present on later models.
3. The engine protection relay may
be faulty. Note: On later models
the Idler/Engine Protection PC
board may be faulty.
4. On later models check the fuel
solenoid circuit breaker located
near the welding output termi-
nals. Reset if tripped.
4. The engine fuel injectors may
need service.
The engine starts but shuts down 1. Check for adequate fuel supply. 1. The oil pressure or oil tempera-
after a short period of time.
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.
2. Check engine oil level.
3. Check engine alternator belt.
2. The engine alternator may be
faulty, causing the CR1 relay
(PC Board on later models) to
activate, which signals the
engine protection relay to shut
off the fuel solenoid.
3. The protection relay may be
faulty. Note: On later models
the Idler Engine Protection PC
board may be faulty.
4. 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
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F-12
F-12
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
The welding arc is loud and spat- 1. The current setting may be too 1. Check the engine speed. High
ters excessively.
high for the electrode and
process.
idle speed should be 1800
RPM.
2. The polarity may be wrong for 2. Check the DC generator brush-
the electrode and process.
es for good commutation and
alignment. Contact the Lincoln
Electric Service Dept. at 1-216-
383-2531 or 1-800-833-9353
(WELD).
The welding arc frequently “pops 1. The Fine Current Control 1. Check the engine speed. High
out.”
Rheostat may be set too low for
the process and electrode.
idle speed should be 1800
RPM.
2. Check the welding cables for 2. The Current Range selector
loose or faulty connections.
switch may be faulty. Check for
proper operation.
3. 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
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F-13
F-13
TROUBLESHOOTING & 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/repairs 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
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F-14
F-14
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR TEST (continued)
FIGURE F.1 – ALTERNATOR COVER REMOVAL
LOOSEN 5
SCREWS
ALTERNATOR
COVER
SLIP
RINGS
BRUSHES
TEST PROCEDURE
5. With the 3/8" socket wrench, remove the
screw and lock washer from the top center
of the alternator cover. See Figure F.1.
1. Turn engine off.
2. With the 3/8" socket wrench, remove the
left case side.
6. With the 3/8" socket wrench, loosen the
two screws on the right side of the alterna-
tor cover.
3. Unlatch, lift and secure the right side door.
Note that there are latches at both ends of
the door.
7. Remove the alternator top cover. Be care-
ful to clear the leads.
4. With the 3/8" nut driver or socket wrench,
loosen the two screws on the left side of
the alternator cover. See Figure F.1.
8. Locate and lift the brushes off of the rotor
slip rings. See Figure F.1.
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F-15
F-15
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR TEST (continued)
9. Working from the left side of the machine,
measure the resistance across the rotor
slip rings.
A. Set the ohmmeter on the low scale (X1).
B. Place one meter probe on one of the
rotor slip rings. 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.
FIGURE F.2 – MEASURING ROTOR RESISTANCE
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F-16
F-16
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR TEST (continued)
10. Measure the rotor resistance to ground.
11. Replace the brushes on the slip rings.
Make sure they are seated correctly.
A. Set the ohmmeter on the high scale
(X100,000).
12. Reinstall the alternator cover.
B. Place one probe on either of the rotor
slip rings. Place the other probe on any
good, unpainted ground. See Figure
F.3.
13. Reinstall the left case side and close and
latch the right side cover door.
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
specifications, then the rotor may be
faulty. Replace the rotor.
FIGURE F.3 – MEASURING ROTOR RESISTANCE TO GROUND
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F-17
F-17
TROUBLESHOOTING & 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.
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
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F-18
F-18
TROUBLESHOOTING & REPAIR
SHUNT FIELD WINDING TEST (continued)
FIGURE F.4 – PLUG P10 LOCATIONS
PLUG P10
TEST PROCEDURE
4. Remove plug P10. See Figure F.4.
1. Turn engine off.
5. Locate the blue lead (U, pin 3) and the
brown lead (N, pin 5) in the harness plug.
See Figure F.5.
2. Unlatch, lift and secure the right side door.
Note that there are latches at both ends of
the door.
3. Locate plug P10. See Figure F.4.
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F-19
F-19
TROUBLESHOOTING & REPAIR
SHUNT FIELD WINDING TEST (continued)
FIGURE F.5 – SHUNT LEAD RESISTANCE CHECK
PIN 3
PIN 5
TAB
6. Using the volt/ohmmeter set on the low
scale (X1), measure the resistance
between the blue and the brown leads.
See Figure F.5. Normal resistance is
approximately 57 ohms.
9. If the plug and associated leads are okay,
then the shunt field coils may be faulty.
Replace.
10. If the test does meet the resistance specifi-
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 be at least 500,000
ohms.
11. Replace plug P10, making sure the leads
and plug are secure.
12. Close and latch the right side door.
8. If the test does not meet the resistance
specifications, then check the harness plug
and inline connectors for loose connec-
tions or shorted leads.
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F-20
F-20
TROUBLESHOOTING & 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.
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.
MATERIALS NEEDED
External 12VDC supply
Wiring Diagram
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F-21
F-21
TROUBLESHOOTING & REPAIR
IDLER SOLENOID TEST (continued)
FIGURE F.6 - SOLENOID/HARNESS LEAD CONNECTIONS
LEADS #56, #57
TEST PROCEDURE
5. The solenoid should deactivate when the
12VDC is removed.
1. Turn engine off.
2. Unlatch, lift and secure the right side door.
Note that there are latches at both ends of
the door.
6. If the solenoid does not operate properly,
check for a mechanical restriction in the link-
age or a missing spring.
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.
7. If the linkage is intact and the solenoid does
not operate correctly when 12VDC is
applied, the solenoid may be faulty.
Replace.
4. Using the external voltage supply, apply
12VDC to the idler solenoid leads. The sole-
noid should activate.
8. When the test is complete and the problem
repaired, be sure to reconnect the two spade
connectors to leads #56 and #57 on the
wiring harness.
NOTE: WHEN THE ENGINE IS NOT RUN-
NING, THE SOLENOID MAY REQUIRE A
SLIGHT MECHANICAL ASSISTANCE TO
OPERATE.
9. Close and latch the right side door.
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F-22
F-22
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT 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.
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.
MATERIALS NEEDED
Slot head screw driver
7/16" wrench
10mm wrench
Strobe-tach, frequency counter, oscilloscope, white or red marking pencil
CLASSIC II
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F-23
F-23
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.7 - STROBE MARK LOCATION
STROBE
MARK
TEST PROCEDURE
5. Start the engine and direct the strobe-tach
light on the blower paddle. Synchronize it to
the rotating mark.
Strobe Tach Method
1. Turn the engine welder OFF.
2. Unlatch, lift and secure the right side door.
Note that there are latches at both ends of
the door.
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.
3. 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 F.7 for loca-
tion.
4. Connect the strobe-tach according to the
manufacturer's instructions.
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F-24
F-24
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
6. If either of the readings is incorrect, adjust
the throttle as follows:
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 col-
lar, to change the amount of throw in the
lever arm, until the frequency reads 47 Hz.
Retighten the locking nut.
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.
Oscilloscope Method
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.
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 waveform should exhibit a period of 21.4
milliseconds. Refer to the NORMAL OPEN
CIRCUIT VOLTAGE WAVEFORM (115
VAC SUPPLY) HIGH IDLE - NO LOAD in
this section of the manual.
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.
2. If either of these periods is incorrect, adjust
the throttle as follows:
Frequency Counter Method
1. Plug the frequency counter into one of the
115 VAC auxiliary receptacles.
Adjust HIGH IDLE: Use the 10mm wrench
to loosen the locking nut. See Figure F.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 period is 16.6 mil-
liseconds. Retighten the locking nut.
2. 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.
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 col-
lar, to change the amount of throw in the
lever arm, until the period is 21.4 millisec-
onds. Retighten the locking nut.
3. If either of the readings is incorrect, adjust
the throttle as follows:
Adjust HIGH IDLE: Use the 10mm wrench
to loosen the locking nut. See Figure F.8
for location of the adjusting screw and 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 locking nut.
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F-25
F-25
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.8 - HIGH IDLE ADJUSTMENT
ADJUSTING
SCREW
LOCKING
NUT
FIGURE F.9 - LOW IDLE ADJUSTMENT
LOCKING
NUT
COLLAR
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F-26
F-26
TROUBLESHOOTING & REPAIR
FLASHING THE FIELDS
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.
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
Wiring Diagram
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F-27
F-27
TROUBLESHOOTING & REPAIR
FLASHING THE FIELDS (continued)
FIGURE F.10 - FLASHING THE FIELDS
NEGATIVE(-)
BRUSH HOLDER
_
+
POSITIVE (+)
BRUSH HOLDER
12 VOLT
BATTERY
PROCEDURE
6. 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.
1. Turn engine welder OFF.
2. Unlatch, lift and secure the right side door.
Note that there are latches at both ends of
the door.
3. Remove the cover from the exciter. See
Figure F.10.
7. Replace the exciter cover.
8. Start the welder. The generator voltage
should build up.
4. Turn the FINE CURRENT ADJUSTMENT
control (rheostat) to "100."
If voltage does not 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-
ator brushes. See OUTPUT PROBLEMS in
the Troubleshooting Guide located in this
section of the manual for recommended
action.
5. 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.
CLASSIC II
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F-28
F-28
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)
HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM
16.6 ms
CH1
0 volts
5 ms
50 volts
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.
Coupling.............................DC
Trigger.........................Internal
CLASSIC II
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F-29
F-29
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AND SELECTOR
SWITCH AT MAXIMUM
CH1
0 volts
5 ms
50 volts
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.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
CLASSIC II
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F-30
F-30
TROUBLESHOOTING & REPAIR
TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM
MACHINE LOADED – SELECTOR SWITCH AT MAXIMUM POSITION
CH1
0 volts
5 ms
20 volts
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.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
CLASSIC II
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F-31
F-31
TROUBLESHOOTING & 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.
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 aid the technician in the removal and replacement of the alternator rotor.
MATERIALS NEEDED
3/8" wrench
1/2" wrench
5/16" nut driver
9/16" wrench
3/4" wrench
1-5/8" wrench
Large slot head screwdriver
Small gear puller
CLASSIC II
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F-32
F-32
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT (continued)
See Figure F.11 for steps 7 - 10.
PROCEDURE
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.
1. Turn the engine off.
2. Unlatch, lift and secure the right side door.
There are latches on both sides.
3. With the 1/2" wrench, disconnect the negative
battery cable.
8. With the 1/2" wrench, remove the six bolts,
nuts and lock washers holding the case front
to the frame ( three on each side).
4. With 3/8" socket wrench, remove the left case
side.
9. With the 5/16" nut driver, remove the two
sheet metal screws from the right side of the
case front. These screws hold the output
terminal assembly to the case front.
5. With the 1/2" wrench, remove the exhaust
pipe rain cap.
6. 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.
10. With the 3/8" wrench remove the screw from
the bottom center of the case front holding
the front to the frame.
FIGURE F.11 – CASE FRONT REMOVAL PREPARATION
TERMINAL
CABLES
BATTERY
REMOVE
FASTENERS
RETAINER
FASTENERS
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F-33
F-33
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT (continued)
See Figure F.12 for steps 11 - 15.
13. Using pliers remove the fuel return line from
the top of the fuel tank.
11. Turn off the fuel at the fuel bowl and remove
the fuel line. Plug the line to prevent
spillage.
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.
12. With the 9/16" wrench, remove the four nuts,
bolts and washers that mount the fuel tank
to the rails.
15. Carefully remove the fuel tank.
FIGURE F.12 – FUEL TANK REMOVAL
FUEL TANK
RETURN LINE
FUEL TANK
MOUNTING
HARDWARE
CABLE
RETAINER
FUEL
LINE
FUEL
BOWL
CLASSIC II
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F-34
F-34
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT (continued)
See Figure F.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.
FIGURE F.13 – OUTPUT TERMINAL STRAP AND CASE FRONT REMOVAL
NEGATIVEOUTPUT
TERMINAL (COPPER
STRAP ON REAR SIDE)
CLASSIC II
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F-35
F-35
TROUBLESHOOTING & 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
on the right side of the alternator cover.
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 – ALTERNATOR COVER REMOVAL
LOOSEN 5
SCREWS
ALTERNATOR
COVER
SLIP
RINGS
BRUSHES
CLASSIC II
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F-36
F-36
TROUBLESHOOTING & REPAIR
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT (continued)
See Figure F.15 for steps 22 - 24.
24. With the 1-5/8" socket wrench, remove the
rotor locking nut, washer and sleeve collar.
Note: The sleeve collar will have to be
removed with a gear puller. Be careful not to
damage the rotor slip ring assembly.
Remove the rotor by pulling it free of the
generator shaft.
22. With the 7/16" wrench, remove the two bolts,
nuts and washers mounting the brush hold-
er assembly to the stator frame.
23. Bend the flat washer away from the rotor
locking nut.
FIGURE F.15 – ROTOR REMOVAL
"BENT"
WASHER
STATOR
FRAME
SLEEVE
COLLAR
BRUSH
HOLDER
ASSEMBLY
NUT
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F-37
F-37
INSTALLATION
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT (continued)
Replacement
25. Carefully mount the rotor onto the generator
shaft. Install a new sleeve collar (part num-
ber T14337), washer, and rotor locking nut.
31. 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.
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.
32. 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).
After the rotor locking nut is properly
torqued, bend the washer down over the
locking nut.
33. Attach the battery retainer clamp with the
two nuts and split ring lock washers.
Check rotor air gap. .017” minimum is
allowed.
34. Attach the case top and door assembly using
the 1/2" and 9/16" wrenches.
26. 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.
35. Install the exhaust pipe rain cap.
36. Replace any cable ties cut for disassembly.
37. Install the left case side.
27. Install the alternator cover with the screw
and washer at top and the screws at the two
sides.
38. Connect the negative battery cable.
28. Mount the case front assembly onto the base
and into position where it attaches to the fuel
tank rails.
29. With the 3/4" wrench, attach the copper strap
to the negative output terminal.
30. 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.
CLASSIC II
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F-38
F-38
TROUBLESHOOTING & 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.
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 aid the technician in the removal and replacement of the alternator stator.
MATERIALS NEEDED
3/8" nut driver
3/8" wrench
1/2" wrench
Slot head screwdriver
Pry bar
5/8" wrench
7/16" wrench
CLASSIC II
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F-39
F-39
TROUBLESHOOTING & REPAIR
ALTERNATOR STATOR REMOVAL AND
REPLACEMENT (continued)
FIGURE F.16 – COMMUTATOR WRAP-AROUND REMOVAL
COMMUTATOR
WRAP-AROUND
ALTERNATOR
BRUSH HOLDER
ASSEMBLY
(REMOVED)
PROCEDURE
8. 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 breaker. See
the Wiring Diagram and Figure F.18.
1. Turn the engine OFF.
2. Perform the Alternator Rotor Removal
procedure.
3. With the 3/8" nut driver, remove the two
leads from the alternator brush holder
assembly. Note lead placement. Set brush
holder aside.
9. Remove the red auxiliary power lead from
the circuit breaker.
Diagram.
See the Wiring
4. With the 3/8" wrench, remove the bottom
alternator cover.
10. Remove the white auxiliary power lead
from the 115VAC receptacle. Cut any nec-
essary cable ties.
5. With the slot head screwdriver, remove the
commutator wrap-around. See Figure F.16.
11. Remove the red lead from the negative ter-
minal of the field rectifier bridge. See
Figure F.18.
6. Disconnect the yellow and white wires at the
in-line connectors. See the Wiring Diagram
and Figure F. 17.
12. Remove the black lead from the positive
terminal of the field rectifier bridge.
7. 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
F.18.
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F-40
F-40
TROUBLESHOOTING & REPAIR
ALTERNATOR STATOR REMOVAL
AND REPLACEMENT (continued)
FIGURE F.17 - LEAD DISCONNECTION POINTS
YELLOW AND WHITE WIRE
IN-LINE CONNECTORS
LOCATEDBEHIND CASE FRONT
FIGURE F.18 - LEAD DISCONNECTION – CIRCUIT BREAKER, RECEPTACLES AND FIELD BRIDGE RECTIFIER
230 VACRECEPTACLE
115 VACRECEPTACLE
CIRCUIT BREAKER
FIELD BRIDGE
RECTIFIER
CLASSIC II
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F-41
F-41
TROUBLESHOOTING & REPAIR
ALTERNATOR STATOR REMOVAL
AND REPLACEMENT (continued)
14. Clear the leads in preparation for remov-
ing the stator/end bracket.
15. Lift the eight brushes from the commuta-
tor. Note the position of the brushes for
reassembly.
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
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F-42
F-42
TROUBLESHOOTING & REPAIR
ALTERNATOR STATOR REMOVAL
AND REPLACEMENT (continued)
FIGURE F.20 - DRILL SPOT LOCATIONS
DRILL SPOT
STATOR/ENDBRACKET
MOUNTING BOLT
17. With the 5/8" wrench, remove the four
bolts mounting the stator/end bracket
assembly to the generator frame. Note
the "drill spot" for reassembly. See Figure
F.20.
24. Install the eight commutator brushes
according to how you marked their posi-
tions at disassembly.
25. Attach the black lead to the positive termi-
nal of the field rectifier bridge. Attach the
red lead to the negative terminal.
18. With the 7/16" wrench, loosen (do not
remove) the generator brush holder
clamping bolt. Note the drill spot for
reassembly . See Figure F.20.
26. 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.
19. Carefully pry the stator/end bracket
assembly away from the generator frame.
NOTE: The generator brush holder assem-
bly will also be removed.
27. 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.
Replacement
20. Mount 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.
28. Install the commutator wrap-around, the
bottom alternator cover, the battery, and
the alternator brush holder assembly.
21. Check armature air gap. Minimum gap is
.035." Loosen the four mounting bolts;
adjust and re-tighten if necessary.
29. Install the alternator rotor according to the
reassembly directions in the Alternator
Rotor Removal and Replacement pro-
cedure. Before installing the case top and
sides, replace any cable ties cut for disas-
sembly.
22. Tighten the generator brush holder assem-
bly with the 7/16" wrench.
23. Connect the four heavy cables from the
generator frame coils to the generator
brush holders.
CLASSIC II
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F-43
F-43
TROUBLESHOOTING & 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.
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 aid the technician in the removal and replacement of the DC generator
frame.
MATERIALS NEEDED
3/4" wrench
Rope sling
1/2" wrench
5/8" wrench
Wood or steel blocks
Pry bars
CLASSIC II
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F-44
F-44
TROUBLESHOOTING & REPAIR
GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.21 – GENERATOR LEAD AND CABLE CONNECTIONS
SELECTOR
SWITCH
CABLES
BLUE AND
BROWN LEADS
PROCEDURE
7. Label the five cables that are connected to the
selector switch. Otherwise, you will need to
see the Wiring Diagram during reassembly.
1. Turn the engine OFF.
2. Perform the Alternator Rotor Removal
procedure.
8. With the 1/2" wrench, remove the five cables
connected to the selector switch.
3. Perform the Alternator Stator Removal
procedure.
9. Carefully clear all remaining leads and set the
front panel assembly to the left side of the
machine. On later models, remove leads #62
and #58 from the circuit breaker located on
the output terminal assembly.
4. Cut all necessary cable ties.
5. Disconnect the blue and the brown wires at
the in-line connectors. See Figure F. 21 and
the Wiring Diagram.
6. With the 3/4" wrench, remove the cable from
the positive output terminal.
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F-45
F-45
TROUBLESHOOTING & REPAIR
GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.22 – FRAME MOUNTING DETAILS
ROPE SLING
ENGINE/GENERATOR
MOUNTING HOLES
See Figure 22 for steps 10 - 13.
15. With the 3/4" wrench, install the frame
mounting bolts, nuts, and spacers to the feet
of the generator frame.
10. With the 3/4" wrench, remove the frame
mounting bolts, nuts and spacers from the
feet of the generator frame.
16. Connect leads #62 and #58 to the circuit
breaker on the output terminal assembly
(newer model machines).
11. 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.
17. Connect the five cables to the selector
switch according to how you labeled them
during disassembly. See the Wiring Diagram
if necessary.
12. With the 9/16" wrench, remove the nine bolts
mounting the engine to the generator frame.
18. Connect the blue and brown wires at their in-
line connectors.
13. 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.
19. Perform the replacement procedures
according to each of the following:
Alternator Stator Removal and Replacement
Alternator Rotor Removal and Replacement
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.
Before installing the machine case top and
sides, be sure to replace any cable ties cut
during disassembly.
CLASSIC II
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F-46
F-46
TROUBLESHOOTING & 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.
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 aid the technician in the removal and replacement of the main armature.
MATERIALS NEEDED
5/8" wrench
Rope sling
Wood or steel blocks
CLASSIC II
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F-47
F-47
TROUBLESHOOTING & REPAIR
GENERATOR ARMATURE REMOVAL
AND REPLACEMENT (continued)
FIGURE F.23 – BLOWER PADDLE REMOVAL
ROPE SLING
BLOWER PADDLE
BLOWER
PADDLE/ARMATURE
MOUNTING BOLTS(8)
Replacement
PROCEDURE
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 under 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.
1. Turn the engine OFF.
2. Perform the Alternator Rotor Removal pro-
cedure.
3. Perform the Alternator Stator Removal pro-
cedure.
4. Perform the Generator Frame Removal pro-
cedure.
5. Using the rope sling, support the armature.
10. Perform the replacement procedures
according to each of the following:
6. Make sure the engine is supported with the
wood or steel blocks.
Generator Frame Removal and Replacement
Alternator Stator Removal and Replacement
Alternator Rotor Removal and Replacement
7. 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.
Before installing the machine case top and sides,
be sure to replace any cable ties cut during dis-
assembly.
8. 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.
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F-48
F-48
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
Retest a machine:
• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the
machine’s electrical characteristics. OR
• If you repair or replace any electrical components.
ENGINE OUTPUT
Mode
Low Idle
High Idle
No Load RPM
1350-1400
1780-1810
Load RPM
NA
1650-1740
WELDER DC OUTPUT
Current Control
Rheostat
Current Selector
Open Circuit
Voltage
Load Volts
Load Amps
Switch
Maximum
Maximum
91-98.5
38-45
300
AC AUXILIARY POWER RECEPTACLE OUTPUT
230 Volt Receptacle
115 Volt Receptacle
Open Circuit
Voltage
Load Volts
Load Amps
Open Circuit
Voltage
Load Volts
Load Amps
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
1.90 - 2.30
Alt. Rotor Amps
RPM
1780 - 1810
123 - 133
2.2 - 2.6
CLASSIC II
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G-1
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
ELECTRICAL DIAGRAMS SECTION
Electrical Diagrams Section ..........................................................................................Section G
Wiring Diagram (Code 9805 ) ...............................................................................................G-2
Wiring Diagram (Code 10000) ..............................................................................................G-3
Wiring Diagram (Code 10070 ) .............................................................................................G-4
Wiring Diagram (Code 10071 ) .............................................................................................G-5
Wiring Diagram (Code 10219 ) .............................................................................................G-6
Wiring Diagram (Code 10220) ..............................................................................................G-7
Idler PC Board (M13708) Schematic ....................................................................................G-8
Idler PC Board (M13708) Components.................................................................................G-9
Idler PC Board (l9902) Schematic.......................................................................................G-10
Idler PC Board (l9902) Components ...................................................................................G-11
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NOTES
CLASSIC II
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G-2
G-2
ELECTRICAL DIAGRAMS
Wiring Diagram (Code 9805 )
2
1
D+
W
59A
59
CR1
BOTTOM VIEW
SHOWN
1
3
TO WELDING
GENERATOR
B+ D-
53B
(
)
ALTERNATOR ROTOR
ALTERNATOR
610
4
6
B
SLIP RINGS
+
-
Y
-
W
+
B
7
9
TERMINAL
STRIP
U
R1
SLIP RING NEAREST
TO IRON
58D
58A
R
600
602
50
A
B
U
R
W
Y
IDLER
P.C.
+
-
600
41
42
602
R
BOARD
8
57
56A
N
AC
AC
Y
61
60B
FUEL
SOLENOID
600A
41
60D
60F
58C
7
ENGINE
W
58B
PROTECTION
RELAY
15A.
FUSE
115 VOLT
IDLER
SOLENOID
RECEPTACLE
START
56
42
+
Y
60C
IGNITION
SWITCH
FUSE
(SFE-14)
POTENTIOMETER
602A
IDLER
SWITCH
SELECTOR
SWITCH
ENGINE
OIL TEMPERATURE
SENSOR
G NONC S
B
HOUR METER
60
R
3
4
ALTERNATOR
AUXILIARY
POWER
W
60A
54B
54A
58
54
CB1
CB2
U
WINDINGS
53
53A
51A
50A
55
OIL PRESSURE
SENSOR
60E
5
6
52
S
I
B
B
G
GND
GAUGE
STARTING
MOTOR
A
5
OIL PRESSURE
51
CURRENT
N
TRANSFORMER
4
3
2
1
50
U
CR2 REED
RELAY
WELDER
LEAD BLOCK
230 VOLT
RECEPTACLE
U
+
A
R
509
503
N
U
N
U
G
+
-
POSITIVE CV &
VV OUTPUT
TERMINAL
N
NEGATIVE
VV OUTPUT
TERMINAL
POS
NEG
CB3
CB4
-
W
Y
TO WELDING
GENERATOR
REMOTE CONTROL (OPTIONAL)
+
4
3
2
1
8
7
6
5
W
SA-250 THERMOSTAT
ASSEMBLY
REMOTE CONTROL PANEL & SWITCH
RESISTORS
CV ADAPTER
Y
608
609
COPPER
CONNECT TO NEGATIVE
BRUSH HOLDER
TERMINAL
COPPER
PLUG FOR
TERMINAL
REMOTE CONTROL
POTENTIOMETER
#2 HEAVY LEAD
W
NEGATIVE CV OUTPUT TERMINAL
PIN CONFIGURATION
ON ENGINE
CONNECTOR
GROUND TERM.
(WIDE SLOT)
B
B
G
W
G
41
602
600
42
*
GROUND TERM.
(WIDE SLOT)
SEE
ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODE
BELOW
CONNECT
TO CASE
R-RED
B-BLACK
G-GREEN
N-BROWN
U-BLUE
SWITCH FOR
W-WHITE
Y-YELLOW
LOCAL OR REMOTE
CONTROL SHOWN IN
LOCAL POSITION.
CONTROL PANEL COMPONENTS
SHOWN AS VEIWED FROM REAR.
REMOTE CONTROL
POTENTIOMETER BOX
*
WITH MACHINE NOT RUNNING, REMOVE JUMPER 42 TO
600 AT THE TERMINAL STRIP. CONNECT THESE LEADS
TO THE CORRESPONDING NUMBERS AT THE TERMINAL
STRIP.
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.
CLASSIC II
Download from Www.Somanuals.com. All Manuals Search And Download.
G-3
G-3
ELECTRICAL DIAGRAMS
Wiring Diagram (Code 10000)
2
1
D+
W
59A
59
CR1
BOTTOM VIEW
SHOWN
1
3
TO WELDING
GENERATOR
B+ D-
53B
(
)
ALTERNATOR ROTOR
ALTERNATOR
610
4
7
A
6
B
SLIP RINGS
+
-
Y
-
W
+
B
9
TERMINAL
STRIP
U
U
R
W
Y
R1
SLIP RING NEAREST
TO IRON
58D
58A
R
600
602
50
B
IDLER
P.C.
+
-
600
41
42
602
R
BOARD
8
57
56A
N
AC
AC
Y
61
60B
FUEL
SOLENOID
600A
41
60D
60F
58C
7
ENGINE
W
58B
PROTECTION
RELAY
15A.
FUSE
115 VOLT
IDLER
SOLENOID
RECEPTACLE
START
56
42
+
Y
60C
IGNITION
SWITCH
FUSE
(SFE-14)
POTENTIOMETER
602A
IDLER
SWITCH
SELECTOR
SWITCH
ENGINE
OIL TEMPERATURE
SENSOR
G NONC S
B
HOUR METER
60
R
3
4
ALTERNATOR
AUXILIARY
POWER
W
60A
54B
54A
58
54
CB1
U
WINDINGS
53
(30 AMP)
53A
51A
50A
55
OIL PRESSURE
SENSOR
60E
5
6
52
S
I
B
B
G
GND
GAUGE
STARTING
MOTOR
A
5
OIL PRESSURE
51
CURRENT
N
TRANSFORMER
4
3
2
1
50
U
CR2 REED
RELAY
WELDER
LEAD BLOCK
230 VOLT
U
RECEPTACLE
+
A
R
509
503
N
U
N
U
G
+
-
POSITIVE CV &
VV OUTPUT
TERMINAL
N
NEGATIVE
VV OUTPUT
TERMINAL
POS
NEG
CB2
(15 AMP)
-
W
Y
TO WELDING
GENERATOR
REMOTE CONTROL (OPTIONAL)
+
4
3
2
1
8
7
6
5
W
SA-250 THERMOSTAT
ASSEMBLY
REMOTE CONTROL PANEL & SWITCH
RESISTORS
CV ADAPTER
Y
608
609
COPPER
CONNECT TO NEGATIVE
BRUSH HOLDER
TERMINAL
COPPER
PLUG FOR
TERMINAL
REMOTE CONTROL
POTENTIOMETER
#2 HEAVY LEAD
W
NEGATIVE CV OUTPUT TERMINAL
PIN CONFIGURATION
ON ENGINE
CONNECTOR
GROUND TERM.
(WIDE SLOT)
B
B
G
W
G
41
602
600
42
*
GROUND TERM.
(WIDE SLOT)
SEE
ELECTRICAL SYMBOLS PER E1537
LEAD COLOR CODE
BELOW
CONNECT
TO CASE
R-RED
B-BLACK
G-GREEN
N-BROWN
U-BLUE
SWITCH FOR
W-WHITE
Y-YELLOW
LOCAL OR REMOTE
CONTROL SHOWN IN
LOCAL POSITION.
CONTROL PANEL COMPONENTS
SHOWN AS VIEWED FROM REAR.
REMOTE CONTROL
POTENTIOMETER BOX
*
WITH MACHINE NOT RUNNING, REMOVE JUMPER 42 TO
600 AT THE TERMINAL STRIP. CONNECT THESE LEADS
TO THE CORRESPONDING NUMBERS AT THE TERMINAL
STRIP.
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.
CLASSIC II
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ELECTRICAL DIAGRAMS
Wiring Diagram (Code 10070 )
ELECTRICAL SYMBOLS
CONTROL PANEL COMPONENTS
SHOWN AS VIEWED FROM REAR.
NEUTRAL BONDED TO FRAME
PIN CONFIGURATION
PER E1537
ON ENGINE
P10
J5
4
3
2
1
8
7
6
5
LEAD COLOR CODE
CONNECTOR
'
NEUTRE RACCORDE AU BATI
CR1
BOTTOM VIEW
SHOWN
9
8
2
1
11
6
5
4
12
7
3
10
R-RED
B-BLACK
G-GREEN
N-BROWN
1
3
U-BLUE
W
B
(
)
W-WHITE
Y-YELLOW
U
W
Y
U
R
+Y
4
7
A
6
9
B
N
-W
IDLER
P.C.
BOARD
ALTERNATOR ROTOR
U
ENGINE
NOTES
SLIP RINGS
PROTECTION
RELAY
ENGINE
HOUR
METER
N.A. EARLIER MODELS DO NOT
-
54
HAVE THIS DIODE.
+
B
610
610
SLIP RING
NEAREST
TO IRON
56A
57
+
B
59A
W
58D
58A
53B
61
602B
R
AC
AC
Y
60F
600B
58C
IDLER
FUSE
(SFE-14)
41
1
2
3
START
R1
50
SOLENOID
-
+
56
115 VOLT
RECEPTACLE
600A
42
230 VOLT
RECEPTACLE
-
IGNITION
SWITCH
51A
G NONC S
B
IDLER
Y
OIL TEMP.
SENSOR
SWITCH
N.A.
58B
15A.
4
5
G
FUSE
602A
RHEOSTAT
3
4
60
59
52
54B
6
60A
P9
J8
Y
OIL PRESSURE
SENSOR
58
B
SELECTOR
SWITCH
53 53A
B
50A
R
6
5
54A
55
B
G
ALTERNATOR
AUXILIARY
POWER
60C
B
B
CB2
CB3
W
CB4
CB1
S
I
GND
G
8
7
WINDINGS
FUEL
SOLENOID
GAUGE
OIL PRESSURE
STARTING
MOTOR
GENERATOR
B
G
U
50
A
60B
2
B
1
D+
W
+
5
4
3
2
1
B
60E
-
+
CURRENT
TRANSFORMER
A
CR2 REED
RELAY
WELDER
B+ D-
LEAD BLOCK
51
U
N
R
U
ALTERNATOR
-W
+Y
60D
N
POSITIVE
NEGATIVE
(CC- )
REMOTE CONTROL (OPTIONAL)
WIRE FEED MODULE (OPTIONAL)
PLUG FOR
REMOTE CONTROL RECEPTACLE & SWITCH
REMOTE CONTROL
POTENTIOMETER
ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
G
B
R
X
SEE
RESISTORS
*
X
Y
INLINE
PLUG
(P5)
BELOW
CONNECTORS
W.F.M.
1
2
3
41
600
42
CONTROL
PANEL
Y
SEE
BELOW
*
W
R
B
#8 LEAD
POS.
4
5
602
CONNECT TO POS. & NEG.
OUTPUT TERMINALS
WIRE FEED
MODULE
G
W
NEG.
6
CONNECT
TO CASE
NEGATIVE CV
OUTPUT TERMINAL
PANEL
P8
#2 HEAVY LEAD
608
SWITCH FOR LOCAL OR REMOTE CONTROL
SHOWN IN LOCAL POSITION.
609
CONNECT TO NEG.
BRUSH HOLDER
REMOTE CONTROL
WITH MACHINE NOT RUNNING, REMOVE PLUG "P9" ON
MACHINE FROM CONNECTOR "J8". THEN CONNECT
PLUG "P8" ON REMOTE CONTROL TO
CONNECTOR "J8" ON MACHINE.
*
POTENTIOMETER BOX
#2 HEAVY LEAD
250 AMP
MACHINE MUST NOT BE RUNNING
*
RED & BLACK LEADS NOT CONNECTED ON THIS
MACHINE.
THERMOSTAT
ASSEMBLY
WHEN MAKING THESE CONNECTIONS.
R
L9012
CLEVELAND, OHIO U.S.A.
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.
CLASSIC II
Download from Www.Somanuals.com. All Manuals Search And Download.
G-5
G-5
ELECTRICAL DIAGRAMS
Wiring Diagram (Code 10071 )
ELECTRICAL SYMBOLS
PER E1537
CONTROL PANEL COMPONENTS
SHOWN AS VIEWED FROM REAR.
NEUTRAL BONDED TO FRAME
PIN CONFIGURATION
ON ENGINE
P10
J5
4
3
2
1
8
7
6
5
LEAD COLOR CODE
CONNECTOR
'
CR1
BOTTOM VIEW
SHOWN
9
8
2
1
11
6
5
4
NEUTRE RACCORDE AU BATI
12
7
3
10
R-RED
B-BLACK
G-GREEN
N-BROWN
1
3
U-BLUE
W
B
(
)
W-WHITE
Y-YELLOW
U
W
Y
U
R
+Y
4
7
A
6
9
B
N
-W
IDLER
P.C.
BOARD
ALTERNATOR ROTOR
U
54
NOTES
ENGINE
N.A. EARLIER MODELS DO NOT
HAVE THIS DIODE.
SLIP RINGS
PROTECTION
RELAY
ENGINE
HOUR
METER
-
+
B
610
610
SLIP RING
NEAREST
TO IRON
56A
57
+
B
59A
W
58D
58A
53B
61
602B
R
AC
AC
Y
60F
600B
58C
IDLER
FUSE
(SFE-14)
41
1
2
3
START
R1
50
SOLENOID
-
+
56
115 VOLT
RECEPTACLE
600A
42
230 VOLT
RECEPTACLE
-
15A.
IGNITION
SWITCH
51A
G NONC S
B
Y
IDLER
SWITCH
OIL TEMP.
SENSOR
N.A.
58B
4
5
G
FUSE
602A
RHEOSTAT
3
4
60
59
52
54B
6
60A
P9
J8
Y
OIL PRESSURE
SENSOR
58
SELECTOR
SWITCH
53 53A
B
50A
60C
R
54A
55
6
5
G
ALTERNATOR
AUXILIARY
POWER
CB1
(30AMP)
CB2
(15AMP)
W
G
S
I
GND
B
8
7
WINDINGS
FUEL
SOLENOID
GAUGE
STARTING
MOTOR
GENERATOR
OIL PRESSURE
B
G
50
A
60B
2
B
1
D+
W
5
4
3
2
1
B
+
60E
-
+
CURRENT
TRANSFORMER
A
CR2 REED
RELAY
WELDER
B+ D-
U
LEAD BLOCK
51
U
N
R
U
ALTERNATOR
-W
+Y
60D
N
POSITIVE
NEGATIVE
(CC- )
REMOTE CONTROL (OPTIONAL)
WIRE FEED MODULE (OPTIONAL)
PLUG FOR
REMOTE CONTROL RECEPTACLE & SWITCH
REMOTE CONTROL
ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
POTENTIOMETER
G
B
R
X
SEE
RESISTORS
*
X
Y
INLINE
PLUG
(P5)
BELOW
CONNECTORS
W.F.M.
1
2
3
41
600
42
CONTROL
PANEL
Y
SEE
BELOW
*
W
R
B
#8 LEAD
POS.
4
5
602
CONNECT TO POS. & NEG.
OUTPUT TERMINALS
WIRE FEED
MODULE
G
W
NEG.
6
CONNECT
TO CASE
NEGATIVE CV
OUTPUT TERMINAL
PANEL
P8
#2 HEAVY LEAD
608
SWITCH FOR LOCAL OR REMOTE CONTROL
SHOWN IN LOCAL POSITION.
609
CONNECT TO NEG.
BRUSH HOLDER
REMOTE CONTROL
WITH MACHINE NOT RUNNING, REMOVE PLUG "P9" ON
MACHINE FROM CONNECTOR "J8". THEN CONNECT
PLUG "P8" ON REMOTE CONTROL TO
CONNECTOR "J8" ON MACHINE.
*
POTENTIOMETER BOX
#2 HEAVY LEAD
250 AMP
MACHINE MUST NOT BE RUNNING
*
RED & BLACK LEADS NOT CONNECTED ON THIS
MACHINE.
THERMOSTAT
ASSEMBLY
WHEN MAKING THESE CONNECTIONS.
R
L9013
CLEVELAND, OHIO U.S.A.
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.
CLASSIC II
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
G-6
ELECTRICAL DIAGRAMS
Wiring Diagram (Code 10219 )
ELECTRICAL SYMBOLS
PER E1537
CONTROL PANEL COMPONENTS
SHOWN AS VIEWED FROM REAR.
NEUTRAL BONDED TO FRAME
P10
J5
LEAD COLOR CODE
'
NEUTRE RACCORDE AU BATI
9
8
2
1
11
6
5
4
12
7
3
10
R-RED
B-BLACK
G-GREEN
N-BROWN
61
U-BLUE
ENGINE
FAILURE
LAMP
W
B
W-WHITE
Y-YELLOW
+Y
1
1 2 3 4
J1
5
6
7
8
9 10
N
-W
2
ROTOR
IDLER/ENGINE
PROTECTION
P.C. BOARD
ALTERNATOR
U
58
62
3
53B
J2
4
SLIP RINGS
-
R
+
B
610
610
CB1
SLIP RING
NEAREST
TO IRON
+
57
ENGINE
HOUR
602B
R
AC
AC
Y
600B
53
METER
56A
56
IDLER
60C
41
600A
42
1
2
3
START
SOLENOID
-
+
IGNITION
SWITCH
115 VOLT
RECEPTACLE
230 VOLT
RECEPTACLE
-
15A.
IDLER
Y
SWITCH
OIL TEMP.
SENSOR
J3
P3
3
4
5
G
58A
51A
FUSE
602A
RHEOSTAT
60
54B
4
6
P9
J8
Y
54
OIL PRESSURE
SENSOR
53A
B
SELECTOR
SWITCH
B
50A
6
5
R
B
55
60A
G
ALTERNATOR
AUXILIARY
POWER
B
B
CB2
CB3
W
CB4
52
CB1
7
8
S
I
FUEL
GND
SOLENOID
G
WINDINGS
GAUGE
STARTING
MOTOR
GENERATOR
OIL PRESSURE
59
51
B
9
10
ENGINE
60B
G
CONNECTOR
50
A
1
B
D+
W
5
4
3
2
1
2
B
+
60E
-
+
A
CURRENT
TRANSFORMER
CR2 REED
RELAY
WELDER
B+ D-
W
W
LEAD BLOCK
N
R
U
ALTERNATOR
-W
+Y
N
POSITIVE
(CC+) & (CV+ WITH W.F.M.)
NEGATIVE
(CC- )
REMOTE CONTROL (OPTIONAL)
WIRE FEED MODULE (OPTIONAL)
PLUG FOR
REMOTE CONTROL RECEPTACLE & SWITCH
REMOTE CONTROL
ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
POTENTIOMETER
CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
G
B
R
X
SEE
RESISTORS
*
X
Y
INLINE
PLUG
(P5)
BELOW
CONNECTORS
W.F.M.
1
2
3
41
600
42
CONTROL
PANEL
Y
SEE
BELOW
*
W
R
B
#8 LEAD
4
5
602
POS.
CONNECT TO POS. & NEG.
OUTPUT TERMINALS
WIRE FEED
G
W
NEG.
6
CONNECT
TO CASE
MODULE
NEGATIVE CV
OUTPUT TERMINAL
PANEL
P8
#2 HEAVY LEAD
608
609
SWITCH FOR LOCAL OR REMOTE CONTROL
SHOWN IN LOCAL POSITION.
CONNECT TO NEG.
BRUSH HOLDER
REMOTE CONTROL
WITH MACHINE NOT RUNNING, REMOVE PLUG "P9" ON
MACHINE FROM CONNECTOR "J8". THEN CONNECT
PLUG "P8" ON REMOTE CONTROL TO
CONNECTOR "J8" ON MACHINE.
*
POTENTIOMETER BOX
#2 HEAVY LEAD
250 AMP
MACHINE MUST NOT BE RUNNING
*
RED & BLACK LEADS NOT CONNECTED ON THIS
MACHINE.
THERMOSTAT
ASSEMBLY
WHEN MAKING THESE CONNECTIONS.
R
1-19-96
L9920
CLEVELAND, OHIO U.S.A.
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.
CLASSIC II
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ELECTRICAL DIAGRAMS
Wiring Diagram (Code 10220)
ELECTRICAL SYMBOLS
PER E1537
CONTROL PANEL COMPONENTS
SHOWN AS VIEWED FROM REAR.
NEUTRAL BONDED TO FRAME
P10
J5
LEAD COLOR CODE
'
9
8
2
1
11
6
5
4
NEUTRE RACCORDE AU BATI
12
7
3
10
R-RED
B-BLACK
G-GREEN
N-BROWN
61
U-BLUE
ENGINE
FAILURE
LAMP
W
B
W-WHITE
Y-YELLOW
+Y
1
1 2 3 4
5
6
7
8
9 10
N
-W
2
ROTOR
IDLER/ENGINE
PROTECTION
P.C. BOARD
ALTERNATOR
U
J1
58
62
3
53B
J2
4
SLIP RINGS
-
R
+
B
610
610
CB1
SLIP RING
NEAREST
TO IRON
+
57
ENGINE
HOUR
602B
R
AC
AC
Y
600B
53
METER
56A
56
IDLER
60C
41
600A
42
1
2
3
START
SOLENOID
-
+
IGNITION
SWITCH
115 VOLT
RECEPTACLE
230 VOLT
RECEPTACLE
-
15A.
IDLER
Y
SWITCH
OIL TEMP.
SENSOR
P3
3
J3
4
5
G
58A
51A
FUSE
602A
RHEOSTAT
60
54B
4
6
P9
J8
Y
54
OIL PRESSURE
SENSOR
53A
SELECTOR
SWITCH
B
50A
6
5
R
55
60A
G
ALTERNATOR
AUXILIARY
POWER
CB1
CB2
(15AMP)
B
W
52
G
(30AMP)
7
8
S
I
FUEL
GND
SOLENOID
WINDINGS
GAUGE
STARTING
MOTOR
GENERATOR
OIL PRESSURE
59
51
B
9
10
ENGINE
60B
G
CONNECTOR
50
A
1
B
D+
W
5
4
3
2
1
2
B
+
60E
-
+
CURRENT
TRANSFORMER
A
CR2 REED
RELAY
WELDER
B+ D-
W
W
LEAD BLOCK
N
R
U
ALTERNATOR
-W
+Y
N
POSITIVE
(CC+) & (CV+ WITH W.F.M.)
NEGATIVE
(CC- )
REMOTE CONTROL (OPTIONAL)
WIRE FEED MODULE (OPTIONAL)
PLUG FOR
REMOTE CONTROL RECEPTACLE & SWITCH
REMOTE CONTROL
POTENTIOMETER
ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
G
B
R
X
SEE
RESISTORS
*
X
Y
INLINE
PLUG
(P5)
BELOW
CONNECTORS
W.F.M.
1
2
3
41
600
42
CONTROL
PANEL
Y
SEE
BELOW
*
W
R
B
#8 LEAD
4
5
602
POS.
CONNECT TO POS. & NEG.
OUTPUT TERMINALS
WIRE FEED
G
W
NEG.
6
CONNECT
TO CASE
MODULE
NEGATIVE CV
OUTPUT TERMINAL
PANEL
P8
#2 HEAVY LEAD
608
609
SWITCH FOR LOCAL OR REMOTE CONTROL
SHOWN IN LOCAL POSITION.
CONNECT TO NEG.
BRUSH HOLDER
REMOTE CONTROL
WITH MACHINE NOT RUNNING, REMOVE PLUG "P9" ON
MACHINE FROM CONNECTOR "J8". THEN CONNECT
PLUG "P8" ON REMOTE CONTROL TO
CONNECTOR "J8" ON MACHINE.
*
POTENTIOMETER BOX
#2 HEAVY LEAD
250 AMP
MACHINE MUST NOT BE RUNNING
*
RED & BLACK LEADS NOT CONNECTED ON THIS
MACHINE.
THERMOSTAT
ASSEMBLY
WHEN MAKING THESE CONNECTIONS.
R
1-19-96
L9919
CLEVELAND, OHIO U.S.A.
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.
CLASSIC II
Download from Www.Somanuals.com. All Manuals Search And Download.
G-8
G-8
ELECTRICAL DIAGRAMS
Idler PC Board (M13708) Schematic
M
1 6 9 8 9
NOT USED
9
X1 -C
D2
R8
YEL
B213
1
14
R9
R15
15.0
8
+
56
t
TO BATTERY
15.0
D1
GND
TO SOLENOID
1
WHITE
B212
3
16
DZ1
10V
5W
C3
C4
50
15V
C1
X2
X1
LM2901
12
4536B
8
10K
GND
TO REED SW.
GND
RED
GND
T13157-14
1
R13
B209
13.7K
C10
511
.047
D7
47.5K
100V
10K
22.1K
R20
D
S
13.7K
33.2K
5.11K
R6
C8
Q1
10K
R5
133K
15A
60V
G
16
5
4
1
DZ3
SET
V
DD
15V
1W
DZ2
27V
5W
7
6
X1 -A
11
2
2
3
4
5
6
7
15
14
13
12
11
RESET
MONO IN
OSC INH
1
R17
X1
-B
X2
13
IN
1
1.00K
X1
-D
D8
10
OUT
OUT
1
DECODE
R12
2
D
C
B
26.7K
C9
C7
8
BY-PASS
10
CLOCK INH
VSS
D5
1N4936
10K
8
9
A
3.32K
4536B
Q2
600mA
40V
C2
B210
TO
CURRENT
XFMR.
R14
C6
18
15V
1
22.1K
.5
5W
15.0K
R
C5
D3
B211
1
BLUE
P.C.BOARD IS CONNECTED DIRECTLY
TO FRAME GND THRU MOUNTING SCREW
GND
M16989_2DE
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
R- 21
C- 10
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
D-
8
LABELS
=
Ohms
(
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
SUPPLY
VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
COMPLETE BOARD, THIS DIAGRAM MAY
WITHOUT AFFECTING THE INTERCHANGEABILITY OF
A
FRAME CONNECTION
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
EARTH GROUND CONNECTION
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
Ch'ge.Sht.No.
EQUIP.
TYPE
ENGINE WELDERS
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
10-29-93J
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.O2
.OO2
IDLER PCB SCHEMATIC
SUBJECT
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
NONE
SCALE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
SHT.
AUSTRALIA
CANADA
FRANCE
S16477
I.E.B.
2/10/93
CHK.
SUP'S'D'G.
M
16989
DR.
DATE
NO.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
in danger to the Machine Operator or Technician. Improper PC board repairDsocwonuloladd rfreosmuWltwinw.Sdoammanaugaels.ctoomt.hAell MmaancuahlisnSee.arch And Download.
CLASSIC II
G-9
G-9
ELECTRICAL DIAGRAMS
Idler PC Board (M13708) Components
B210
Q1
B212
B211
B209
B213
R11
C4
C10
X1
X2
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
in danger to the Machine Operator or Technician. Improper PC board repairDsocwonuloladd rfreosmuWltwinw.Sdoammanaugaels.ctoomt.hAell MmaancuahlisnSee.arch And Download.
CLASSIC II
G-10
G-10
ELECTRICAL DIAGRAMS
Idler PC Board (l9902) Schematic
+10V
UNUSED
J2
J2
+10V
3
14
16
16
1
C6
C7
C5
C4
X3
2
13
12
9
8
X1
X2
X4
11
10
X3
X3
4093B
7
LM2901
4536B
8
4536B
8
COM
12
COM
+10V
J1
J1
IDLER SWITCH
2
8
33.2K
C1
.047
100V
+10V
D1
IDLER 12 SEC. TIMER
SET
4.75K
1N4936
SOLENOID
R
16
1
REED SW
100
R3
1
Vdd
D
S
3
2
3
4
5
6
7
15
14
13
12
11
X3
RESET
MONO IN
Q2
2
18A
G
150
162
R7
IN
1
OSC INH
X1
R8
200V
J2
J2
Q1
3
R11
2N4401
OUT
OUT
1
DECODE
100
DZ2
15V
1W
2
D
C
B
DZ1
10V
5W
R10
150
150
R2
R1
TP1
50V
15J
C3
C2
8
BY-PASS
TOROID
4
1.50K
13.7K
.47
10
9
50V
CLOCK INH
Vss
8
A
4536B
5W
.5
R9
150
COM
D2
COM
8A
+10V
400V
J1
R15
R13
FRAME GND
5
D3
133K
47.5K
1N4936
GND
PC BOARD IS CONNECTED DIRECTLY
TO FRAME GND THRU MOUNTING SCREW
7
6
1
26.7K
R16
X4
C8
18
15V
6.19K
COM
+12V
+10V
+12V
68.1
R34
J1
RUN SW
1
R33
+
t
1
C13
100
15V
10.0K
56
R31
68.1
8
X5
10.0K
10.0K
4.75K
68.1K
5
5
3
REF
ENGINE PROTECTION
CR1
TL431
6
2
CR1
CR1
D6
12Vdc
1N4936
16
J1
1
SET
Vdd
4
R30
ENG PROTECT LAMP
4
4
1
2
3
4
5
6
7
15
14
13
12
11
RESET
MONO IN
3.32K
D5
X4
COM
2
J1
J1
D4
33.2K
R26
IN
1
OSC INH
OIL PRESS
TEMP
7
6
R32
X2
5
D
C12
OUT
OUT
1
DECODE
GND
1.00K
Q3
1N4936
C9
.047
C11
0.1
50V
18A
200V
+10V
2
D
C
B
G
C10
7.68K
100V
221K
R20
100
8
BY-PASS
S
J1
J1
200V
.022
R22
COM
HOUR METER
DZ3
15V
1W
10
9
10
CLOCK INH
Vss
COM
8
9
6
5
A
4
COM
COM
4536B
X3
4.75K
18.2K
FUEL SOLENOID
+10V
+12V
R42
R18
COM
100K
R36
6.19K
100K
10.0K
22.1K
9
8
R35
1.00K
COM
14
11
X4
R37
Q4
13
R19
2.67K
+10V
X4
R39
1A
10
100V
1.82K
R38
6.19K
1.21K
25
5W
COM
J1
ALT EXC
3
D7
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
CLASSIC II
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-11
G-11
ELECTRICAL DIAGRAMS
Idler PC Board (l9902) Components
ITEM
REQ'D
IDENTIFICATION
PART NO.
X2
X5
X3
Q4
Q3
R26
R22
C3
R30
CR1
C12
N.A.
R17
DZ2
C10
DZ1
X1
R34
X4
Q2
TP1
C9
D2
R14
R4
R1
D6
B1
J1
J2
R
IDLER ENGINE SHUTDOWN
L9902
N.A.
N.A.
N.A. THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC
ELECTRICITY. SEE E2454 BEFORE HANDLING.
CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRYS
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
CLASSIC II
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Download from Www.Somanuals.com. All Manuals Search And Download.
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