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Lincoln Electric CLASSIC III Service Manual Download Page 39

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Section D-1

Section D-1

Classic III and IIID

TABLE OF CONTENTS

-MAINTENANCE-

Maintenance

.........................................................................................................................

Section D

Safety Precautions ......................................................................................................................D-2

Routine and Periodic Maintenance .............................................................................................D-2

Engine Maintenance.......................................................................................................D-2

Change the Oil ........................................................................................................D-2

Change the Oil Filter ...............................................................................................D-3

Fuel..........................................................................................................................D-3

Fuel Filter.................................................................................................................D-4

Air Cleaner...............................................................................................................D-4

How to Eliminate Air From the Fuel System ...........................................................D-5

Cooling System .......................................................................................................D-6

Spark Plugs .............................................................................................................D-6

Tightening the Fan Belt ...........................................................................................D-7

Engine Maintenance Schedule................................................................................D-8

Battery Maintenance ......................................................................................................D-9

Cleaning the Battery................................................................................................D-9

Checking Specific Gravity........................................................................................D-9

Checking Electrolyte Level ......................................................................................D-9

Charging the Battery ...............................................................................................D-9

Welder/Generator Maintenance ...................................................................................D-10

Storage ..................................................................................................................D-10

Cleaning ................................................................................................................D-10

Nameplates ...........................................................................................................D-10

Commutator and Brushes .....................................................................................D-10

Bearings ................................................................................................................D-10

Current Range Selector Contacts .........................................................................D-10

Receptacles ...........................................................................................................D-10

Cable Connections ................................................................................................D-10

Idler Maintenance.........................................................................................................D-11

Major Component Locations .....................................................................................................D-12

Summary of Contents for CLASSIC III

Page 1: ...y 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 Wo...

Page 2: ...EIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding Cutting ANSI...

Page 3: ...he electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously t...

Page 4: ...arting 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...

Page 5: ...gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussure...

Page 6: ...Applications B 3 Operational Features and Controls B 3 Design Features B 3 Welding Capability B 4 Limitations B 4 Controls and Settings B 5 Engine Operation B 9 Welding Operation B 11 Auxiliary Power...

Page 7: ...ation A 4 Pre operation Engine Service A 4 Oil A 4 Fuel A 4 Battery Connections A 4 Cooling System A 5 Muffler A 5 Exhaust Spark Arrester A 5 Trailer A 5 Electrical Output Connections A 6 Welding Cabl...

Page 8: ...ID 4 cyl 4 cycle 1350 RPM Water coolant 9 3 qt Continental Water cooled Low idle 8 8 liters TMD27 Diesel 45 HP 1700 RPM RATED OUTPUT WELDER Duty Cycle Amps Volts at Rated Amperes 100 Duty Cycle 225 DC...

Page 9: ...ver you use the welder be sure that clean cool ing air can flow through the machine s engine and the generator Avoid dusty dirty areas Also keep the machine away from heat sources Do not place the bac...

Page 10: ...ure Do not overfill the fuel tank Wipe up spilled fuel and allow the fumes to clear before starting the engine Keep sparks and flame away from the fuel tank OIL The Classic III and Classic IIID are sh...

Page 11: ...m age or performance loss Contact the engine manu facturer for specific recommendations TRAILER If you use a non Lincoln trailer you must assume responsibility that the method of attachment and usage...

Page 12: ...ure 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 wel...

Page 13: ...VA 115 230V AC auxiliary power one 115V duplex and one 230V duplex grounding type receptacle are provided The circuit is protected with circuit breakers The rating of 3 0 kVA permits a maximum continu...

Page 14: ...ES A 8 A 8 Classic III and IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 15: ...d Settings B 5 Welder Generator Controls B 5 Control of Welding Current B 6 Gasoline Engine Controls B 7 Diesel Engine Controls B 8 Engine Operation B 9 Before Starting the Engine B 9 Starting the Gas...

Page 16: ...uipment with any of its doors open or guards off Stop the engine before servicing it Keep away from moving parts Only qualified personnel should install use or ser vice this equipment GENERAL DESCRIPT...

Page 17: ...ions See Engine Operation in the Operation section of this manual for details about starting running stopping and breaking in the engine DESIGN FEATURES All copper windings for long life and dependabl...

Page 18: ...r any processes besides those that are normally per formed using DC stick welding SMAW and DC TIG welding Specific limitations on using the Classic III and Classic IIID for these processes are describ...

Page 19: ...n the selected output range See Control of Welding Current for more information 3 230 VOLT DUPLEX RECEPTACLE Connection point for supplying 230 volt power to operate one or two electrical devices 4 11...

Page 20: ...et the CURRENT RANGE SELECTOR to the 190 120 posi tion and then adjust the FINE CURRENT ADJUST MENT for 175 amps When a forceful digging arc is required usually for vertical and overhead welding use a...

Page 21: ...tion for details on setting the choke 4 START PUSHBUTTON Press the START button to start the engine The IGNITION switch must be in the ON position NOTE If you press the START pushbutton when the engin...

Page 22: ...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 w...

Page 23: ...move all loads connected to the AC power receptacles before starting the engine 1 Turn the IDLER switch to HIGH 2 Turn the IGNITION switch to ON 3 Pull out the CHOKE control 4 Press the START button 5...

Page 24: ...ome 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 lev...

Page 25: ...ed welding current 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 9 Strik...

Page 26: ...e size and wire feed speed See Table B 1 for recommended settings 6 Set the VOLTAGE ADJUSTMENT to the setting that gives the best arc characteristics for the range selected 7 Pull the gun trigger and...

Page 27: ...d 3 0 kVA 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 v...

Page 28: ...S B 14 B 14 Classic III and IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 29: ...niversal 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 LN...

Page 30: ...oln Bulletin E695 1 dated October 1987 or later Wire Feed Module K623 1 Provides constant voltage output for semiautomatic welding Includes remote for CV mode and internal Cold Tip Contactor Accessory...

Page 31: ...e CV unit for Innershield pipe welding Control cable operates contactor inside wire feed module for cold electrode Requires K350 and K867 adapter cables NOTE Gas shielded welding requires a Magnum Gun...

Page 32: ...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 damag...

Page 33: ...he HIGH position 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 ov...

Page 34: ...o the LN 25 equipped with the K431 1 remote output control kit 5 Place the IDLER switch in the HIGH position Any increase of the high idle engine RPM by changing the governor setting or overriding the...

Page 35: ...ity switch 3 Connect the K444 2 remote control cable to the 14 pin amphenol on the wire feed module 4 Attach the single lead from the LN 25 control box to the work using the spring clip on the end of...

Page 36: ...for most common processes This may be changed if a different arc characteristic is preferred 8 Set the LOCAL REMOTE control toggle switch to REMOTE 9 Set the IDLER switch to the AUTO position The HIG...

Page 37: ...dule and or the Classic III or Classic IIID 6 Place the IDLER switch on the Classic III or Classic IIID in the HIGH position Any increase of the high idle engine RPM by changing the governor setting o...

Page 38: ...S C 10 C 10 Classic III and IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 39: ...Cleaner D 4 How to Eliminate Air From the Fuel System D 5 Cooling System D 6 Spark Plugs D 6 Tightening the Fan Belt D 7 Engine Maintenance Schedule D 8 Battery Maintenance D 9 Cleaning the Battery D...

Page 40: ...e first More fre quent service may be required depending on your spe cific application and operating conditions OIL Check the oil level after every 8 hours of operation or daily BE SURE TO MAINTAIN TH...

Page 41: ...n turn it down another 1 2 turn Do not overtighten the new filter 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...

Page 42: ...ilter refer to engine Owner s Manual AIR CLEANER The 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 Servi...

Page 43: ...e of filter used loosen connec tion B at the fuel injection pump Also loosen con nection B instead of A if B is higher than A 3 Loosen any two injector high pressure pipe nuts at the end of the inject...

Page 44: ...g system at the radiator filler with a 50 50 mixture of water and antifreeze SPARK PLUGS Gasoline Engine Classic III Clean or replace the spark plugs after every 250 hours of operation as follows 1 Be...

Page 45: ...nd the adjustment link fasteners 2 2 Change the position of the alternator to give the cor rect tension Tighten the pivot fasteners of the alter nator and the adjustment link fasteners 3 Check the bel...

Page 46: ...ap 032 4 Cooling System Cooling System Fuel Filter 4 Fuel Filter 5 Fuel Filter 6 Valve Clearance Battery TYPE OR CAPACITY 7 Qts Including Filter Fram PH 8A Purolator PER 1A Donaldson P181050 Nelson 70...

Page 47: ...ore rapid discharge and early battery failure CHECKING SPECIFIC GRAVITY Check each battery cell with a hydrometer A fully charged battery will have a specific gravity of 1 260 Charge the battery if th...

Page 48: ...t properly In addi tion stone slip ring with a fine stone Brushes must be seated 100 Arcing or excessive exciter brush wear indicates a pos sible misaligned shaft Uncovered rotating equipment can be d...

Page 49: ...oid plunger with the vent hole on the lower side 3 Proper operation of the idler requires good ground ing of the printed circuit board through its mount ing reed switch and battery 4 If desired the we...

Page 50: ...12 Classic III and IIID FIGURE D 7 MAJOR COMPONENT LOCATIONS CLASSIC IIID SHOWN 1 2 4 6 8 7 3 5 11 10 9 12 13 14 15 1 RIGHT CASE SIDE DOOR 2 BASE WITH BATTERY 3 ALTERNATOR BRUSHES 4 ALTERNATOR 5 GENER...

Page 51: ...S D 13 D 13 Classic III and IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 52: ...S D 14 D 14 Classic III and IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 53: ...itch Circuits Classic III E 3 Battery Starter Engine Alternator and Engine Protection Circuitry Classic IIID E 4 Engine Generator Armature and Frame Alternator Stator and Rotor E 5 Excitation Flashing...

Page 54: ...C III BLOCK LOGIC DIAGRAM GENERAL DESCRIPTION The Classic III and Classic IIID are heavy duty engine driven DC arc welding power sources capable of pro viding constant current output for stick welding...

Page 55: ...r and through the ignition switch the engine ignition and fuel shutoff solenoid The engine alternator supplies charging current for the battery circuit If the oil pres sure switch does not close due t...

Page 56: ...cuit through the ignition switch In the event of a low oil pressure or high oil temperature condition the engine protection system will shut down the engine by remov ing power from the fuel solenoid...

Page 57: ...f auxiliary power to the appropriate receptacles The other 115VAC isolated winding is rectified to a DC voltage It supplies field feedback voltage to the rotor It also sup plies exciter voltage to the...

Page 58: ...ings it controls the amount of magnetism created in the shunt field windings Open circuit weld voltage is also controlled by the field rheostat control ENGINE IDLER CIRCUIT The idler solenoid is mecha...

Page 59: ...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...

Page 60: ...ES E 8 E 8 Classic III and IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 61: ...d Test F 23 Engine Throttle Adjustment Test Classic IIID Diesel F 25 Engine Throttle Adjustment Test Classic III Gasoline F 29 Oscilloscope Waveforms F 34 Normal Open Circuit Voltage Waveform 115VAC S...

Page 62: ...E 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 conducted wi...

Page 63: ...static dissipative 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...

Page 64: ...RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS The engine starts and runs at cor rect speed but there is no or very low welder output voltage There is no AC auxiliary output voltage 1 Check the 15 amp...

Page 65: ...r very low welder output voltage The AC auxiliary output voltage is normal 1 Check for loose or missing brushes in the welding genera tor 2 Check the welding cables for loose or faulty connections 1 C...

Page 66: ...S The welding output varies abnor mally The auxiliary output remains constant The engine is operating correctly 1 May be a normal condition The machine will normally lose some output as the components...

Page 67: ...there is no AC auxiliary output voltage The DC welding generator is functioning correctly 1 Check the AC auxiliary output circuit breakers Reset if tripped 2 Check the 115VAC and 230VAC receptacles a...

Page 68: ...53 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS The engine will not return to low idle when the welding and auxiliary loads are removed 1 Make sur...

Page 69: ...power receptacles 1 Check welding cables for loose or faulty connections 1 Check the reed switch CR2 for proper operation The reed switch should close when there is current flow in the welding cir cu...

Page 70: ...nd engine speed when the Idler switch is in the High position 1 Check the welding cables and auxiliary load leads for loose or faulty connections 2 Check for mechanical restric tions or missing parts...

Page 71: ...connections See the Wiring Diagram 2 Check the fuel shut off solenoid Make sure it is opening when 12VDC is applied to it See the Wiring Diagram 3 The engine ignition system or engine may be in need...

Page 72: ...con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RE...

Page 73: ...welding arc is loud and spat ters excessively 1 The current setting may be too high for the electrode and process 2 The polarity may be wrong for the electrode and process 1 Check the engine speed Hi...

Page 74: ...d 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 under...

Page 75: ...1 ALTERNATOR COVER REMOVAL ALTERNATOR ROTOR TEST continued TEST PROCEDURE 1 Turn engine off 2 With the 3 8 nut driver or socket wrench loosen the screws on the left and right sides and bottom of the...

Page 76: ...III and IIID FIGURE F 2 MEASURING ROTOR RESISTANCE 6 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 met...

Page 77: ...ound a Set the ohmmeter on the high scale X100 000 b Place one probe on either of the rotor slip rings Place the other probe on any good unpainted ground See Figure F 3 c Check the resistance It shoul...

Page 78: ...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...

Page 79: ...ING REPAIR F 19 F 19 Classic III and IIID FIELD SHUNT WINDING TEST continued FIGURE F 4 PLUG P10 LOCATIONS PLUG P10 TEST PROCEDURE 1 Turn engine off 2 Unlatch lift and secure the left side door Note t...

Page 80: ...asure 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 7 If the test does not meet the resistanc...

Page 81: ...ocedures 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 9...

Page 82: ...holder nearest the rotor lamination See Figure F 6 and the Wiring Diagram DO NOT remove brush holder 5 With the engine OFF use the other lead with alligator clips and touch the positive battery termin...

Page 83: ...ures 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...

Page 84: ...See Figure F 7 and the Wiring Diagram Using the 5 16 wrench remove the leads from the solenoid 5 Using the external voltage supply apply 12VDC to the idler solenoid terminals Attach positive to the t...

Page 85: ...lec 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 s...

Page 86: ...engine welder OFF 2 Unlatch lift and secure the left side door Note that there are latches at both ends of the door 3 With a white or red marking pencil place a mark on one of the blower paddles See...

Page 87: ...F 9 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 frequency reads 60 Hz Retighten the locki...

Page 88: ...ster TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING REPAIR F 28 F 28 Classic III and IIID ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE F 9 HIGH IDLE ADJUSTMENT...

Page 89: ...ranty 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...

Page 90: ...ACH METHOD 1 Conduct this procedure with the engine OFF 2 Unlatch lift and secure the right and left side doors 3 With the white or red marking pencil place mark on one of the blower paddles See Figur...

Page 91: ...ease the idle speed by a maximum of 50 RPM FREQUENCY COUNTER METHOD 1 Plug the frequency counter into one of the 115 VAC auxiliary receptacles 2 Start the engine and check the frequency counter At HIG...

Page 92: ...left side of the engine See Figure F 12 d Using the 3 8 wrench to turn the adjustment screw and locking nut adjust the high idle speed to between 1780 1810 RPM It may not be neces sary to remove the...

Page 93: ...eturn to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE F...

Page 94: ...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 connecte...

Page 95: ...e 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 m...

Page 96: ...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 Sco...

Page 97: ...edures 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 1 800 833 935...

Page 98: ...G REPAIR F 38 F 38 Classic III and IIID ALTERNATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 14 BATTERY PANEL REMOVAL NEGATIVE BATTERY CABLE BATTERY MOUNTING PANEL PROCEDURE 1 Turn the engine o...

Page 99: ...RNATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 15 ALTERNATOR COVER AND WRAPAROUND REMOVAL ALTERNATOR COVER BRUSHES WRAPAROUND SLIP RINGS See Figure F 15 for steps 3 5 3 With the 3 8 wrench lo...

Page 100: ...UT SLEEVE COLLAR BENT WASHER BRUSH HOLDER ASSEMBLY See Figure F 16 for steps 6 8 6 With the 7 16 wrench remove the two bolts nuts and washers mounting the brush holder assembly to the stator frame 7 B...

Page 101: ...en the brush holder and slip rings must be 050 to 090 Adjust as required c Before placing the exciter brushes in their holders twist the brush pigtail at its entrance to the brush until the strands ar...

Page 102: ...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...

Page 103: ...tor wraparound See Figure F 17 6 Disconnect the yellow and white wires at the in line connectors See the Wiring Diagram and Figure F 18 7 Disconnect the two yellow leads One is located at the field br...

Page 104: ...and IIID FIGURE F 18 LEAD DISCONNECTION POINTS YELLOW AND WHITE WIRE IN LINE CONNECTORS YELLOW LEADS BLACK CURRENT TRANSFORMER LEAD ALL LOCATED BEHIND CASE FRONT ALTERNATOR STATOR REMOVAL AND REPLACE...

Page 105: ...e the position of the brushes for reassembly TROUBLESHOOTING REPAIR F 45 F 45 Classic III and IIID ALTERNATOR STATOR REMOVAL AND REPLACEMENT continued FIGURE F 20 GENERATOR BRUSH HOLDER CABLE REMOVAL...

Page 106: ...osen the four mounting bolts adjust and re tighten if necessary 21 Tighten the generator brush holder assembly with the 7 16 wrench Note brush holder drill spot 22 Connect the four heavy cables from t...

Page 107: ...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 8...

Page 108: ...Removal procedure 3 Perform the Alternator Stator Removal procedure See Figure F 22 for steps 4 9 4 Turn off the fuel at the fuel bowl and remove the fuel line Plug the line to prevent spillage 5 Rem...

Page 109: ...th the 1 2 wrench remove the cables connect ed to the selector switch TROUBLESHOOTING REPAIR F 49 F 49 Classic III and IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to...

Page 110: ...clear and disconnect any necessary remaining leads and lift up and set the front panel assembly to the left side of the machine Make sure all leads are clear TROUBLESHOOTING REPAIR F 50 F 50 Classic...

Page 111: ...ng and pry bars carefully lift and wiggle the generator frame away from the engine and armature assembly Be careful to support the generator frame as you remove it Replacement 21 Support the generator...

Page 112: ...nt procedures according to each of the following Alternator Stator Removal and Replacement Alternator Rotor Removal and Replacement Before installing the machine case top and sides be sure to replace...

Page 113: ...o 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...

Page 114: ...t bolts and lock washers holding the blower paddles and the armature to the engine flywheel See Figure F 26 8 With the armature supported and balanced in the rope sling carefully rotate the armature 1...

Page 115: ...any electrical components ENGINE OUTPUT Mode No Load RPM Load RPM Low Idle 1325 1475 NA High Idle 1780 1810 1650 1750 WELDER DC OUTPUT Current Control Current Selector Open Circuit Load Volts Load Amp...

Page 116: ...S F 56 F 56 Classic III and IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master...

Page 117: ...n to Master TOC Return to Master TOC Return to Master TOC Electrical Diagrams Section Section G Wiring Diagram G 3 Wiring Diagram G 5 Wiring Diagram Wire Feed Module G 7 Idler PC Board Schmatic G 9 Id...

Page 118: ...otes G 2 G 2 CLASSIC III IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TO...

Page 119: ...EE BELOW W G PLUG FOR REMOTE CONTROL POTENTIOMETER B P8 1 2 3 4 5 6 X 41 600 42 602 R W R BELOW SEE REMOTE CONTROL RECEPTACLE SWITCH X Y CONNECT TO CASE WITH MACHINE NOT RUNNING REMOVE PLUG P9 ON MACH...

Page 120: ...otes G 4 G 4 CLASSIC III IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TO...

Page 121: ...R B A T R B R A L T E R N A T E I G N I T I O N C I R C U I T W I T H R E S I S T O R S U P P L I E D O N E A R L I E R E N G I N E S L E A D S A P P E A R O N E A R L I E R U N I T S O N L Y 10 31 97...

Page 122: ...otes G 6 G 6 CLASSIC III IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TO...

Page 123: ...7 8 9 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 1 2 1 2 3 4 5 6 1 2 3 4 5 6 7 8 75A 75 W Y 510 POS NEG Y W 503 602 509 610 600 31 32 GND 31 32 GND 609 610A 510 501 75 503A 602 76 77 2 4 75A 4 2 4A 2A 77A WIRE...

Page 124: ...otes G 8 G 8 CLASSIC III IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TO...

Page 125: ...or 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 Th...

Page 126: ...tes G 10 G 10 CLASSIC III IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master T...

Page 127: ...dual 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...

Page 128: ...tes G 12 G 12 CLASSIC III IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master T...

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