Page 2 - SAFETY; CLASSIC II; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY i i CLASSIC II FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. _____________________________________...
Page 3 - ii; ELECTRIC SHOCK can kill.
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY ii ii CLASSIC II ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield a...
Page 4 - iii
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC CLASSIC II FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Elec...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iv iv CLASSIC II PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les préca...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
MASTER TABLE OF CONTENTS FOR ALL SECTIONS v v CLASSIC II Page Safety .................................................................................................................................................i-iv Installation .......................................................................
Page 7 - TABLE OF CONTENTS; Tilting
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Section A-1 CLASSIC II Installation Technical Specifications ...................................................................................................
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS - CLASSIC II
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-2 A-2 CLASSIC II TECHNICAL SPECIFICATIONS - CLASSIC II INPUT - DIESEL ENGINE Manufacturer Description Spe...
Page 9 - SAFETY PRECAUTIONS; LOCATION AND VENTILATION; STORING; Maintenance section of
Read this entire installation section before youstart installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you havethoroughly read all the operation and maintenancemanuals supplied with your machine. They includeimportant safety precautions; detailed engine starting,operating,...
Page 10 - PRE-OPERATION ENGINE SERVICE; Operation and Maintenance sections of
STACKING Classic II machines CANNOT be stacked. TILTING Place the machine on a secure, level surface whenev-er you use it or store it. Any surfaces you place it onother than the ground must be firm, non-skid, andstructurally sound. The diesel engine is designed to run in a level positionfor best per...
Page 11 - Design capacity of the undercarriage vs. the weight; CAUTION
MUFFLER This welder is supplied with an adjustable rain cap forthe muffler. Install the rain cap using the clamp provid-ed with the outlet facing away from the direction inwhich this unit will be transported. This will minimizethe amount of water and debris that could enter themuffler during transpo...
Page 12 - WELDING CABLE CONNECTIONS; • Loose connections will cause the output terminals to; FIGURE A.1 - CLASSIC II OUTPUT CONNECTIONS
ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the 115 and 230 voltreceptacles, weld output terminals, and ground stud. WELDING CABLE CONNECTIONS CABLE INSTALLATION, POLARITY CONTROL,AND CABLE SIZES With the engine off, route the electrode and workcables through the strain relief b...
Page 13 - MACHINE GROUNDING; Accessories section of this manual for details.; for the GFCI Receptacle kit.; CIRCUIT BREAKERS; may tend to trip at lower loads than it would normally.
MACHINE GROUNDING Because the Classic II creates its ownpower from its diesel-engine driven gener-ator, you do not need to connect themachine frame to an earth ground.However, for best protection against elec- trical shock, connect a heavy gauge wire (#8 AWG orlarger) from the ground stud located on...
Page 14 - NOTES
NOTES A-8 A-8 CLASSIC II Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC
Page 15 - Operation
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section B-1 Section B-1 CLASSIC II TABLE OF CONTENTS - OPERATION SECTION - Operation ..................................................................................................................................
Page 16 - GENERAL DESCRIPTION; OPERATION
OPERATING INSTRUCTIONS Read and understand this entire section before operat-ing your Classic II. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you havethoroughly read all the operation and maintenancemanuals supplied with your machine. They includeimportant safety precautions; deta...
Page 17 - RECOMMENDED APPLICATIONS; WELDER; Welding; GENERATOR; Engine Operation in the Operation; DESIGN FEATURES
RECOMMENDED APPLICATIONS WELDER The Classic II provides excellent constant current DCwelding output for stick (SMAW) welding and for DCTIG welding. It also offers constant voltage output forDC semiautomatic wire feed welding. For more detailson using the machine as a welder, see Welding Operation in...
Page 18 - • The Classic II is not recommended for any process-
WELDING CAPABILITY The Classic II is rated 250 amps, 30 volts constant cur-rent DC at 60% duty cycle based on a ten minute timeperiod. Longer duty cycles at lower output currents arepossible. The current is continuously variable from 40 to 325amps DC. LIMITATIONS • The Classic II is not recommended ...
Page 19 - WELDER/GENERATOR CONTROLS; Control of Welding Current for; CONTROLS AND SETTINGS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION B-5 B-5 CLASSIC II FIGURE B.1 – OUTPUT CONTROLS 1. CURRENT RANGE SELECTOR2. FINE CURRENT ADJUSTMENT3. 230 VOLT...
Page 20 - CONTROL OF WELDING CURRENT; FIGURE B.2 – CURRENT CONTROLS
CONTROL OF WELDING CURRENT DO NOT turn the CURRENT RANGE SELECTORwhile welding because the current may arc betweenthe contacts and damage the switch. See Figure B.2. The CURRENT RANGE SELECTORprovides five overlapping current ranges. The FINECURRENT ADJUSTMENT adjusts the current fromminimum to maxi...
Page 21 - DIESEL ENGINE CONTROLS
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 twopositions, "HIGH" and "AUTO." In "HIGH," theengine runs continuously at high idle. In "AUTO,"t...
Page 22 - ENGINE OPERATION; BEFORE STARTING THE ENGINE; Check and fill the engine oil level:; Maintenance section of this manual.; Check and fill the engine fuel tank:; Remove the fuel tank cap.; STARTING THE ENGINE
ENGINE OPERATION DO NOT RUN THE ENGINE AT EXCESSIVESPEEDS. The maximum allowable high idle speed forthe Classic II is 1800 RPM, no load. Do NOT increasethe idle speed on the engine. Severe personal injuryand damage to the machine can result if it is operatedat speeds above the maximum rated speed. R...
Page 23 - STOPPING THE ENGINE; Place the IGNITION switch in the OFF position.; COLD WEATHER STARTING; If the engine is frequently started below 10
STOPPING THE ENGINE 1. Remove all welding and generator power loadsand let the engine cool by running it for severalminutes at low idle. 2. Place the IGNITION switch in the OFF position. When an engine is started for the first time, some of theoil will be needed to fill the passages of the lubricati...
Page 24 - WELDING OPERATION; GENERAL INFORMATION; Technical; engine high speed is controlled by the governor.
WELDING OPERATION GENERAL INFORMATION 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 TIGwelding is possible across the entire range from 40 to325 amps. Output can be adjusted by setting the C...
Page 26 - Select the appropriate electrode.; Engine Operation in; this section of the manual.; Control of Welding Current in this; section of the manual.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION B-12 B-12 CLASSIC II TABLE B.1 RANGE SETTINGS FOR WIRE SIZE/SPEED Diameter (inches) Wire Speed Range Appropria...
Page 27 - AUXILIARY POWER; Generator Power; To use the generator as an auxiliary power supply:
AUXILIARY POWER Be sure that any electrical equipment plugged into thegenerator AC power receptacles can withstand a ±10%voltage and a ±3% frequency variation. The AC auxiliary power, supplied as a standard, has arating of 3.0 kVA of 115/230V AC power (60 hertz). One 115V duplex and one 230V groundi...
Page 29 - Accessories
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories ...............
Page 30 - ACCESSORIES
OPTIONS/ACCESSORIES The following options/accessories are available foryour Classic II from your local Lincoln Distributor. Undercarriage - Under 10 MPH (K768) - For in-plantor yard towing of the Classic II. Not intended for high-way towing. Undercarriage (K913-1) - Two-wheeled undercarriagefor in-p...
Page 32 - and duty cycle of application.; NOTE: Figure C.1 shows the electrode connected; Connect the K867 Universal Adapter to the K291 or; NOTE: For remote control, a K775 remote control is; CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS; CLASSIC II/LN-7 WITH K867 ADAPTER CONNECTION DIAGRAM
ELECTRIC SHOCK can kill. • Do not operate with panels open. • Disconnect NEGATIVE (-) BATTERY LEAD before servicing. • Do not touch electrically live parts. MOVING PARTS can injure. • Keep guards in place. • Keep away from moving parts. • Only qualified personnel should install, use or service this ...
Page 33 - Connect the electrode cable from the LN-7 to the; NOTE: Welding cable must be sized for current and; duty cycle of application.; NOTE: Figure C.2 shows the electrode connected for; Connect the input cable from the K584-XX Input; CLASSIC II/LN-7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM
CONNECTION OF THE LN-7 TO THECLASSIC II USING K584 INPUT CABLEASSEMBLY (SEE FIGURE C.2.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-7 to the “+” terminal of the welder. Connect the work cableto the “CV-” terminal of the welder. NOTE: Welding cable must be sized for current an...
Page 34 - Connect the electrode cable from the LN-25 to the; NOTE: Figure C.3 shows the electrode connected for; Connect the K867 Universal adapter to the K432-L
CONNECTION OF THE LN-25 TO THECLASSIC II USING K867 UNIVERSALADAPTER (SEE FIGURE C.3.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-25 to the “+” terminal of the welder. Connect the work cableto the “CV-” terminal of the welder. NOTE: Welding cable must be sized for current and...
Page 35 - Connect the electrode cable from the LN-25 to the; NOTE: Welding cable must be sized for current
CONNECTION OF THE LN-25 TO THECLASSIC II “ACROSS THE ARC”(SEE FIGURE C.4.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-25 to the “+” terminal of the welder. Connect the work cableto the “CV–” terminal of the welder. NOTE: Welding cable must be sized for current and duty cycle ...
Page 37 - Maintenance
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section D-1 Section D-1 CLASSIC II TABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D S...
Page 38 - ENGINE MAINTENANCE; MAINTENANCE
SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when themaintenance requiring their removal is complete. • If cove...
Page 39 - Change the Oil section,
CHANGE THE OIL FILTER: Change the oil filter thefirst time after 50 hours of operation. Then, under nor-mal operating conditions, change the oil filter afterevery 750 hours of operation. If the engine is operatedunder heavy load or in high ambient temperatures,change the oil filter more frequently. ...
Page 40 - TIGHTENING THE FAN BELT:
FUEL FILTER: Inspect the fuel filter daily. Drain anyaccumulated water from the engine fuel filter/waterseparator daily. Change the fuel filter after the first 50hours of operation and every 1000 hours thereafter.Dust and dirt in the fuel system can cause the injectionpump and injection nozzle to we...
Page 41 - • Check fuel lines and clamps.
MAINTENANCE D-5 D-5 CLASSIC II Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE D.1 DEUTZ ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Befor...
Page 42 - BATTERY MAINTENANCE; CLEANING THE BATTERY
BATTERY MAINTENANCE 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 thebattery. To prevent EXPLOSION when: • INS...
Page 43 - COMMUTATOR AND BRUSHES:; The generator; IDLER MAINTENANCE
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 aweek in particularly dirty areas. ALTERNATOR BRUSH REMOVAL AND REPLACE-MENT: It's normal for the brush...
Page 45 - FIGURE E.1 – CLASSIC II BLOCK LOGIC DIAGRAM
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section E-1 Section E-1 CLASSIC II Theory of Operation ............................................................................................................. Section E General Description ....................
Page 46 - THEORY OF OPERATION
GENERAL DESCRIPTION The Classic II is a heavy duty, engine driven DC arcwelding power source capable of providing constantcurrent 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 IIis manufactured wi...
Page 49 - DC GENERATOR MACHINES
DC GENERATOR MACHINES The armature winding of a DC generator is located onthe rotating member. Current is conducted from it bymeans of carbon brushes. The field winding is locatedin the stator, which is stationary, and is excited by directcurrent. The armature coil sides are placed at opposite point...
Page 52 - HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; The; Electrical Diagrams Section Table of
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personn...
Page 53 - PC BOARD TROUBLESHOOTING PROCEDURES
ELECTRIC SHOCK can kill. Have an electrician install and servicethis equipment. Turn the machine OFFbefore working on equipment. Do nottouch electrically hot parts. Sometimes machine failures appear to be due to PCboard failures. These problems can sometimes betraced to poor electrical connections. ...
Page 54 - TROUBLESHOOTING GUIDE; OUTPUT PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-4 F-4 CLASSIC II Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginnin...
Page 55 - Observe Safety Guidelines; Check the welding cables for; Shunt Field; Check the continuity of the
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-5 F-5 CLASSIC II TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginnin...
Page 56 - detailed in the beginning of this manual.; The armature commutator may
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-6 F-6 CLASSIC II Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginnin...
Page 57 - Check the AC auxiliary output
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-7 F-7 CLASSIC II TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginnin...
Page 58 - FUNCTION PROBLEMS; Idler Solenoid
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-8 F-8 CLASSIC II Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginnin...
Page 60 - Check the welding cables and
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-10 F-10 CLASSIC II Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginn...
Page 61 - ENGINE PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-11 F-11 CLASSIC II TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginn...
Page 62 - WELDING PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-12 F-12 CLASSIC II TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginn...
Page 63 - ALTERNATOR ROTOR TEST; TEST DESCRIPTION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-13 F-13 CLASSIC II ALTERNATOR ROTOR TEST WARNING Service and repair should be performed b...
Page 64 - FIGURE F.1 – ALTERNATOR COVER REMOVAL; TEST PROCEDURE; ful to clear the leads.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-14 F-14 CLASSIC II LOOSEN 5SCREWS ALTERNATORCOVER SLIPRINGS BRUSHES FIGURE F.1 – ALTERNAT...
Page 65 - Working from the left side of the machine,
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-15 F-15 CLASSIC II FIGURE F.2 – MEASURING ROTOR RESISTANCE 9. Working from the left side ...
Page 67 - SHUNT FIELD WINDING TEST
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SHUNT FIELD WINDING TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unaut...
Page 68 - FIGURE F.4 – PLUG P10 LOCATIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-18 F-18 CLASSIC II SHUNT FIELD WINDING TEST (continued) FIGURE F.4 – PLUG P10 LOCATIONS P...
Page 69 - FIGURE F.5 – SHUNT LEAD RESISTANCE CHECK; TAB
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-19 F-19 CLASSIC II SHUNT FIELD WINDING TEST (continued) 6. Using the volt/ohmmeter set on...
Page 70 - IDLER SOLENOID TEST
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC IDLER SOLENOID TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthoriz...
Page 72 - ENGINE THROTTLE ADJUSTMENT TEST
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only Lincoln Electric factory trained personne...
Page 73 - STROBE; Strobe Tach Method; Turn the engine welder OFF.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-23 F-23 CLASSIC II ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.7 - STROBE MARK L...
Page 74 - Frequency Counter Method
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-24 F-24 CLASSIC II ENGINE THROTTLE ADJUSTMENT TEST (continued) 6. If either of the readin...
Page 75 - COLLAR
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-25 F-25 CLASSIC II ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.8 - HIGH IDLE ADJ...
Page 76 - FLASHING THE FIELDS; DESCRIPTION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FLASHING THE FIELDS Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthoriz...
Page 77 - PROCEDURE; Turn engine welder OFF.; DO NOT remove brush holder.; Replace the exciter cover.; Troubleshooting Guide located in this
TROUBLESHOOTING & REPAIR F-27 F-27 CLASSIC II Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FLASHING THE FIELDS (continued) FIGURE F.10 - FLASHING THE FIELDS NEGA...
Page 78 - SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY); HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM; volts
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-28 F-28 CLASSIC II This is the typical auxiliary outputvoltage generated from a properlyo...
Page 79 - NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM; HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AND SELECTOR
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-29 F-29 CLASSIC II This is the typical DC output voltagegenerated from a properly operati...
Page 80 - TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM; MACHINE LOADED – SELECTOR SWITCH AT MAXIMUM POSITION; MACHINE LOADED TO 250 AMPS AT 40 VDC
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-30 F-30 CLASSIC II This is the typical DC output voltagegenerated from a properly operati...
Page 82 - ALTERNATOR ROTOR REMOVAL; FIGURE F.11 – CASE FRONT REMOVAL PREPARATION; There are latches on both sides.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-32 F-32 CLASSIC II ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.11 – CAS...
Page 83 - FIGURE F.12 – FUEL TANK REMOVAL; Turn off the fuel at the fuel bowl and remove
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-33 F-33 CLASSIC II ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.12 – FUE...
Page 84 - FIGURE F.13 – OUTPUT TERMINAL STRAP AND CASE FRONT REMOVAL; Carefully lift the case front assembly up from
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-34 F-34 CLASSIC II ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.13 – OUT...
Page 85 - FIGURE F.14 – ALTERNATOR COVER REMOVAL; on the left side of the alternator cover.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-35 F-35 CLASSIC II ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.14 – ALT...
Page 86 - FIGURE F.15 – ROTOR REMOVAL; NUT; Bend the flat washer away from the rotor
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-36 F-36 CLASSIC II ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.15 – ROT...
Page 87 - Replacement
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION F-37 F-37 CLASSIC II ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued) Replacement 25. Carefully mount t...
Page 88 - ALTERNATOR STATOR REMOVAL AND REPLACEMENT
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ALTERNATOR STATOR REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory traine...
Page 89 - ALTERNATOR STATOR REMOVAL AND; FIGURE F.16 – COMMUTATOR WRAP-AROUND REMOVAL; Alternator Rotor Removal
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-39 F-39 CLASSIC II ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued) FIGURE F.16 – CO...
Page 90 - ALTERNATOR STATOR REMOVAL; CIRCUIT BREAKER
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-40 F-40 CLASSIC II FIGURE F.17 - LEAD DISCONNECTION POINTS YELLOW AND WHITE WIREIN-LINE C...
Page 91 - FIGURE F.19 - GENERATOR BRUSH HOLDER CABLE REMOVAL; GENERNATOR
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 forreassembly. TROUBLESHOOTING & REPAIR F-41 F-41 CLASSIC II Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n t...
Page 94 - GENERATOR FRAME REMOVAL; FIGURE F.21 – GENERATOR LEAD AND CABLE CONNECTIONS; SELECTOR; Disconnect the blue and the brown wires at
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-44 F-44 CLASSIC II GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.21 – GENE...
Page 95 - FIGURE F.22 – FRAME MOUNTING DETAILS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-45 F-45 CLASSIC II GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.22 – FRAM...
Page 97 - GENERATOR ARMATURE REMOVAL; FIGURE F.23 – BLOWER PADDLE REMOVAL; BLOWER PADDLE; Make sure the engine is supported with the
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-47 F-47 CLASSIC II GENERATOR ARMATURE REMOVAL AND REPLACEMENT (continued) FIGURE F.23 – B...
Page 98 - RETEST AFTER REPAIR; ENGINE OUTPUT
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-48 F-48 CLASSIC II RETEST AFTER REPAIR Retest a machine: • If it is rejected under test f...
Page 99 - ELECTRICAL DIAGRAMS
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-1 G-1 CLASSIC II Electrical Diagrams Section ..........................................................................................Section G Wiring Diagram (Code 9805 ) ....................
Page 101 - R E M O T E C O N T R O L ( O P T I O N A L )
G-2 ELECTRICAL DIAGRAMS CLASSIC II Wiring Diagram (Code 9805 ) 8594 5-1-92 CLASSIC II (WITH CV ADAPTER) WIRING DIAGRAM JE NONE 8594 7-9-91 t UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS .02 WITH PUBLISHED STANDARDS. ON 3 PLACE DECIMALS IS .002 ON ALL ANGLES IS ...
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