Lincoln Electric Welding System SVM 137 A User Manual
RETURN TO MAIN INDEX  
SVM 137-A  
January, 1998  
CLASSIC III/IIID  
Gasoline & Diesel Engine Driven DC Arc Welding Power Source  
For use with machine code numbers 10061, 10072 or 10156.  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However,  
your overall safety can be in-  
creased by proper installation . . .  
and thoughtful operation on  
your part. DO NOT INSTALL,  
OPERATE OR REPAIR THIS  
EQUIPMENT WITHOUT  
READING THIS MANUAL AND  
THE SAFETY PRECAUTIONS  
CONTAINED 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 III and IIID  
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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 III and IIID  
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iv  
iv  
SAFETY  
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  
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.  
1. Protegez-vous contre la secousse électrique:  
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.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
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  
zones où l’on pique le laitier.  
Mar. ‘93  
Classic III and IIID  
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v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS  
RETURN TO MAIN INDEX  
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  
Electrical Output Connections.....................................................................................................A-6  
Operation...............................................................................................................................Section B  
Safety Instructions.......................................................................................................................B-2  
General Description ....................................................................................................................B-2  
Recommended Applications........................................................................................................B-3  
Operational Features and Controls.............................................................................................B-3  
Design Features..........................................................................................................................B-3  
Welding Capability ......................................................................................................................B-4  
Limitations .................................................................................................................................B-4  
Controls and Settings..................................................................................................................B-5  
Engine Operation ........................................................................................................................B-9  
Welding Operation.....................................................................................................................B-11  
Auxiliary Power .........................................................................................................................B-13  
Accessories ..........................................................................................................................Section C  
Maintenance..........................................................................................................................Section D  
Safety Precautions......................................................................................................................D-2  
Routine and Periodic Maintenance.............................................................................................D-2  
Major Component Locations.....................................................................................................D-12  
Theory of Operation .............................................................................................................Section E  
Troubleshooting and Repair................................................................................................Section F  
Electrical Diagrams..............................................................................................................Section G  
Parts  
Parts List Classic III Diesel .....................................................................................................P-232  
Parts List Classic III Gas.........................................................................................................P-302  
Classic III and IIID  
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Section A-1  
Installation  
Section A-1  
TABLE OF CONTENTS  
- INSTALLATION SECTION -  
Technical Specifications..............................................................................................................A-2  
Safety Precautions ......................................................................................................................A-3  
Location and Ventilation ..............................................................................................................A-3  
Storing .................................................................................................................................A-3  
Stacking ................................................................................................................................A-4  
Tilting .................................................................................................................................A-4  
Lifting .................................................................................................................................A-4  
High Altitude Operation ........................................................................................................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 Cable Connections .................................................................................................A-6  
Cable Installation and Cable Sizes..........................................................................A-6  
Machine Grounding ..............................................................................................................A-7  
Auxiliary Power Receptacles, Plugs, and Hand-held Equipment .........................................A-7  
Circuit Breakers ....................................................................................................................A-7  
Classic III and IIID  
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A-2  
A-2  
INSTALLATION  
TECHNICAL SPECIFICATIONS - CLASSIC III AND IIID  
INPUT - ENGINE  
Manufacturer Description  
Speed  
Displacement  
Ignition  
Capacities  
Classic III:  
Continental  
TM27  
4 cyl., 4 cycle  
Water-cooled  
Gasoline  
1725 RPM  
Full load  
164.7 cu. in.  
(2700 cc)  
Electric  
Fuel: 15 gal.  
(57 liters)  
38.9 HP @  
1700 RPM  
1800 RPM  
High idle  
Oil: 7 qt.  
(6.7 liters)  
Classic IIID:  
Continental  
TMD27  
4 cyl., 4 cycle  
Water-cooled  
Diesel  
1350 RPM  
Low idle  
Water/coolant: 9.3 qt.  
(8.8 liters)  
45 HP @  
1700 RPM  
RATED OUTPUT - WELDER  
Duty Cycle  
Amps  
Volts at Rated Amperes  
100% Duty Cycle  
50% Duty Cycle  
30% Duty Cycle  
225 DC Constant Current  
300 DC Constant Current  
350 DC Constant Current  
29V  
32V  
34V  
OUTPUT - WELDER AND GENERATOR  
Welding Ranges Max. Open Circuit Voltage  
Auxiliary Power  
40-350 Amps DC  
98.5  
3.0 kVA of 115/230 V, 60Hz Power  
26 Amps @ 115 V(1)  
13 Amps @ 230 V  
PHYSICAL DIMENSIONS  
Height  
Width  
Depth  
Weight  
Classic III  
1406 lb.  
638 kg  
Classic IIID  
1445 lb.  
657 kg  
40.94 in.  
1040 mm  
24 in.  
610 mm  
66.25 in.  
1683 mm  
1 15 amps can be drawn from either half of the receptacle. Total combined load of all receptacles cannot exceed 3.0 kVA.  
Classic III and IIID  
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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 III and Classic IIID 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 components completely assembled.  
SAFETY PRECAUTIONS  
WARNING  
Whenever 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  
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, out-  
side area.  
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.  
The Classic III and Classic IIID may be used outdoors.  
Do not set the machine in water. Such practices pose  
safety hazards and cause improper operation and cor-  
rosion of parts.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live  
parts or electrodes with your  
skin or wet clothing.  
• Insulate yourself from the work  
and ground.  
STORING  
• Always wear dry insulating  
gloves.  
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. See the Maintenance section for information  
about charging the battery.  
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 III and IIID  
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A-4  
A-4  
INSTALLATION  
STACKING  
WARNING  
Classic III and Classic IIID 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 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 con-  
dition. Also, fuel capacity will be a little less at an angle.  
• Keep sparks and flame away from the fuel tank.  
OIL  
The Classic III and Classic IIID are shipped  
with the engine filled with SAE 10W-30 oil.  
This should be fine for most ambient oper-  
ating temperature conditions. See the engine opera-  
tion manual for specific recommendations. CHECK  
THE OIL LEVEL BEFOREYOU 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 dip-  
stick. If it is not full, add enough oil to fill it to the full  
mark. DO NOT overfill.  
LIFTING  
The Classic III weighs 1406 lb./638 kg. The Classic IIID  
weighs 1445 lb./657 kg. A lift bail is provided for lifting  
with a hoist.  
For more oil fill and service information, see the  
Maintenance section of this manual.  
WARNING  
FALLING EQUIPMENT can  
cause injury.  
FUEL  
Do not lift this machine using the lift bail  
if it is equipped with a heavy accessory  
such as a trailer.  
Fill the fuel tank with the grade of fuel rec-  
ommended in the engine operation manual.  
The Classic III and Classic IIID have 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.  
Lift only with equipment of adequate  
lifting capacity. Be sure the machine is stable when lift-  
ing.  
HIGH ALTITUDE OPERATION  
BATTERY CONNECTIONS  
It may be necessary to derate welder output at higher  
altitudes. Some engine adjustment may be required.  
Contact a Continental Service Representative.  
The Classic III and Classic IIID are 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 discon-  
nected 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.  
PRE-OPERATION ENGINE SERVICE  
Read and understand the information about the engine  
in the Operation and Maintenance sections of this  
manual before you operate the Classic III or Classic  
IIID.  
Classic III and IIID  
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A-5  
A-5  
INSTALLATION  
COOLING SYSTEM  
TRAILER  
The cooling system has been filled at the factory with a  
50-50 mixture of ethylene glycol antifreeze and water.  
Check the radiator level and add a 50-50 solution as  
needed. (See your engine manual or antifreeze con-  
tainer for alternate antifreeze recommendations.)  
If you use a non-Lincoln trailer, you must assume  
responsibility that the method of attachment and usage  
does not result in a safety hazard nor damage the  
welding equipment. Some of the factors to be consid-  
ered are as follows:  
1. Design capacity of the trailer vs. the weight of the  
Lincoln equipment and likely additional attach-  
ments.  
MUFFLER  
This welder is supplied with an adjustable rain cap for  
the muffler. Install the rain cap using the clamp provid-  
ed with the outlet facing away from the direction in  
which this unit will be transported. This will minimize  
the amount of water and debris that could enter the  
muffler during transportation.  
2. Proper support of, and attachment to, the base of  
the welding equipment so there will be no undue  
stress to the framework.  
3. Proper placement of the equipment on the trailer to  
ensure stability side to side and front to back. This  
includes when being moved and when standing by  
itself for operation or service.  
4. Typical conditions of use, such as travel speed,  
roughness of the surfaces where the trailer will be  
used, environmental conditions, likely maintenance.  
EXHAUST SPARK ARRESTER  
Some federal, state or local laws may require that  
gasoline or diesel engines be equipped with exhaust  
spark arresters when they are operated in certain loca-  
tions where unarrested sparks may present a fire haz-  
ard. The standard mufflers included with these welders  
do not qualify as a spark arrester. When required by  
local regulations, suitable spark arresters must be  
installed and properly maintained.  
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  
Use of an incorrect arrester may lead to engine dam-  
age or performance loss. Contact the engine manu-  
facturer for specific recommendations.  
Classic III and IIID  
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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 AND CABLE SIZES  
With the engine off, connect the electrode and work  
cables to the terminals located on the fuel tank mount-  
ing rail. (See size recommendations below.) For posi-  
tive polarity, connect the electrode cable to the terminal  
marked Positive (+). For Negative polarity, connect the  
electrode cable to the Negative (-) terminal. These con-  
nections should be checked periodically and tightened  
if necessary.  
When welding at a considerable distance from the  
welder, be sure you use ample size welding cables.  
Table A.1 lists recommended cable sizes and lengths  
for rated current and duty cycle. Length refers to the  
distance from the welder to the work and back to the  
welder. Cable diameters are increased for long cable  
lengths to reduce voltage drops.  
Lincoln Electric offers a welding accessory kit with the  
properly specified welding cables.  
See the  
Accessories section of this manual for more  
information.  
FIGURE A.1 - CLASSIC III & CLASSIC IIID OUTPUT CONNECTIONS  
3
4
1. 230 VAC RECEPTACLE  
2. 115 VAC RECEPTACLE  
3. OUTPUT TERMINALS  
4. GROUND STUD  
2
1
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  
225  
Duty Cycle  
100%  
Up to 200 ft.  
200 to 250 ft.  
1
1/0  
2/0  
3/0  
300  
50%  
1/0  
2/0  
350  
30%  
Classic III and IIID  
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A-7  
A-7  
INSTALLATION  
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.  
MACHINE GROUNDING  
According to the United States National Electrical  
Code, the frame of this portable generator is not  
required to be grounded and is permitted to serve as  
the grounding means for cord connected equipment  
plugged into its receptacles.  
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  
If you need ground fault protection for hand-held equip-  
ment, refer to the Accessories section of this manual  
for the GFCI Receptacle kit.  
particular situation and follow them explicitly.  
A
machine grounding stud marked with the symbol  
is provided on the welding generator frame foot.  
(If an older portable welder does not have a grounding  
stud, connect the ground wire to an unpainted frame  
screw. See Figure A.2.  
CIRCUIT BREAKERS  
Classic III and Classic IIID welders are  
equipped with circuit breakers on the  
115 and the 230 volt receptacles for  
overload protection. Under high heat a  
breaker may tend to trip at lower loads than it would  
normally.  
In general, if the machine is to be grounded, it should  
be connected with a #8 or larger copper wire to a solid  
earth ground such as a metal water pipe going into the  
ground for at least ten feet and having no insulated  
joints, or to the metal framework of a building which has  
been effectively grounded. The U.S. National Electrical  
Code lists a number of alternate means of grounding  
electrical equipment.  
Operation with high ambient temperatures may cause  
the breakers to trip at lower than normal loads.  
CAUTION  
Never bypass the circuit breakers. Without overload  
protection, the Classic III and Classic IIID could over-  
heat and/or cause damage to the equipment being  
used.  
WARNING  
Do not ground the machine to a pipe that carries explo-  
sive or combustible material.  
When the Classic III and Classic IIID are mounted on a  
truck or a trailer, the machine generator ground stud  
MUST be securely connected to the metal frame of the  
vehicle. See Figure A.2. The ground stud is marked  
with the ground symbol.  
FIGURE A.2 - GROUND STUD LOCATION  
AUXILIARY POWER RECEPTACLES,  
PLUGS, AND HAND-HELD EQUIPMENT  
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 duplex grounding type  
receptacle are provided. The circuit is protected with  
circuit breakers.  
1
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 to be drawn from either half of the receptacle.  
The total combined load of all receptacles is not to  
exceed 3.0 kVA.  
1. GROUND STUD  
Classic III and IIID  
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A-8  
A-8  
NOTES  
Classic III and IIID  
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Section B-1  
Section B-1  
TABLE OF CONTENTS  
- OPERATION SECTION -  
Operation...............................................................................................................................Section B  
Safety Instructions.......................................................................................................................B-2  
General Description ....................................................................................................................B-2  
Recommended Applications .......................................................................................................B-3  
Welder .................................................................................................................................B-3  
Generator..............................................................................................................................B-3  
Operational Features and Controls.............................................................................................B-3  
Design Features..........................................................................................................................B-3  
Welding Capability.......................................................................................................................B-4  
Limitations .................................................................................................................................B-4  
Controls and Settings..................................................................................................................B-5  
Welder/Generator Controls...................................................................................................B-5  
Control of Welding Current ...................................................................................................B-6  
Gasoline Engine Controls.....................................................................................................B-7  
Diesel Engine Controls.........................................................................................................B-8  
Engine Operation ........................................................................................................................B-9  
Before Starting the Engine ...................................................................................................B-9  
Starting the Gasoline Engine................................................................................................B-9  
Starting the Diesel Engine....................................................................................................B-9  
Stopping the Engine ...........................................................................................................B-10  
Break-in Period...................................................................................................................B-10  
Welding Operation.....................................................................................................................B-11  
DC Constant Current Stick or TIG Welding ........................................................................B-11  
DC Wire Feed Welding (Constant Voltage).........................................................................B-12  
Auxiliary Power..........................................................................................................................B-13  
Classic III and IIID  
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B-2  
B-2  
OPERATION  
WARNING  
OPERATING INSTRUCTIONS  
Read and understand this entire section before operat-  
ing your Classic III or Classic IIID.  
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 III and Classic IIID are heavy duty engine  
driven DC arc welding power sources capable of pro-  
viding constant current output for stick welding or DC  
TIG welding. These welders are wound with all copper  
coils and feature improved door latches and stainless  
steel hinges. With the addition of the optional K623-1  
Wire Feed Module, the welders will provide constant  
voltage output for running the LN-7, LN-23P, or LN-25  
wire feeders.  
FUMES AND GASES can be dan-  
gerous.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
The Classic III and Classic IIID have a current range of  
40-350 DC amps with a 50% duty cycle at 300  
amps/32 volts. The units are also capable of providing  
3.0 kVA of 115/230 volt, 60 Hertz AC auxiliary power.  
WELDING SPARKS can cause  
fire or explosion.  
• Keep flammable material away.  
• Do not weld on containers that have held  
combustibles.  
The Classic III uses the Continental TM27 four-cylin-  
der, industrial water-cooled gasoline engine, and the  
Classic IIID uses the Continental TMD27 industrial  
water cooled diesel engine.  
ARC RAYS can burn.  
• Wear eye, ear, and body protection.  
Classic III and IIID  
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B-3  
B-3  
OPERATION  
RECOMMENDED APPLICATIONS  
DESIGN FEATURES  
• All copper windings for long life and dependable  
operation.  
WELDER  
The Classic III and Classic IIID provide excellent con-  
stant current DC welding output for stick (SMAW) weld-  
ing and for DC TIG welding. When equipped with the  
wire feed module, they also offer constant voltage out-  
put 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 Stick welding (SMAW) process  
capability with output range from 40 - 350 DC amps.  
• Constant current DC TIG Welding with output across  
the entire range of settings.  
• Work and Electrode welding cable mounting termi-  
nals.  
GENERATOR  
• Separate ground stud for safe connection of case to  
earth ground.  
The Classic III and Classic IIID are also capable of pro-  
viding 3.0 kVA of 115/230 volts of 60 Hertz AC auxiliary  
power.  
• Duplex, 230 volt auxiliary power receptacle.  
• Duplex, 115 volt auxiliary power receptacle.  
• Integrated generator output overload protection  
through four 15 amp circuit breakers.  
OPERATIONAL FEATURES AND  
CONTROLS  
• Electric starting.  
• Battery Charging Ammeter.  
• Engine Oil Pressure Gauge. (Classic III D only)  
The Classic III and Classic IIID are designed for sim-  
plicity. Therefore, it has very few operating controls.  
Two controls are used for welding operations:  
• Engine Hour Meter for determining periodic mainte-  
nance.  
• A five-position CURRENT RANGE SELECTOR  
switch selects current output ranges for constant cur-  
rent stick or TIG applications and constant voltage  
wire feed applications (with optional Wire Feed  
Module - see the Accessories section)  
• Top-of-the-line 38.9 HP Continental gasoline  
(Classic III) or 45 HP Continental diesel engine  
(Classic IIID).  
• Top-mounted 15 gallon (57.0 litter) fuel tank with con-  
venient top fill.  
• A FINE CURRENT ADJUSTMENT control for fine  
adjustment of current from minimum to maximum  
within each range  
• Automatic engine shutdown protection for low oil  
pressure or high engine coolant temperature  
(Classic IIID).  
Controls for the engine include a two-position  
IGNITION ON/OFF toggle switch, a START push-  
button, and a two-position IDLER switch that selects  
engine speed for welding or auxiliary power applica-  
tions. See Engine Operation in the Operation section  
of this manual for details about starting, running,  
stopping, and breaking in the engine.  
• Automatic engine idler goes to low idle approximate-  
ly 15 seconds after welding for greater fuel economy;  
includes high idle switch.  
Classic III and IIID  
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B-4  
B-4  
OPERATION  
WELDING CAPABILITY  
LIMITATIONS  
The Classic III and Classic IIID are rated 300 amps, 32  
volts constant current DC at 50% duty cycle based on  
a ten minute time period. Longer duty cycles at lower  
output currents are possible.  
The Classic III and Classic IIID are not recommended  
for 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 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 350  
amps DC.  
Classic III and IIID  
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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 left side, under the  
door. See Figures B.1, B.2 and B.3 and the explana-  
tions that follow.  
The welder/generator controls are located on the  
Output Control Panel of the machine case front.  
E
ngine idler control and start/stop controls are also on  
FIGURE B.1 – OUTPUT CONTROLS  
8
1
2
3
4
6
5
7
1. CURRENT RANGE SELECTOR  
2. FINE CURRENT ADJUSTMENT  
3. 230 VOLT DUPLEX RECEPTACLE  
4. 115 VOLT DUPLEX RECEPTACLE  
5. WELD OUTPUT TERMINAL (–)  
6. WELD OUTPUT TERMINAL (+)  
7. GROUND STUD  
8. OPTIONAL WIRE FEED MODULE  
CONTROLS  
WELDER/GENERATOR CONTROLS  
See Figure B.1 for the location of the following features:  
1. CURRENT RANGE SELECTOR: Selects ranges  
of continuous current output for constant current  
stick or TIG applications and constant voltage wire  
feed applications (with optional Wire Feed Module).  
See Control of Welding Current for more informa-  
tion.  
4. 115 VOLT DUPLEX RECEPTACLE: Connection  
point for supplying 115 volt power to operate one or  
two electrical devices.  
5. 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.  
6. WELD OUTPUT TERMINAL (+) WITH FLANGE  
NUT: Provides the connection point for either the  
electrode holder or the work cable.  
3. 230 VOLT DUPLEX RECEPTACLE: Connection  
point for supplying 230 volt power to operate one or  
two electrical devices.  
7. GROUND STUD: Provides a connection point for  
connecting the machine case to earth ground for the  
safest grounding procedure.  
Classic III and IIID  
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B-6  
B-6  
OPERATION  
A high open circuit voltage setting provides the soft  
"buttering" 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.  
CONTROL OF WELDING CURRENT  
CAUTION  
• DO NOT turn the CURRENT RANGE SELECTOR  
while welding because the current may arc between  
the contacts and damage the switch.  
• DO NOT attempt to set the CURRENT RANGE  
SELECTOR between the five points designated on  
the nameplate.  
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.  
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.  
FIGURE B.2 – CURRENT CONTROLS  
CURRENT RANGE  
SELECTION  
FINE CURRENT  
ADJUSTMENT  
190-120  
240-160  
50  
60  
130-80  
70  
80  
90  
40  
30  
20  
220  
MAX  
90  
MIN  
CURRENT  
RANGE  
SELECTOR  
FINE  
CURRENT  
ADJUSTMENT  
10  
100  
ENGINE  
PROTECTION  
IDLER IGNITION  
START  
REMOTE  
CONTROL  
230 VOLTAC  
115 VOLTAC  
Classic III and IIID  
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B-7  
B-7  
OPERATION  
FIGURE B.3 – GASOLINE ENGINE CONTROLS  
CURRENT RANGE  
SELECTION  
FINE CURRENT  
ADJUSTMENT  
190-120  
240-160  
5
4
50  
60  
130-80  
70  
80  
90  
40  
30  
20  
220  
MAX  
90  
MIN  
10  
100  
OIL  
PRESSURE  
IDLER IGNITION  
START  
REMOTE  
CONTROL  
230 VOLT AC  
115 VOLTAC  
1. IDLER CONTROL TOGGLE  
SWITCH  
2. IGNITION TOGGLE SWITCH  
3. CHOKE  
4. START PUSHBUTTON  
5. ENGINE HOUR METER  
6. AMMETER  
1
6
2
3
GASOLINE ENGINE CONTROLS  
(CLASSIC III)  
4. START PUSHBUTTON: Press the START button  
to start the engine. The IGNITION switch must be  
in the ON position.  
See Figure B.3 for the location of the following features:  
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:  
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.  
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.  
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.  
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.  
2. IGNITION CONTROL TOGGLE SWITCH: Has  
two positions, ON and OFF. When the switch is in  
the ON position, the engine can be started by  
pressing the START pushbutton. When the switch  
is placed in the OFF position, the engine stops.  
3. CHOKE: Provides a richer air/fuel mixture for cold  
engine starting conditions. See the topic Engine  
Operation for details on setting the choke.  
Classic III and IIID  
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B-8  
B-8  
OPERATION  
FIGURE B.4 – DIESEL ENGINE CONTROLS  
3
CURRENT RANGE  
SELECTION  
FINE CURRENT  
ADJUSTMENT  
190-120  
240-160  
50  
60  
5
4
130-80  
70  
80  
90  
40  
30  
20  
220  
MAX  
90  
MIN  
10  
100  
IDLER IGNITION  
RESET  
START  
REMOTE  
CONTROL  
230 VOLT AC  
115 VOLTAC  
1. IDLER CONTROL TOGGLE  
SWITCH  
2. IGNITION TOGGLE SWITCH  
3. RESET BUTTON  
4. START PUSHBUTTONS  
5. ENGINE HOUR METER  
6. OIL PRESSURE GAUGE  
7. AMMETER  
1
8
7
6
8. TEMPERATURE GAUGE  
2
DIESEL ENGINE CONTROLS  
(CLASSIC IIID)  
See Figure B.4 for the location of the following features:  
4. START AND GLOW PLUG PUSHBUTTONS:  
Press the START button to start the diesel engine.  
The IGNITION switch must be in the ON position.  
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:  
NOTE: If you press the START pushbutton when  
the engine is running, you may damage the engine  
flywheel gear or starter motor.  
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.  
5. ENGINE HOUR METER: Records engine running  
time. Use the meter to determine when to  
perform required maintenance.  
6. 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.  
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.  
7. 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.  
8. TEMPERATURE GAUGE: Indicates temperature  
3. RESET BUTTON: Resets engine protection circuit.  
of engine coolant.  
Press this button before starting the diesel engine.  
Classic III and IIID  
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B-9  
B-9  
OPERATION  
STARTING THE CLASSIC III CONTINEN-  
ENGINE OPERATION  
WARNING  
TAL TM27 GASOLINE ENGINE  
NOTE: Remove all loads connected to the AC power  
receptacles before starting the engine.  
DO NOT RUN THE ENGINE AT EXCESSIVE  
SPEEDS. The maximum allowable high idle speed for  
the Classic III and Classic IIID 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.  
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. If the engine fails to start in 60 seconds, wait 30  
seconds before repeating the above procedure.  
6. Allow engine to run at high idle speed for several  
minutes to warm the engine. Cold engines tend to  
run at a speed too slow to supply the voltage  
required for proper automatic idler operation.  
Read and understand all safety instructions included in  
the Continental engine instruction manual that is  
shipped with your welder.  
7. As engine warms, slowly return the CHOKE control  
to the OFF position.  
BEFORE STARTING THE ENGINE  
Check and fill the engine oil level:  
1. Be sure the machine is on a level  
surface.  
STARTING THE CLASSIC IIID CONTINEN-  
TAL TMD27 ENGINE  
2. Remove the engine oil dipstick and wipe it with a  
clean cloth. Reinsert the dipstick and check the  
NOTE: Remove all loads connected to the AC power  
receptacles before starting the engine.  
level on the dipstick.  
See Figure D.1 in the  
Maintenance section of this manual.  
1. Place the IDLER switch in the "HIGH" position and  
the IGNITION switch in the ON position. Press the  
RESET button.  
3. Add oil (if necessary) to bring the level up to the full  
mark. Do not overfill.  
2. Press the GLOW PLUG button for 10 to 20 sec-  
onds.  
4. Replace the dipstick.  
3. While holding down the GLOW PLUG button, press  
the START button. Release both buttons when the  
engine starts.  
Check and fill the engine fuel tank:  
WARNING  
NOTE: If the engine fails to start in 60 seconds, the  
RESET button will pop out. Wait 30 seconds then  
repeat step 1, 2, and 3.  
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.  
4. 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.  
5. Allow the engine to run at high idle for several min-  
utes to warm the engine prior to welding. Extreme  
cold weather may require longer glow plug opera-  
tion.  
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.  
WARNING  
Under NO conditions should ether or other starting  
fluids be used in conjunction with the glow plugs. This  
may cause an explosion or fire!  
3. Replace the fuel tank cap and tighten securely.  
NOTE: Purchase fuel in quantities that will be used  
within 30 days, to assure freshness.  
Classic III and IIID  
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B-10  
B-10  
OPERATION  
STOPPING THE ENGINE  
(GASOLINE OR DIESEL)  
BREAK-IN PERIOD  
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.  
1. Place the IGNITION switch in the OFF position.  
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 (diesel engine, Classic IIID)  
per instructions in the engine manufacturer’s operating  
manual. Refill the fuel tank to minimize moisture con-  
densation in the tank. Also, running out of fuel tends to  
draw dirt into the fuel system. Check the crankcase oil  
level.  
The engine controls were properly set at the factory  
and should require no adjusting when received.  
Any engine will use a small amount of oil during its  
break-in period. For the gasoline or diesel engine on  
the Classic III or Classic IIID, break-in is about 200 run-  
ning hours.  
When hauling the welder between job sites, close the  
fuel feed valve beneath the tank. In gasoline engines,  
failing to turn off the fuel when traveling can cause car-  
buretor flooding and difficult starting at the new job site.  
Check the oil twice a day during break-in. Change the  
oil and oil filter cartridge after the first 25 hours of oper-  
ation. Also change the fuel filter cartridge on the diesel  
engine. For more details, see the Maintenance sec-  
tion 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. See “How to Eliminate  
Air From the Fuel System” in the Maintenance section.  
CAUTION  
During break-in, subject the Classic III or Classic IIID to  
only moderate loads. Avoid long periods running at  
idle. Before stopping the engine, remove all loads and  
allow the engine to cool several minutes.  
Classic III and IIID  
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B-11  
B-11  
OPERATION  
WELDING OPERATION  
TO USE THE CLASSIC III OR CLASSIC IIID  
FOR DC CONSTANT CURRENT STICK OR  
TIG WELDING:  
After you finish welding:  
1. Remove the flange nuts from the weld output ter-  
minals and place the work and electrode welding  
cables over the terminals. See Figure B.5.  
Replace and tighten the flange nuts securely. Be  
sure the connections are tight.  
1. Stop the engine. See Engine Operation in this  
section of the manual.  
2. Allow the electrode and work to cool completely.  
3. Remove the work clamp from the work.  
2. Select the appropriate electrode.  
4. Remove any remaining piece of electrode from the  
electrode holder.  
3. Attach the work clamp securely to the work you are  
welding.  
4. Insert the electrode into the electrode holder.  
5. Start the engine. See Engine Operation in this  
section of the manual.  
6. Set the Idler Switch to “AUTO.”  
7. Set the CURRENT RANGE SELECTOR to a set-  
ting equal to or slightly higher than the desired  
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. Strike an arc and begin welding.  
FIGURE B.5 – WELDING CIRCUIT CONNECTIONS FOR STICK WELDING  
1. FLANGE NUT  
2. ELECTRODE CABLE  
3. ELECTRODE HOLDER  
4. ELECTRODE  
5. WORK  
6. WORK CLAMP  
7. WORK CABLE  
1
7
6
5
4
3
2
Classic III and IIID  
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B-12  
B-12  
OPERATION  
TO USE THE CLASSIC III OR CLASSIC  
IIID FOR DC WIRE FEED WELDING  
(CONSTANT VOLTAGE WITH WIRE FEED  
MODULE):  
1. Connect the LN-25, LN-23P, or LN-7 Wire Feeder.  
Follow the installation instructions provided with  
the wire feeder.  
2. Set the machine for CV operation.  
3. Start the engine. See Engine Operation in this  
section of the manual.  
4. Set the Idler Switch to "AUTO."  
5. Set the CURRENT RANGE SELECTOR to a set-  
ting appropriate for your wire 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 begin welding.  
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  
80 to 130 Amps  
120 to 190 Amps  
150 to 240 Amps  
Classic III and IIID  
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B-13  
B-13  
OPERATION  
AUXILIARY POWER  
WARNING  
To use the generator as an auxiliary power supply:  
Be sure that any electrical equipment plugged into the  
generator AC power receptacles can withstand a ±10%  
voltage and a ±3% frequency variation.  
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.  
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 duplex grounding type  
receptacle 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 permits 15 amps to be drawn from  
either half. The total combined load of all receptacles  
must not exceed 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 volt receptacle kit is also avail-  
able. Note that the use of this GFCI kit reduces available  
current to a total of 20 Amps of available 115 volt power.  
See the Accessories section of this manual.  
Classic III and IIID  
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B-14  
B-14  
NOTES  
Classic III and IIID  
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Section C-1  
Section C-1  
TABLE OF CONTENTS  
- ACCESSORIES -  
Accessories...........................................................................................................................Section C  
Options/Accessories ...................................................................................................................C-2  
TIG Welding Accessories............................................................................................................C-3  
Semiautomatic FCAW and MIG Welding Accessories ...............................................................C-3  
Connection of Lincoln Electric Wire Feeders..............................................................................C-4  
Connection of the LN-7 using K867 Universal Adapter .......................................................C-4  
Connection of the LN-7 using K584 Input Cable Assembly.................................................C-5  
Connection of the LN-25 using K867 Universal Adapter .....................................................C-6  
Connection of the LN-25 “Across the Arc” ...........................................................................C-7  
Connection of the LN-23P using the K1350-1 Adapter Kit ..................................................C-8  
Connection of the K488 SG Control Module and K487 Magnum Spool Gun......................C-9  
Classic III and IIID  
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C-2  
C-2  
ACCESSORIES  
Wire Feed Module - (K623-1) - Provides constant  
voltage output for semiautomatic welding. Includes  
remote for CV mode and internal “Cold Tip Contactor.”  
OPTIONS/ACCESSORIES  
The following options/accessories are available for your  
Classic III or Classic IIID from your local Lincoln  
Distributor.  
Accessory Kit (K703) - Includes the following:  
Trailer (K913) - Two-wheeled trailer for in-plant and  
yard towing. Various hitches and accessories are  
available. For highway use, consult applicable federal,  
state, and local laws.  
• Electrode cable  
• Work cable  
• Headshield  
• Work clamp  
Trailer (K780) - Two-wheeled trailer with brakes, lights,  
and fenders. (For highway use, consult applicable  
state and local laws.)  
• Insulated electrode holder  
Remote Control - (K924-1) - Includes a receptacle  
switch and control box with 100 ft. (7.5 meters) of 4-  
conductor cable. Allows fine current and OCV to be  
controlled remotely.  
Power Plug Kit (K802-C) - Provides a plug for each  
auxiliary receptacle.  
Linc Thaw™ Control Unit (L2964-5) - Includes meter  
and fuses to protect the welder when thawing frozen  
water pipes.  
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 fac-  
tory installed 115 volt duplex receptacle.  
WARNING  
PIPE THAWING is not a CSA approved procedure. If  
not done properly, it can result in fire, explosion, dam-  
age 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 III and IIID  
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C-3  
C-3  
ACCESSORIES  
TIG WELDING ACCESSORIES  
SEMIAUTOMATIC WELDING ACCESSORIES  
K930-2 TIG Module - The TIG Module is an accessory  
that provides high frequency & shielding gas control for  
DC GTAW (TIG) welding applications.  
LN-25 Wire Feeder - This portable wire feeder is capa-  
ble of CC/CV wire feed welding.  
LN-7 Wire Feeder - Semiautomatic, constant speed  
The TIG Module is supplied without accessories. Arc  
start switches, amptrols, cables, torches and mounting  
brackets must be purchased separately.  
wire feeder. For CV operation only.  
LN-23P Wire Feeder - Portable 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.  
Gasless welding requires an Innershield Gun.  
Magnum Spool Gun (K487-25) - A lightweight, semi-  
automatic wire feeder for aluminum welding with argon  
gas. Has built-in remote wire speed control in the han-  
dle. Requires the K488 SG Control Module with appro-  
priate control cable. Includes 25 feet (7.6 meters) of  
power cable.  
Classic III and IIID  
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C-4  
C-4  
ACCESSORIES  
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS  
4. Connect the K291 or K404 input cable to the LN-7.  
5. Place the IDLER switch in the “HIGH” position.  
CONNECTION OF THE LN-7 TO THE  
CLASSIC III OR CLASSIC IIID (EQUIPPED  
WITH K623-1 WIRE FEED MODULE)  
USING K867 UNIVERSAL ADAPTER  
(SEE FIGURE C.1.)  
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.1 shows the electrode connected for  
positive polarity. To change polarity, shut the welder  
off and reverse the electrode and work cables at the  
Classic III or Classic IIID output terminals.  
6. Adjust wire feed speed at the LN-7.  
NOTE: For remote control, a K775 remote control is  
required. See Figure C.1.  
3. Connect the K867 Universal Adapter to the K291 or  
K404 input cable and the 14 pin amphenol of the  
Classic III or Classic IIID as indicated in Figure C.1.  
Make the proper connections for local or remote  
control according to Figure C.1.  
CAUTION  
When the welder is in local control, the electrode is  
always “HOT.”  
FIGURE C.1  
CLASSIC III OR CLASSIC IIID/LN-7 WITH K867 ADAPTER CONNECTION DIAGRAM  
SPARE  
Insulate Each  
Unused Lead  
Individually  
82  
81  
42  
41  
LN-7  
CONTROL  
BOX  
14 PIN  
AMPHENOL  
31  
32  
2
4
21  
GND  
31  
32  
2
4
21  
+
CV-  
K291 OR K404  
INPUT CABLE  
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 III and IIID  
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C-5  
C-5  
ACCESSORIES  
CONNECTION OF THE LN-7 TO THE  
CLASSIC III OR CLASSIC IIID (EQUIPPED  
WITH K623-1 WIRE FEED MODULE)  
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.  
6. Adjust wire feed speed at the LN-7.  
NOTE: For remote control, a K857 control is required.  
Connect it to the K864 adapter.  
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 III or Classic IIID output terminals.  
CAUTION  
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.  
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 III or Classic IIID.  
5. Place the IDLER switch in the “HIGH” position.  
FIGURE C.2  
CLASSIC III OR CLASSIC IIID/LN-7 WITH K584 INPUT CABLE ASSEMBLY CONNECTION DIAGRAM  
LN-7  
CONTROL  
BOX  
14 PIN  
AMPHENOL  
14 PIN  
AMPHENOL  
K584-"L" INPUT CABLE  
+
CV-  
6 PIN  
AMPHENOL  
K864  
ADAPTER  
TO  
WORK  
K857  
REMOTE CONTROL  
ELECTRODE CABLE  
TO LN-7  
Classic III and IIID  
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C-6  
C-6  
ACCESSORIES  
4. Connect the K432-L cable to the LN-25 equipped  
with the K431-1 remote output control kit.  
CONNECTION OF THE LN-25 TO THE  
CLASSIC III OR CLASSIC IIID (EQUIPPED  
WITH K623-1 WIRE FEED MODULE)  
USING K867 UNIVERSAL ADAPTER  
(SEE FIGURE C.3.)  
5. Place the IDLER switch in the “HIGH” position.  
CAUTION  
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.  
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.  
NOTE: Welding cable must be sized for current and  
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 III or Classic IIID output terminals. Reverse the  
LN-25 polarity switch.  
6. Adjust wire feed speed and voltage at the LN-25.  
3. Connect the K867 Universal adapter to the K433  
cable and the 14 pin amphenol of the Classic III or  
Classic IIID as indicated in Figure C.3. Mount the  
K433 to the welder according to instructions  
included with the K433 kit.  
FIGURE C.3  
CLASSIC III OR CLASSIC IIID/LN-25 CONNECTION DIAGRAM  
SPARE  
82  
81  
42  
41  
21  
Insulate Each  
14 PIN  
AMPHENOL  
Unused Lead  
Individually  
K433  
+
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 III and IIID  
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C-7  
C-7  
ACCESSORIES  
LN-25 polarity switch.  
CONNECTION OF THE LN-25 TO THE  
CLASSIC III OR CLASSIC IIID (EQUIPPED  
WITH K623-1 WIRE FEED MODULE)  
“ACROSS THE ARC” (SEE FIGURE C.4.)  
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 the  
lead. This is only a control lead — it carries no  
welding current.  
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.  
5. Place the IDLER switch in the “HIGH” position.  
6. Adjust wire feed speed and voltage at the LN-25.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
NOTE: Figure C.4 shows the electrode connected for  
positive polarity. To change polarity, shut the welder  
off and reverse the electrode and work cables at the  
Classic III or Classic IIID output terminals. Reverse the  
FIGURE C.4  
CLASSIC III OR CLASSIC IIID/LN-25 ACROSS THE ARC CONNECTION DIAGRAM  
14 PIN  
AMPHENOL  
+
LN-25 WIRE FEEDER  
WITH K444-2 REMOTE  
VOLTAGECONTROL OPTION  
CV-  
ELECTRODE CABLE  
TO  
WORK  
WORK CLIP  
LEAD TO WORK  
Classic III and IIID  
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C-8  
C-8  
INSTALLATION  
6. Connect control lead marked “21” to the work as  
indicated in Figure C.5.  
CONNECTION OF THE LN-23P TO THE  
CLASSIC III OR CLASSIC IIID (EQUIPPED  
WITH K623-1 WIRE FEED MODULE) USING  
THE K-350-1 ADAPTER KIT (SEE FIGURE  
C.5)  
7. Set the CURRENT RANGE SELECTOR switch to  
the 190-120 (middle) position for most common  
processes. This may be changed if a different arc  
characteristic is preferred.  
1. Shut the welder off.  
8. Set the LOCAL/REMOTE control toggle switch to  
REMOTE.  
2. Connect the electrode cable from the LN-23P to the  
“CV” output terminal of the engine welder. Connect  
the work cable to the “+” output terminal.  
9. Set the IDLER switch to the AUTO position. The  
HIGH position may be required when welding with  
low current processes.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
3. Mount the K350-1 adapter per instructions included  
with the adapter.  
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 specification listed in the manual.  
4. Connect the LN-23P to the K350-1 adapter as indi-  
cated in Figure C.5. The adapter allows two wire  
feeders to be connected. If only one is used, con-  
nect it to Feeder “A” terminal strip.  
5. Connect the adapter cable from the K350-1 to the  
14-pin amphenol on the Classic III or Classic IIID  
wire feed module.  
WARNING  
The output terminals are energized when the engine is  
running. The CV output will be de-energized only if  
WFM mode switch is in remote position.  
FIGURE C.5  
CLASSIC III OR CLASSIC IIID/LN-23P CONNECTION DIAGRAM  
SPARE  
82  
Insulate Each  
14 PIN  
K488 SG  
81  
AMPHENOL  
Unused Lead  
CONTROL  
K487-25  
SPOOL  
GUN  
42  
41  
21  
MODULE  
Individually  
+
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 III and IIID  
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C-9  
C-9  
ACCESSORIES  
6. Place the IDLER switch on the Classic III or Classic  
CONNECTION OF THE K488 SG CONTROL  
MODULE AND K487 MAGNUM SPOOL GUN  
TO THE CLASSIC III OR CLASSIC IIID  
(EQUIPPED WITH K623-1 WIRE FEED  
MODULE) (SEE FIGURE C.6.)  
IIID in the “HIGH” position.  
CAUTION  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. 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 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.6 shows the electrode connected  
for positive polarity. To change polarity, shut the  
welder off and reverse the electrode and work  
cables at the Classic III or Classic IIID output ter-  
minals.  
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.6. Connect the  
other end of the adapter to the 14 pin amphenol on  
the Classic III or Classic IIID.  
CAUTION  
When the welder is in local control, the electrode is  
always “HOT.”  
4. Connect the K492 Input Cable to the SG Control  
Module.  
5. Set the slide switch on the SG Control Module to  
the “Lincoln” position.  
CAUTION  
Be sure this switch is set to the “Lincoln” (contact clo-  
sure) position before attempting to operate the SG  
Control Module. Incorrect switch position could result  
in damage to the SG Control Module and/or the  
Classic III or Classic IIID.  
FIGURE C.6  
CLASSIC III OR CLASSIC IIID/K492/K488/K487 SPOOL GUN CONNECTION DIAGRAM  
SPARE  
82  
Insulate Each  
14 PIN  
K488 SG  
81  
AMPHENOL  
Unused Lead  
CONTROL  
K487-25  
SPOOL  
GUN  
42  
41  
21  
MODULE  
Individually  
+
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 III and IIID  
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C-10  
C-10  
NOTES  
Classic III and IIID  
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Section D-1  
Section D-1  
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  
Classic III and IIID  
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D-2  
D-2  
MAINTENANCE  
SAFETY PRECAUTIONS  
WARNING  
ROUTINE AND PERIODIC  
MAINTENANCE  
ENGINE MAINTENANCE  
• Have qualified personnel do all maintenance and  
troubleshooting work.  
CAUTION  
• Turn the engine off before working inside the  
machine.  
To prevent the engine from accidentally starting, dis-  
connect the negative battery cable before servicing the  
engine.  
• Remove covers or guards only when necessary to  
perform maintenance and replace them when the  
maintenance requiring their removal is complete.  
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.  
• If covers or guards are missing from the machine, get  
replacements from a Lincoln Distributor.  
Read the Safety Precautions in the front of this manu-  
al and in the instruction manual for the engine used  
with your machine before working on the Classic III or  
Classic IIID.  
OIL: Check the oil level after every 8  
hours of operation or daily. BE SURE TO  
MAINTAIN THE OIL LEVEL.  
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 the first time between 25 and 50 hours  
of operation. Then, under normal operating conditions,  
change the oil as specified in Table D.1. If the engine is  
operated under heavy load or in high ambient temper-  
atures, change the oil more frequently.  
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. If the plug  
is equipped with a washer, examine and replace it  
if it appears damaged.  
2. Replace the plug and washer and tighten securely.  
3. Remove the oil fill cap and add oil until the level  
reaches the “MAX” mark on the dipstick. See  
Figure D.1. Use high quality oil viscosity grade  
10W30. Consult the engine manual for oil specifi-  
cations. Always check the level with the dipstick  
before adding more oil.  
4. Reinstall the oil fill cap and the dipstick.  
Classic III and IIID  
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D-3  
D-3  
MAINTENANCE  
FIGURE D.1 – OIL DRAIN AND REFILL  
2
MAX  
MIN  
5
{
4
1. OIL DRAIN PLUG (LOCATION)  
2. OIL FILL CAP  
3
3. DIPSTICK  
4. OIL FILTER  
5. DIPSTICK LEVELS  
1
CHANGE THE OIL FILTER: Change the oil filter the  
first time between 25 and 50 hours of operation. Then,  
under normal operating conditions, change the oil filter  
per Table D.1 or consult your engine Owner’s Manual.  
If the engine is operated under heavy load or in high  
ambient temperatures, change the oil filter more fre-  
quently. See Table D.1 for recommended maintenance  
intervals. Order Fram oil filter #PH-8A or Purolator  
#PER-1A from your local engine 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 (usually by  
retightening the filter, but only enough to stop  
leaks) before placing the Classic III or Classic IIID  
back in service.  
6. See Figure D.1. If there are no leaks, stop the  
engine and recheck the oil level. If necessary, add  
oil to bring the level up to the “MAX” mark, but do  
not overfill.  
Change the oil filter as follows:  
1. See Figure D.1. Remove the oil drain plug (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. See Figure D.1. Remove the old filter (spin it off)  
and discard it (2). Wipe off the filter mounting sur-  
face and adapter.  
Refer to your engine Owner’s Manual for recom-  
mended grade of fuel.  
3. Fill the new filter with fresh engine oil. Apply a thin  
coat of new oil to the rubber gasket on the new oil  
filter.  
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 III and IIID  
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D-4  
D-4  
MAINTENANCE  
FUEL FILTER - DIESEL ENGINE (CLASSIC IIID  
CODES ABOVE 10061 WITH STANADYNE FUEL  
FILTER):  
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.  
Service the air cleaner as follows:  
The diesel engine fuel filter is a metal canister ele-  
ment type. It cannot be cleaned. Replace the filter  
per Table D.1 or if there is reason to believe it is  
plugged. Change the fuel filter as follows:  
1. Remove the dust cup from the bottom of the air  
cleaner housing. Clean out any accumulated dust.  
2. Loosen the wing nut and remove the filter element.  
1. See Figure D.2. Release the two spring clamps  
(1).  
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 30 psi.  
2. Pull the old element (2) off the filter bracket.  
3. Lube the grommets on the new element with  
clean diesel fuel and push the element into place.  
4. Check the element for damage before reassem-  
bling the air cleaner. Replace the element if it  
appears damaged. Order Donaldson element part  
#P181050 or Nelson #70206N.  
4. Snap the two spring clamps into position.  
5. Bleed the air from the fuel system. See How to  
Eliminate Air from the Fuel System.  
Order Continental fuel filter from your local Continental  
Service Center (diesel - Classic IIID). See Table D.1  
notes 5 and 6.  
NOTE: If your fuel filter is not a Stanadyne filter, refer  
to engine Owner’s Manual.  
FIGURE D.2 – FUEL FILTER REPLACEMENT  
1
2
Classic III and IIID  
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D-5  
D-5  
MAINTENANCE  
HOW TO ELIMINATE AIR FROM THE FUEL SYSTEM  
– DIESEL ENGINE (CLASSIC IIID)  
The following procedure is for Classic IIID diesel  
engines with a Stanadyne type fuel filter (Figure D.2).  
If your filter is different, refer to your engine Owner’s  
Manual for the correct procedure for eliminating air  
from the system.  
1. Set the IDLER switch to HIGH and turn the ignition  
switch ON.  
2. See Figure D.3. Loosen the fuel filter outlet con-  
nection “A” and allow fuel to flow until it is free of  
air.  
NOTE: For this step, if connection “A” is inacces-  
sible, due to the type 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 injectors.  
4. Press the START pushbotton and crank the engine  
until fuel free of air flows from the injector pipe  
nuts. Tighten the nuts.  
5. Energize the glow plugs, then start the engine.  
FIGURE D.3 – ELIMINATING AIR FROM THE FUEL SYSTEM  
3
4
1
2
INJECTORS  
FUEL FILTER  
INJECTION LINES  
A
INJECTION PUMP  
B
TRANSFER PUMP  
SEDIMENTER  
FUEL TANK  
Classic III and IIID  
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D-6  
D-6  
MAINTENANCE  
FIGURE D.4 – ENGINE COOLANT DRAIN PLUG AND RADIATOR DRAIN COCK  
COOLING SYSTEM: The Continental engine, gaso-  
SPARK PLUGS (Gasoline Engine - Classic III):  
Clean or replace the spark plugs after every 250 hours  
of operation as follows.  
line or diesel, is water cooled. Check the coolant level  
at the radiator filler daily. Add a 50-50 mixture of water  
and antifreeze as needed. To drain and refill the sys-  
tem, do the following:  
1. Before removing the plugs, clean the base area to  
keep dirt from falling into the engine through the  
plug hole.  
1. Ensure that the machine is on level ground.  
2. Remove and inspect the plugs. Plugs showing  
signs of fouling or electrode wear should be  
replaced. Do not blast the spark plugs clean with an  
abrasive cleaning device. Clean the plugs by scrap-  
ing or by using a wire brush. Wash the plugs with a  
commercial solvent.  
WARNING  
To avoid personal injury, never remove the radiator  
pressure cap nor the reserve tank cap while the engine  
is running or immediately after it has stopped. Hot  
water may gush out, which can scald people nearby.  
3. After cleaning or when installing a new spark plug,  
set the terminal gap with a feeler gauge or gapping  
tool. See Figure D.5.  
2. Remove the radiator filler cap.  
Gap Specifications: 0.032 inch (.8 mm).  
4. Tighten plugs to 30 ft·lbs (40 N·m).  
3. Remove the drain plug from the side of the cylinder  
block in order to drain the engine. Ensure that the  
drain hole is not restricted. See Figure D.4.  
FIGURE D.5 – SET SPARK PLUG GAP  
4. Open the radiator drain cock at the bottom of the  
radiator in order to drain the radiator.  
5. If necessary, flush the system with clean water.  
6. Fit the engine drain plug and the radiator drain cock.  
7. Fill the cooling system at the radiator filler with a 50-  
50 mixture of water and antifreeze.  
Classic III and IIID  
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D-7  
D-7  
MAINTENANCE  
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 belt  
should deflect no more than 13 mm (0.5 in.). See  
Figure D.6.  
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 belt tension again to ensure that it is still  
correct.  
If a new belt is fitted, the belt tension must be checked  
again after the first 25 hours of operation.  
To adjust the fan belt, do the following:  
1. See Figure D.6. Loosen the pivot fasteners of the  
alternator (1) and the adjustment link fasteners (2).  
FIGURE D.6 – TIGHTENING THE FAN BELT  
1
2
3
4
5
6
7
8
9
Classic III and IIID  
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D-8  
D-8  
MAINTENANCE  
TABLE D.1  
ENGINE MAINTENANCE SCHEDULE  
HOURS BETWEEN SERVICING  
DAILY  
50  
250  
500  
MAINTENANCE ITEM  
Engine Oil (1)  
TYPE OR CAPACITY  
I
R
R
Engine Oil (1)  
Oil Filter  
7 Qts. (Including Filter)  
Fram #PH-8A  
Purolator #PER-1A  
I
Air Cleaner  
C
Air Cleaner  
R
Air Cleaner Cartridge  
Donaldson #P181050  
Nelson #70206N  
C
I
PCV System  
Fan Belt Tension  
Throttle or Governor Linkage  
Spark Plugs (Gap = .032”) (4)  
Cooling System  
Cooling System  
Fuel Filter (4)  
Fuel Filter (5)  
Fuel Filter (6)  
Valve Clearance  
Battery  
C
C or R  
Champion #RN12YC  
I
C
R
R
R
I
9.3 Qts.  
Lincoln #S17753 (2)  
Continental #TMD27F00506  
Continental #TMD20F00400  
Intake = .014”; Exhaust = .018”  
BCI Group 24  
(3)  
I
I = Inspect  
NOTES:  
C = Clean  
R = Replace  
(1) Consult engine Owner’s Manual for all recommendations.  
(2) Or Equivalent.  
(3) First inspection after 50 hours; every 500 thereafter.  
(4) Gasoline engine only.  
(5) Diesel engine only. (Welder Code Numbers 10061 and below)  
(6) Diesel engine only. (Welder Code Numbers above 10061)  
(7) Consult Engine Owner’s Manual for additional maintenance schedule information.  
Classic III and IIID  
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D-9  
D-9  
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 III and Classic IIID are 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 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.  
Classic III and IIID  
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D-10  
D-10  
MAINTENANCE  
tion, stone slip ring with a fine stone. Brushes must be  
seated 100%.  
WELDER/GENERATOR  
MAINTENANCE  
Arcing or excessive exciter brush wear indicates a pos-  
sible misaligned shaft.  
STORAGE: Store the Classic III or Classic IIID in  
clean, dry, protected 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.  
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 ston-  
ing the commutator.  
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.  
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.  
COMMUTATOR AND BRUSHES: The generator  
brushes are properly adjusted when the welder is  
shipped. They require no particular attention.  
BEARINGS: The Classic III and Classic IIID are  
equipped with double-shielded ball bearings having  
sufficient grease to last indefinitely under normal ser-  
vice. Where the welder is used constantly or in exces-  
sively 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.  
CAUTION  
DO NOT SHIFT THE BRUSHES or adjust the rocker  
setting.  
Shifting of the brushes may result in:  
• Change in machine output  
• Commutator damage  
• Excessive brush wear  
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.  
Periodically inspect the DC generator commutator, AC  
exciter slip rings, and brushes by removing the covers.  
DO NOT remove these covers while the machine is  
running.  
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. Never rotate the han-  
dle while the machine is under load.  
Commutators and brushes require little attention.  
However, if they are black or appear uneven, have  
them cleaned by experienced maintenance personnel  
using a commutator stone. Never use emery cloth or  
paper for this purpose.  
Replace brushes when they wear within 1/4" of the pig-  
tail. A complete set of replacement brushes should be  
kept on hand. Lincoln brushes have a curved face to fit  
the commutator. Have experienced maintenance per-  
sonnel seat these brushes by lightly stoning the com-  
mutator as the armature rotates at full speed until con-  
tact is made across the full face of the brushes. After  
stoning, blow out the dust with low pressure air.  
Put a drop of oil on the CURRENT RANGE SELEC-  
TOR shaft at least once every month.  
RECEPTACLES: Keep the electrical receptacles in  
good condition. Remove any dirt, oil, or other debris  
from their surfaces and holes.  
CABLE CONNECTIONS: Check the welding cable  
connections at the weld output terminals often. Be  
sure that the connections are always tight.  
Seat the brushes on the AC exciter as follows. 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 pressure on top of the brushes, pull the sandpa-  
per around the circumference of the rings - in direction  
of rotation only - until brushes seat properly. In addi-  
Classic III and IIID  
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D-11  
D-11  
MAINTENANCE  
IDLER MAINTENANCE  
1. The solenoid plunger must work freely because  
binding can cause engine surging. If surging  
occurs, be sure the plunger is properly lined up  
with the throttle lever. Dust the plunger about once  
a year with graphite powder.  
2. When any service is done, reassemble the rubber  
bellows on the solenoid 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 welder can be used without auto-  
matic idling by setting the IDLER switch to the  
HIGH position.  
Classic III and IIID  
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D-12  
D-12  
MAINTENANCE  
FIGURE D.7 - MAJOR COMPONENT LOCATIONS  
(CLASSIC IIID SHOWN)  
1. RIGHT CASE SIDE (DOOR)  
2. BASE (WITH BATTERY)  
3. ALTERNATOR BRUSHES  
4. ALTERNATOR  
5. GENERATOR  
6. GENERATOR BRUSHES  
7. OUTPUT TERMINALS  
8. FUEL TANK  
9. CASE FRONT WITH CONTROL PANEL  
10. LEFT CASE SIDE  
11. CASE TOP  
12. CASE BACK WITH RADIATOR  
13. COOLING FAN  
14. AIR CLEANER  
15. IDLER CONTROL  
11  
10  
12  
15  
13  
14  
9
7
8
6
5
4
3
2
1
Classic III and IIID  
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D-13  
D-13  
NOTES  
Classic III and IIID  
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D-14  
D-14  
NOTES  
Classic III and IIID  
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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 Oil Switch 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)........................................................................................................E-5  
Auxiliary and Field Feedback Coils.................................................................................E-5  
Interpole and Series Coils...............................................................................................E-5  
Current Range Selector ..................................................................................................E-6  
Fine Current Adjustment .................................................................................................E-6  
Engine Idler Circuit..........................................................................................................E-6  
DC Generator Machines........................................................................................................E-7  
Classic III and IIID  
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E-2  
E-2  
THEORY OF OPERATION  
GENERAL DESCRIPTION  
power is available at the 115 or 230VAC receptacles.  
The Classic III and Classic IIID models are manufac-  
tured with all copper windings.  
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 or DC  
TIG welding. Also, a total of 3000 watts of auxiliary  
FIGURE E.1a – CLASSIC III BLOCK LOGIC DIAGRAM  
FIGURE E.1b – CLASSIC IIID BLOCK LOGIC DIAGRAM  
Classic III and IIID  
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E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.2a – BATTERY, STARTER, ENGINE ALTERNATOR AND OIL SWITCH CIRCUIT (CLASSIC III)  
BATTERY, STARTER, ENGINE  
ALTERNATOR AND OIL SWITCH  
CIRCUIT (CLASSIC III)  
The 12VDC battery powers the starter motor 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 to low oil pressure or  
inadequate oil supply, the oil pressure light will not  
glow, the hour meter will not operate and the engine  
alternator and automatic idler will not function  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
Classic III and IIID  
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E-4  
E-4  
THEORY OF OPERATION  
FIGURE E.2b – BATTERY, STARTER, ENGINE ALTERNATOR AND  
ENGINE PROTECTION CIRCUITRY (CLASSIC IIID)  
BATTERY, STARTER, ENGINE  
ALTERNATOR AND PROTECTION  
CIRCUITRY (CLASSIC IIID)  
The 12VDC battery powers the starter motor, glow  
plugs and the engine protection circuitry. The fuel  
pump and solenoid are powered from the protection cir-  
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 and lift pump. If the  
normally open oil pressure switch does not close, due  
to low pressure or inadequate oil supply, the engine  
alternator and automatic idler circuit will not function.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
Classic III and IIID  
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E-5  
E-5  
THEORY OF OPERATION  
FIGURE E.3 – ENGINE, GENERATOR ARMATURE AND FRAME, ALTERNATOR STATOR AND ROTOR (CLASSIC III)  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
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 field shunt windings in the  
main generator frame. This voltage is controlled by the  
ENGINE, GENERATOR ARMATURE  
AND FRAME, ALTERNATOR  
STATOR AND ROTOR  
generator field control.  
EXCITATION (FLASHING)  
INTERPOLE AND SERIES COILS  
When the engine is started and running, the residual  
magnetism voltage is applied to the alternator rotor  
through a brush and slip ring configuration. This exci-  
tation (“flashing”) voltage magnetizes the rotor lamina-  
tion. The alternator rotor is connected to the armature  
shaft, which is mechanically coupled to the engine.  
This rotating magnet (rotor) induces a voltage in the  
stationary windings of the alternator stator.  
The generator armature rotates within the magnetic  
field created by the field shunt windings. A voltage is  
induced in the armature and transferred, through the  
armature commutator and brushes, to the series and  
interpole coils. The interpole coils, which are connect-  
ed in series with the positive output terminal, are locat-  
ed so as to counteract any magnetic influences that  
could cause distortion in the rotating field. The series  
coils are designed to oppose or “buck” the DC voltage  
generated by the armature.  
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  
Classic III and IIID  
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E-6  
E-6  
THEORY OF OPERATION  
CURRENT RANGE SELECTOR  
ENGINE IDLER CIRCUIT  
The selector switch acts as a coarse current adjustment The idler solenoid is mechanically connected to the  
by allowing varying amounts of series windings to be engine governor linkage. When welding current is being  
included in the welding current path. The series coils drawn, the reed switch CR2 is closed. This signals the  
and selector switch are connected in series with the idler PC board to release (deactivate) the idler solenoid,  
negative output terminal.  
which then lets the machine go to a high speed condi-  
tion. Also, when auxiliary power is being used, the cur-  
rent is passed through the current transformer. This sig-  
nals the idler PC board to release the idler solenoid.  
FINE CURRENT ADJUSTMENT  
The field rheostat control functions as a fine output cur-  
rent adjustment. By controlling the current through the  
shunt windings, it controls the amount of magnetism  
created in the shunt field windings. Open circuit weld  
voltage is also controlled by the field rheostat control.  
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 returns to a low  
speed condition.  
Classic III and IIID  
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E-7  
E-7  
THEORY OF OPERATION  
FIGURE E.4 – DC GENERATOR MACHINES  
C
U
F
R
I
R
E
E
L
N
D
T
SHUNT FIELD WINDINGS  
DC CURRENT  
MAGNETIC FIELD  
GENERATOR  
BRUSH  
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
DC GENERATOR MACHINES  
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 DC Generator, rectification is provided  
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. Stationary carbon brushes held  
against the commutator surface connect the armature  
windings to external terminals. The commutator pro-  
vides full-wave rectification, transforming the voltage  
waveform between brushes and making a DC voltage  
available to the external circuit.  
The armature winding of a DC generator is located on  
the rotating member. Current is conducted from it by  
means of carbon brushes. The field winding is located  
in the stator, which is stationary, and is excited by direct  
current.  
The armature coil sides are placed at opposite points  
on the rotating shaft with the conductors parallel to the  
shaft. The armature assembly is normally turned at a  
constant speed by a source of mechanical power con-  
nected to the shaft. Rotation of the armature through  
the magnetic field produced by the stationary field  
Classic III and IIID  
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E-8  
E-8  
NOTES  
Classic III and IIID  
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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 ................................................................................................F-4 - F-13  
Test Procedures...................................................................................................................F-14  
Alternator Rotor Test......................................................................................................F-14  
Field Shunt Winding Test...............................................................................................F-18  
Flashing the Fields ........................................................................................................F-21  
Idler Solenoid 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 Supply) ...........................................F-34  
Normal Open Circuit DC Weld Voltage Waveform.........................................................F-35  
Typical DC Weld Output Voltage Waveform...................................................................F-36  
Replacement Procedures ....................................................................................................F-37  
Alternator Rotor Removal and Replacement ................................................................F-37  
Alternator Stator Removal and Replacement................................................................F-42  
Generator Frame Removal and Replacement...............................................................F-47  
Generator Armature Removal and Replacement..........................................................F-53  
Retest After Repair ..............................................................................................................F-55  
Classic III and IIID  
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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 four 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 conducted  
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.  
Classic III and IIID  
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F-3  
F-3  
TROUBLESHOOTING & REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
WARNING  
• 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.  
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.  
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:  
• 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.  
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 temperature.  
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  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
ohm resistive cord connected to a  
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 pre-  
vent static build-up. Be sure not to  
touch any electrically live parts at  
the same time.  
Workstations  
NOTE: Following this procedure and writing on the  
warranty report, “INSTALLED AND SWITCHED PC  
BOARDS TO VERIFY PROBLEM,” 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.  
Classic III and IIID  
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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 and  
Fields in this section.  
associated leads and connec-  
tions. See the Wiring Diagram.  
3. Check for loose or missing-  
brushes in the exciter alternator 3. Perform the Alternator Rotor  
and welding generator.  
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.  
Classic III and IIID  
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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 or missing 1. Check the Fine Current  
rect speed, but there is no, or very  
low, welder output voltage. The AC  
auxiliary output voltage is normal.  
brushes in the welding genera-  
tor.  
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 connections.  
2. Perform the Shunt Field  
Winding Test.  
3. Check the continuity of the inter-  
pole coils. They should show  
continuity from the positive  
brush holders to the positive  
output 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  
brush holders, through the  
Current Range Selector switch,  
to the negative output terminal  
and should NOT be grounded.  
Also check the Selector switch  
for proper operation.  
5. The main armature may be  
faulty. Check for grounds and/or  
shorts.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-  
383-2531 or 1-800-833-9353.  
Classic III and IIID  
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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  
mally. The auxiliary output remains  
constant. The engine is operating  
correctly.  
machine will normally lose  
some output as the components  
get heated.  
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 for loose, worn, dirty, or  
poorly seated DC generator  
brushes.  
2. Perform the Field Shunt  
3. The armature commutator may  
need cleaning.  
Winding Test.  
3. Check the Current Range  
Selector switch and contacts for  
proper operation.  
4. Check for loose or faulty welding  
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 III and IIID  
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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.  
tripped.  
Reset if  
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 alternator stator  
for shorted turns or grounds.  
Check the continuity of the  
windings.  
Diagram.  
See the Wiring  
The engine starts and runs normal- 1. Contact your local Authorized 1. Check the “flashing” diode locat-  
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.  
ed on the DC generator brush  
holder. The diode may be  
“shorted” or installed incorrectly.  
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 III and IIID  
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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” posi-  
tion.  
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 idler and throttle link-  
age.  
3. Check for loose or faulty con-  
nections at the Idler PC board.  
4. Make sure lead #60D is ground-  
ed correctly. See the Wiring  
Diagram.  
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 III and IIID  
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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. 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 III and IIID  
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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 III. 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. Replace.  
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 1. The Classic III gasoline model  
is turned off and operating cor-  
rectly.  
ignition switch supplies 12VDC  
to both the ignition coil and the  
fuel shut-off solenoid. Check  
that these circuits are operating  
correctly.  
See the Wiring  
Diagram. When the ignition  
switch is in the “off” position,  
there should NOT be 12VDC  
applied to the ignition coil nor  
the fuel shut-off solenoid.  
2. The Classic IIID diesel model  
ignition switch supplies 12VDC  
to the pump solenoid and the  
fuel lift pump. Check that these  
circuits are operating correctly.  
See the Wiring Diagram. When  
the ignition switch is in the “off”  
position, there should NOT be  
12 VDC applied to the pump  
solenoid nor the fuel lift pump.  
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 III and IIID  
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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 (Classic III gasoline models  
only).  
proper operation. Check the  
associated leads for loose or  
faulty connections. See the  
Wiring Diagram.  
2. Make sure the ignition switch is  
in the “ON” position.  
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 of ser-  
vice.  
The engine “cranks” but will not 1. Check for adequate fuel supply. 1. Check the ignition switch for  
start (Classic IIID diesel models  
only).  
proper operation. Check the  
associated leads for loose or  
faulty connections. See the  
Wiring Diagram.  
2. Make sure the ignition switch is  
in the “ON” position.  
3. Press the glow plug button for  
10 to 20 seconds.  
2. Check the pump solenoid and  
fuel lift pump. Make sure they  
are operating when 12VDC is  
applied to them. See the Wiring  
Diagram.  
4. Maker sure the engine protec-  
tion “Reset” button is pressed.  
5. Check the fuse in the engine  
protection relay. See the Wiring  
Diagram.  
3. The engine protection relay may  
be faulty. Replace.  
6. If the fuel supply is cut off or  
runs out while the fuel pump is 4. The engine fuel injectors may  
operating, air may be entrapped  
in the fuel distribution system. If  
this happens, bleeding of the  
fuel system may be necessary.  
See the Engine Operating  
Manual.  
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 III and IIID  
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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  
ENGINE PROBLEMS  
The engine starts but shuts down 1. Check for adequate fuel supply. 1. The Classic IIID diesel only:  
after a short period of time.  
The oil pressure switch or tem-  
perature sensor may be causing  
the engine protection relay to  
shut off the fuel supply to the  
engine.  
2. Check the engine oil level.  
3. Check the coolant.  
2. The protection relay may be  
faulty.  
3. 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 III and IIID  
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F-13  
F-13  
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. 1-216-  
383-2531 or 1-800-833-9353  
(WELD).  
The welding arc frequently “pops 1. The Fine Current Control rheo- 1. Check the engine speed. High  
out.”  
stat may be set too low for the  
electrode and process.  
idle speed should be 1800  
RPM. See Engine Throttle  
Adjustment.  
2. Check the welding cables for  
loose or faulty connections.  
2. The Current Range Selector  
switch may be faulty. Check for  
proper operation.  
3. Check the DC generator brush-  
es for good commutation and  
alignment. Contact the Lincoln  
Electric Service Dept. 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 III and IIID  
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F-14  
F-14  
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  
5/16” nut driver or socket wrench  
Classic III and IIID  
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F-15  
F-15  
TROUBLESHOOTING & REPAIR  
ALTERNATOR ROTOR TEST (continued)  
FIGURE F.1 – ALTERNATOR COVER REMOVAL  
WRAPAROUND  
SLIP RINGS  
ALTERNATOR  
COVER  
BRUSHES  
TEST PROCEDURE  
3. With the 5/16" socket wrench, remove the  
four screws from the alternator cover. See  
Figure F.1.  
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 alternator wrap-  
around. See Figure F.1.  
4. Remove the alternator cover and wrap-  
around. Be careful to clear the leads.  
5. Locate and lift the brushes off of the rotor  
slip rings. See Figure F.1.  
Classic III and IIID  
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F-16  
F-16  
TROUBLESHOOTING & REPAIR  
ALTERNATOR ROTOR TEST (continued)  
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 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  
Classic III and IIID  
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F-17  
F-17  
TROUBLESHOOTING & REPAIR  
ALTERNATOR ROTOR TEST (continued)  
7. Measure the rotor resistance to ground.  
a. Set the ohmmeter on the high scale  
sure they are seated correctly.  
9. Reinstall the alternator cover and wrap-  
around.  
(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 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.  
8. Replace the brushes on the slip rings. Make  
FIGURE F.3 – MEASURING ROTOR RESISTANCE TO GROUND  
Classic III and IIID  
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F-18  
F-18  
TROUBLESHOOTING & REPAIR  
FIELD SHUNT 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 field shunt coils are shorted, open or grounded.  
MATERIALS NEEDED  
Volt/Ohmmeter  
Wiring Diagram  
Classic III and IIID  
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F-19  
F-19  
TROUBLESHOOTING & REPAIR  
FIELD SHUNT WINDING TEST (continued)  
FIGURE F.4 – PLUG P10 LOCATIONS  
PLUG P10  
TEST PROCEDURE  
4. Locate the blue lead (U, pin 3) and the  
brown lead (N, pin 5) in the harness plug.  
See Figure F.5.  
1. Turn engine off.  
2. Unlatch, lift and secure the left side door.  
Note that there are latches at both ends of  
the door.  
3. Locate and remove plug P10. See Figure  
F.4.  
Classic III and IIID  
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F-20  
F-20  
TROUBLESHOOTING & REPAIR  
FIELD SHUNT WINDING TEST (continued)  
FIGURE F.5 – SHUNT LEAD RESISTANCE CHECK  
PIN 3  
PIN 5  
TAB  
5. 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 50 ohms.  
8. If the plug and associated leads are okay,  
then the shunt field coils may be faulty.  
Replace.  
9. If the test does meet the resistance specifi-  
cations, then the shunt coils are okay.  
6. 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.  
10. Replace plug P10, making sure the leads  
and plug are secure.  
11. Close and latch the left side door.  
7. If the test does not meet the resistance  
specifications, then check the harness plug  
and inline connectors for loose connections  
or shorted leads.  
Classic III and IIID  
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F-21  
F-21  
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  
Classic III and IIID  
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F-22  
F-22  
TROUBLESHOOTING & REPAIR  
FLASHING THE FIELDS (continued)  
FIGURE F.6 - FLASHING THE FIELDS  
NEGATIVE (-)  
BRUSH HOLDER  
_
+
POSITIVE (+)  
BRUSH HOLDER  
12 VOLT  
BATTERY  
PROCEDURE  
5. 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 OFF.  
2. Remove the cover from the exiter. See  
Figure F.6.  
3. Turn the FINE CURRENT ADJUSTMENT  
control (rheostat) to “100.”  
6. Replace the exciter cover.  
4. 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.6 and the  
Wiring Diagram.  
7. Start the welder. The generator voltage  
should build up.  
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.  
DO NOT remove brush holder.  
Classic III and IIID  
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F-23  
F-23  
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  
5/16" nut driver  
5/16" wrench  
Classic III and IIID  
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F-24  
F-24  
TROUBLESHOOTING & REPAIR  
IDLER SOLENOID TEST (continued)  
FIGURE F.7 - SOLENOID LEAD CONNECTIONS  
LEADS  
56 & 57  
SOLENOID  
TEST PROCEDURE  
1. Turn engine off.  
6. The solenoid should deactivate when the  
12VDC is removed.  
2. Unlatch, lift and secure the left side door.  
Note that there are latches at both ends of  
the door.  
7. If the solenoid does not operate properly,  
check for a mechanical restriction in the  
linkage or a missing spring.  
3. Using the 5/16" nut driver, remove the two  
washers, nuts, and screws holding the fan  
guard. If necessary, remove the fan guard  
(Classic IIID only).  
8. If the linkage is intact and the solenoid  
does not operate correctly when 12VDC is  
applied, the solenoid may be faulty.  
Replace. Normal solenoid coil resistance  
is approximately 9 ohms.  
4. Locate leads #56 and #57 on the idler sole-  
noid. See Figure F.7 and the Wiring  
Diagram. Using the 5/16" wrench, remove  
the leads from the solenoid.  
9. When the test is complete and the problem  
repaired, be sure to reconnect leads #56  
and #57 to the idler solenoid.  
5. Using the external voltage supply, apply  
12VDC to the idler solenoid terminals.  
Attach positive (+) to the terminal where lead  
#56 was connected. The solenoid should  
activate.  
10. Replace the fan guard if removed earlier  
(Classic IIID only).  
11. Close and latch the left side door.  
Classic III and IIID  
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F-25  
F-25  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST - CLASSIC IIID  
(DIESEL)  
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  
5/16” wrench  
White or red marking pencil, strobe-tach, frequency counter, or oscilloscope  
Classic III and IIID  
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F-26  
F-26  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.8 - 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 left 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 1325 and 1475 RPM.  
3. With a white or red marking pencil, place a  
mark on one of the blower paddles. See  
Figure F.8 for location.  
4. Connect the strobe-tach according to the  
manufacturer's instructions.  
Classic III and IIID  
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F-27  
F-27  
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.10. Adjust the  
threaded solenoid lever arm shaft, 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 5/16” wrench to  
loosen the locking nut. See Figure 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 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.10.  
Adjust the threaded solenoid lever arm  
shaft, to change the amount of throw in the  
lever arm, until the tach reads between 1325  
and 1475 RPM. Retighten the locking nut.  
Frequency Counter Method  
2. If either of these periods is incorrect, adjust  
the throttle as follows:  
1. Plug the frequency counter into one of the  
115 VAC auxiliary receptacles.  
Adjust HIGH IDLE: Use the 5/16” wrench to  
loosen the locking nut. See Figure 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 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.10. Adjust the  
threaded solenoid lever arm shaft, to  
change the amount of throw in the lever  
arm, until the period is 21.4 milliseconds.  
Retighten the locking nut.  
3. If either of the readings is incorrect, adjust  
the throttle as follows:  
Adjust HIGH IDLE: Use the 5/16” wrench to  
loosen the locking nut. See Figure 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 locking nut.  
Classic III and IIID  
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F-28  
F-28  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.9 - HIGH IDLE ADJUSTMENT  
ADJUSTING SCREW  
LOCKING NUT  
FIGURE F.10 - LOW IDLE ADJUSTMENT  
SOLENOID  
LOCKING NUT  
THREADED  
LEVER ARM  
Classic III and IIID  
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F-29  
F-29  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST - CLASSIC III  
(GASOLINE)  
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  
White or red marking pencil  
7/16" wrench  
3/8” wrench  
Classic III and IIID  
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F-30  
F-30  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.11 - BLOWER PADDLE MARK LOCATION  
STROBE  
MARK  
TEST PROCEDURE  
4. Connect the strobe-tach according to the  
manufacturer’s instructions.  
STROBE TACH METHOD  
1. Conduct this procedure with the engine OFF.  
5. Start the engine and direct the strobe-tach  
light on the blower paddle and synchronize it  
to the rotating mark.  
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  
Figure F.11.  
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 1325 and 1475 RPM.  
Classic III and IIID  
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F-31  
F-31  
TROUBLESHOOTING & REPAIR  
6. If either of these readings 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  
a. Make sure there is no load on the machine.  
b. Set the Idler switch to the HIGH position.  
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 very  
slightly above or below.  
c. Locate the governor on the 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 seal. See Figure F.12.  
3. If either of the readings is incorrect, adjust the  
throttle as follows.  
e. If further adjustments are necessary, consult the  
Engine Manual.  
Adjust High Idle  
a. Make sure there is no load on the machine.  
b. Set the Idler switch to the HIGH position.  
Adjust Low Idle  
c. Locate the governor on the left side of the engine.  
a. Make sure there is no load on the machine.  
See Figure F.12.  
b. Set the Idler switch to AUTO and wait for the  
engine to change to low idle speed.  
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 seal. See Figure F.12.  
c. Check the alignment of the idler rod so that the  
plunger can move freely.  
d. Using the 7/16” wrench, loosen the idler rod lock-  
ing nut. This is located on the idler rod between  
the carburetor ball joint and the idler solenoid. See  
Figure F.13.  
e. If further adjustments are necessary, consult the  
Engine Manual.  
Adjust Low Idle  
e. Rotate the carburetor shaft, and while holding it  
against the idle stop screw on the carburetor,  
adjust this screw to obtain low idle RPM (1325  
RPM).  
a. Make sure there is no load on the machine.  
b. Set the Idler switch to AUTO and wait for the  
engine to change to low idle speed.  
f. With the idler plunger fully seated, adjust idle  
speed by rotating the threaded rod in the ball joint.  
Lock the position by tightening the nut with the ball  
joint.  
c. Check the alignment of the idler rod so that the  
plunger can move freely.  
d. Using the 7/16” wrench, loosen the idler rod lock-  
ing nut. This is located on the idler rod between  
the carburetor ball joint and the idler solenoid. See  
Figure F.13.  
g. RPM should be 1325-1475 RPM. If necessary,  
adjust the idle screw to increase the idle speed by  
a maximum of 50 RPM.  
e. Rotate the carburetor shaft, and while holding it  
against the idle stop screw on the carburetor,  
adjust this screw to obtain low idle RPM (1325  
RPM).  
f. With the idler plunger fully seated, adjust idle  
speed by rotating the threaded rod in the ball joint.  
Lock the position by tightening the nut with the ball  
joint.  
g. RPM should be 1325-1475 RPM. If necessary,  
adjust the idle screw to increase the idle speed by  
a maximum of 50 RPM.  
Classic III and IIID  
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F-32  
F-32  
TROUBLESHOOTING & REPAIR  
OSCILLOSCOPE METHOD  
Adjust Low Idle  
1. Connect the oscilloscope to the 115 VAC recepta-  
cle, 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.  
a. Make sure there is no load on the machine.  
b. Set the Idler switch to AUTO and wait for the  
engine to change to low idle speed.  
c. Check the alignment of the idler rod so that the  
plunger can move freely.  
d. Using the 7/16” wrench, loosen the idler rod lock-  
ing nut. This is located on the idler rod between  
the carburetor ball joint and the idler solenoid. See  
Figure F.13.  
2. If either if the periods is incorrect, adjust the throt-  
tle as follows.  
e. Rotate the carburetor shaft, and while holding it  
against the idle stop screw on the carburetor,  
adjust this screw to obtain low idle RPM (1325  
RPM).  
Adjust High Idle  
a. Make sure there is no load on the machine.  
b. Set the Idler switch to the HIGH position.  
f. With the idler plunger fully seated, adjust idle  
speed by rotating the threaded rod in the ball joint.  
Lock the position by tightening the nut with the ball  
joint.  
c. Locate the governor on the left side of the engine.  
See Figure F.12.  
g. RPM should be 1325-1475 RPM. If necessary,  
adjust the idle screw to increase the idle speed by  
a maximum of 50 RPM.  
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 seal. See Figure F.12.  
e. If further adjustments are necessary, consult the  
Engine Manual.  
FIGURE F.12 - HIGH IDLE ADJUSTMENT  
GOVERNOR  
LOCKING  
ADJUSTMENT  
NUT  
SCREW  
Classic III and IIID  
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F-33  
F-33  
INSTALLATION  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.13 - LOW IDLE ADJUSTMENT  
SPEED  
ADJUSTMENT  
SCREW  
IDLER  
ROD  
LOCKING  
NUT  
Classic III and IIID  
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F-34  
F-34  
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 III and IIID  
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F-35  
F-35  
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 III and IIID  
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F-36  
F-36  
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 III and IIID  
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F-37  
F-37  
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  
1-5/8" wrench  
Large slot head screwdriver  
Small gear puller  
5/16” nut driver  
Classic III and IIID  
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F-38  
F-38  
TROUBLESHOOTING & REPAIR  
ALTERNATOR ROTOR REMOVAL  
AND REPLACEMENT (continued)  
PROCEDURE  
1. Turn the engine off.  
2. Using the 7/16” wrench, remove the two bolts  
and washers and partially slide out the battery  
mounting panel. See Figure F.14  
3. With the 1/2" wrench, disconnect the negative  
battery cable.  
FIGURE F.14 – BATTERY PANEL REMOVAL  
NEGATIVE  
BATTERY  
CABLE  
BATTERY  
MOUNTING  
PANEL  
Classic III and IIID  
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F-39  
F-39  
TROUBLESHOOTING & REPAIR  
ALTERNATOR ROTOR REMOVAL  
AND REPLACEMENT (continued)  
See Figure F.15 for steps 3 - 5.  
3. With the 3/8" wrench, loosen the screws on  
the left and right sides and bottom of the alter-  
nator wrap-around.  
4. With the 5/16" wrench, remove the 4 screws  
from the alternator cover.  
5. Remove the alternator cover and wrap-  
around. Be careful to clear the leads.  
FIGURE F.15 – ALTERNATOR COVER AND WRAPAROUND REMOVAL  
WRAPAROUND  
SLIP RINGS  
ALTERNATOR  
COVER  
BRUSHES  
Classic III and IIID  
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F-40  
F-40  
TROUBLESHOOTING & REPAIR  
ALTERNATOR ROTOR REMOVAL  
AND REPLACEMENT (continued)  
See Figure F.16 for steps 6 - 8.  
8. With the 1-5/8" socket wrench, remove the  
rotor locking nut, washer and sleeve collar.  
6. With the 7/16" wrench, remove the two bolts,  
nuts and washers mounting the brush holder  
assembly to the stator frame.  
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.  
7. Bend the flat washer away from the rotor lock-  
ing nut.  
FIGURE F.16 – ROTOR REMOVAL  
"BENT"  
WASHER  
STATOR  
FRAME  
SLEEVE  
COLLAR  
BRUSH  
HOLDER  
ASSEMBLY  
NUT  
Classic III and IIID  
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F-41  
F-41  
INSTALLATION  
ALTERNATOR ROTOR REMOVAL  
AND REPLACEMENT (continued)  
Replacement  
d. The exciter brush spring must lie flat on  
the corner of the brush and not touch  
either side of the retainer.  
9. Carefully mount the rotor onto the generator  
shaft. Install a new sleeve collar (part num-  
ber T14337), washer, and rotor locking nut.  
e. With the brushes in place, insert one end  
of a minimum 24" long piece of 180 grit  
sandpaper between the slip rings and  
brushes (abrasive against brushes). With  
slight additional finger pressure on top of  
brushes, pull the paper around the cir-  
cumference of the rings in the direction of  
rotation only. Repeat this procedure until  
the entire face of the brush is contoured  
to the radius of the slip ring.  
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 ft.-lbs.  
After the rotor locking nut is properly torqued,  
bend the washer down over the locking nut.  
Check rotor air gap. .017" minimum is  
allowed.  
f. Check the brushes to be certain that there  
is spring tension holding them firmly  
against the slip rings.  
10. Mount the brush holder assembly to the sta-  
tor frame using two bolts, washers, and nuts.  
Installing and Seating Exciter Slip Ring Brushes  
11. Install the alternator cover and wrap-around.  
12. Connect the negative battery cable.  
a. Make sure the slip rings are clean and  
free from oil and grease.  
b. Spacing between 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 are  
tightly packed and no part of the pigtail  
protrudes beyond the brush surface in the  
pigtail slot. When the brush is placed in  
the holder, clear the pigtail from the side  
of the holder to allow free radial move-  
ment of the brush.  
Classic III and IIID  
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F-42  
F-42  
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 III and IIID  
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F-43  
F-43  
TROUBLESHOOTING & REPAIR  
ALTERNATOR STATOR REMOVAL AND  
REPLACEMENT (continued)  
FIGURE F.17 – COMMUTATOR WRAP-AROUND REMOVAL  
COMMUTATOR  
WRAPAROUND  
ALTERNATOR  
BRUSH HOLDER  
ASSEMBLY  
(REMOVED)  
PROCEDURE  
1. Turn the engine OFF.  
8. Remove the tape and using the 3/8"  
wrench and slot head screw driver, discon-  
nect the black auxiliary power lead from  
the current transformer. Cut any neces-  
sary cable ties. See the Wiring Diagram  
and Figure F.18.  
2. Perform the Alternator Rotor Removal  
procedure.  
3. With the 1/2" wrench, remove the four nuts  
and bolts holding the case top and doors  
assembly to the welder frame. Carefully lift  
up and remove the top and doors assembly.  
9. Remove the red auxiliary power lead from  
the CB4 circuit breaker. See the Wiring  
Diagram and Figure F.19.  
4. With the 3/8" nut driver, remove the two  
leads from the alternator brush holder  
assembly. Note lead placement. Set brush  
holder aside.  
10. Remove the white auxiliary power lead  
from the 115VAC receptacle. Cut any nec-  
essary cable ties. See Figure F.19.  
5. With the slot head screwdriver, remove the  
commutator wraparound. See Figure F.17.  
NOTE: The CB1 circuit breaker may have to be  
removed to access the terminal for the white  
lead.  
6. Disconnect the yellow and white wires at the  
in-line connectors. See the Wiring Diagram  
and Figure F.18.  
11. Remove the red lead from the negative ter-  
minal of the field rectifier bridge. See  
Figure F.19.  
7. Disconnect the two yellow leads. One is  
located at the field bridge and the other at  
the field fuse holder. Cut any necessary  
cable ties. See Figure F.18 and F.19.  
12. Remove the black lead from the positive  
terminal of the field rectifier bridge. See  
Figure F.19.  
Classic III and IIID  
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F-44  
F-44  
TROUBLESHOOTING & REPAIR  
ALTERNATOR STATOR REMOVAL  
AND REPLACEMENT (continued)  
FIGURE F.18 - LEAD DISCONNECTION POINTS  
YELLOW AND WHITE WIRE  
IN-LINE CONNECTORS;  
YELLOW LEADS; BLACK  
CURRENT TRANSFORMER  
LEAD  
ALL LOCATED BEHIND  
CASE FRONT  
FIGURE F.19- LEAD DISCONNECTION – CIRCUIT BREAKER, RECEPTACLES, FIELD BRIDGE RECTIFIER  
230 VAC RECEPTACLE  
CB1 CIRCUIT BREAKER  
115 VAC RECEPTACLE  
CB4 CIRCUIT BREAKER  
FIELD FUSE HOLDER  
FIELD RECTIFIER BRIDGE  
Classic III and IIID  
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F-45  
F-45  
TROUBLESHOOTING & REPAIR  
ALTERNATOR STATOR REMOVAL  
AND REPLACEMENT (continued)  
13. Clear the leads in preparation for remov-  
ing the stator/end bracket.  
14. Lift the eight brushes from the commuta-  
tor. Note the position of the brushes for  
reassembly.  
FIGURE F.20 - GENERATOR BRUSH HOLDER CABLE REMOVAL  
GENERNATOR  
BRUSH HOLDER/COIL  
CABLES (4)  
15. 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.20. Label leads and posi-  
tions for re-assembly.  
Classic III and IIID  
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F-46  
F-46  
TROUBLESHOOTING & REPAIR  
ALTERNATOR STATOR REMOVAL  
AND REPLACEMENT (continued)  
FIGURE F.21 - DRILL SPOT LOCATIONS  
BRUSH HOLDER  
DRILL SPOT  
LOCATION  
STATOR END BRACKET  
DRILL SPOT  
STATOR/END BRACKET  
MOUNTING BOLT  
16. 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.21.  
22. Connect the four heavy cables from the  
generator frame coils to the generator  
brush holders.  
23. Install the eight commutator brushes  
according to how you marked their posi-  
tions at disassembly.  
17. With the 7/16" wrench, loosen (do not  
remove) the generator brush holder  
clamping bolt. Note the drill spot for  
reassembly. See Figure F.21.  
24. Attach the black lead to the positive termi-  
nal of the field rectifier bridge. Attach the  
red lead to the negative terminal.  
18. Carefully pry the stator/end bracket  
assembly away from the generator frame.  
25. Attach the white auxiliary power lead to  
the 115 VAC receptacle. Attach the red  
auxiliary power lead to the CB4 circuit  
breaker. Attach the black auxiliary power  
lead to the current transformer. Tape the  
bolted connection.  
NOTE: The generator brush holder assembly  
will also be removed.  
Replacement  
19. Mount the stator/end bracket assembly to  
the generator frame. Line up the mating  
parts at the stator end bracket drill spot.  
Tighten the four mounting bolts with the  
5/8" wrench.  
26. 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.  
27. Install the commutator wraparound, the  
bottom alternator cover, the battery, and  
the alternator brush holder assembly.  
20. Check armature air gap. Minimum gap is  
.035." Loosen the four mounting bolts;  
adjust and re-tighten if necessary.  
28. Install the alternator rotor according to the  
reassembly directions in the Alternator  
Rotor Removal and Replacement proce-  
dure. Before installing the case top and  
sides, replace any cable ties cut for disas-  
sembly.  
21. Tighten the generator brush holder  
assembly with the 7/16" wrench. Note  
brush holder drill spot.  
Classic III and IIID  
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F-47  
F-47  
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  
Rope sling  
3/4" wrench  
1/2" wrench  
9/16" wrench  
Wood or steel blocks  
Pry bars  
Classic III and IIID  
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F-48  
F-48  
TROUBLESHOOTING & REPAIR  
GENERATOR FRAME REMOVAL  
AND REPLACEMENT (continued)  
FIGURE F.22 – FUEL TANK / OUTPUT CABLE REMOVAL  
(DIESEL ONLY)  
FUEL TANK  
RETURN LINE  
POSITIVE CABLE  
COPPER  
STRAP  
FUEL TANK  
MOUNTING  
HARDWARE  
FUEL LINE  
FUEL  
BOWL  
PROCEDURE  
1. Turn the engine OFF.  
7. Carefully remove the fuel tank.  
2. Perform the Alternator Rotor Removal  
NOTE: At reassembly, the fuel line may have to  
be purged. See the Maintenance section (Diesel  
only).  
procedure.  
3. Perform the Alternator Stator Removal  
procedure.  
8. With the 3/4" wrench, remove the copper  
strap/reed switch assembly from the negative  
output terminal. Clear the strap.  
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.  
9. With the 3/4" wrench, remove the cable from  
the positive output terminal.  
5. Remove the fuel return line from the top of the  
fuel tank (diesel engine only).  
6. With the 9/16" wrench, remove the four nuts,  
bolts, and washers that mount the fuel tank to  
the rails.  
Classic III and IIID  
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F-49  
F-49  
TROUBLESHOOTING & REPAIR  
GENERATOR FRAME REMOVAL  
AND REPLACEMENT (continued)  
FIGURE F.23 – WIRE AND SELECTOR SWITCH CONNECTIONS  
IDLER PC BOARD  
SELECTOR  
SWITCH  
FINE CURRENT  
ADJUSTMENT  
RHEOSTAT  
FIELD BRIDGE  
IN-LINE CONNECTORS  
BLUE/BROWN LEADS  
See Figure F.23 for steps 10 - 13.  
10. Cut all necessary cable ties.  
12. Label the cables that are connected to the selector  
switch. Otherwise, you will need to see the Wiring  
Diagram during reassembly.  
11. Disconnect the blue and the brown wires at the in-  
line connectors. See Figure F.23 and the Wiring  
Diagram.  
13. With the 1/2" wrench, remove the cables connect-  
ed to the selector switch.  
Classic III and IIID  
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F-50  
F-50  
TROUBLESHOOTING & REPAIR  
GENERATOR FRAME REMOVAL  
AND REPLACEMENT (continued)  
FIGURE F.24 – CASE FRONT REMOVAL  
STEP #16  
STEP #15  
STEP #14  
See Figure F.24 for steps 14 - 16.  
14. With the 9/16" wrench, remove the four bolts and  
lock washers holding the case front to the welder  
frame. There are two bolts on each side.  
15. With the 1/2" wrench, remove the two bolts and  
nuts and washers from the fuel tank rails - one on  
each side.  
16. Carefully 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.  
Classic III and IIID  
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F-51  
F-51  
TROUBLESHOOTING & REPAIR  
GENERATOR FRAME REMOVAL  
AND REPLACEMENT (continued)  
FIGURE F.25 – FRAME MOUNTING DETAILS  
ROPE SLING  
ENGINE/GENERATOR  
MOUNTING HOLES  
See Figure F.25 for steps 17 - 20.  
Replacement  
17. With the 3/4" wrench, remove the frame  
mounting bolts, nuts and spacers from the  
feet of the generator frame.  
21. Support the generator frame with the rope  
sling. Mount the generator frame to the  
engine and armature 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 bolts that  
attach the generator frame to the engine.  
18. 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.  
19. With the 9/16" wrench, remove the bolts  
mounting the engine to the generator frame.  
22. With the 3/4" wrench, install the frame  
mounting bolts, nuts, and spacers to the feet  
of the generator frame. See Figure F.25.  
20. 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.  
23. Install the case front to the welder frame. See  
steps 14 - 16.  
24. Connect the cables to the selector switch  
according to how you labeled them during  
disassembly. See the Wiring Diagram if nec-  
essary.  
25. Reconnect the blue and brown leads at the  
in-line connectors.  
26. Install the copper strap/reed switch assembly  
to the negative output terminal.  
Classic III and IIID  
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F-52  
F-52  
TROUBLESHOOTING & REPAIR  
GENERATOR FRAME REMOVAL  
AND REPLACEMENT (continued)  
27. Re-attach the positive output terminal cable.  
28. Set the fuel tank into position on the rails and  
secure it with the four bolts, washers, and nuts.  
29. Attach the fuel return line at the top of the fuel tank  
(Diesel engine only). Remove the plug from the  
fuel line and attach it to the fuel bowl.  
30. Perform the replacement procedures according to  
each of the following:  
Alternator Stator Removal and Replacement  
Alternator Rotor Removal and Replacement  
Before installing the machine case top and sides,  
be sure to replace any cable ties cut during disas-  
sembly.  
Classic III and IIID  
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F-53  
F-53  
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  
Rope sling  
5/8" wrench  
Wood or steel blocks  
Classic III and IIID  
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F-54  
F-54  
TROUBLESHOOTING & REPAIR  
GENERATOR ARMATURE REMOVAL  
AND REPLACEMENT (continued)  
FIGURE F.26 – BLOWER PADDLE REMOVAL  
ROPE SLING  
BLOWER PADDLE  
BLOWER  
PADDLE/ARMATURE  
MOUNTING BOLTS(8)  
PROCEDURE  
CAUTION  
1. Turn the engine OFF.  
The armature is now free to be removed from the  
engine.  
2. Perform the Alternator Rotor Removal pro-  
cedure.  
3. Perform the Alternator Stator Removal pro-  
cedure.  
Replacement  
4. Perform the Generator Frame Removal pro-  
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.  
cedure.  
5. Using the rope sling, support the armature.  
6. Make sure the engine is supported with the  
wood or steel blocks.  
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.26.  
10. Perform the replacement procedures accord-  
ing to each of the following:  
8. With the armature supported and “balanced”  
in the rope sling, carefully rotate the armature  
1/8 turn in either direction to release.  
Generator Frame Removal and Replacement  
Alternator Stator Removal and Replacement  
Alternator Rotor Removal and Replacement  
Classic III and IIID  
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F-55  
F-55  
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  
1325 - 1475  
1780 - 1810  
Load RPM  
NA  
1650 - 1750  
WELDER DC OUTPUT  
Current Control  
Rheostat  
Current Selector  
Open Circuit  
Voltage  
Load Volts  
Load Amps  
Switch  
Maximum  
Maximum  
Maximum  
Maximum  
91 - 98.5  
91 - 98.5  
36 - 45 Gas  
38 - 47 Diesel  
350  
350  
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  
2.0 - 2.4  
Alt. Rotor Amps  
RPM  
1780 - 1810  
123 - 133  
2.2 - 2.6  
Classic III and IIID  
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F-56  
F-56  
NOTES  
Classic III and IIID  
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G-1  
G-1  
ELECTRICAL DIAGRAMS  
TABLE OF CONTENTS  
ELECTRICAL DIAGRAMS SECTION  
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  
Idler PC Board Layout ...............................................................................................................G-11  
CLASSIC III/IIID  
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G-2  
G-2  
Notes  
CLASSIC III/IIID  
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G-3  
G-3  
ELECTRICAL DIAGRAMS  
Wiring Diagram- Classic IIID  
+
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 III/IIID  
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G-4  
G-4  
Notes  
CLASSIC III/IIID  
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G-5  
G-5  
ELECTRICAL DIAGRAMS  
Wiring Diagram- Classic III  
TO PLUGS  
TO PLUGS  
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 repairs could result in damage to the machine.  
CLASSIC III/IIID  
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G-6  
G-6  
Notes  
CLASSIC III/IIID  
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G-7  
G-7  
ELECTRICAL DIAGRAMS  
Wiring Diagram - Wire Feed Module  
POS  
NEG  
R502  
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 III/IIID  
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G-8  
G-8  
Notes  
CLASSIC III/IIID  
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G-9  
G-9  
ELECTRICAL DIAGRAMS  
Idler PC Board Schematic  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your  
factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided  
for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design  
and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.  
CLASSIC III/IIID  
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G-10  
G-10  
Notes  
CLASSIC III/IIID  
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G-11  
G-11  
ELECTRICAL DIAGRAMS  
Idler PC Board Layout  
C2  
R4  
C7  
R19  
D8  
C9  
D3  
C5  
D7  
R14  
R18  
R3  
R21  
R7  
R6  
R10  
R2  
Q2  
DZ1  
C6  
R17  
R16  
DZ2  
C8  
R12  
D5  
DZ3  
C3  
R5  
C1  
D1  
R9  
R8  
R15  
R13  
R20  
R1  
D2  
ENGINE WELDER IDLER  
M13708-3  
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 repairs could result in damage to the machine.  
CLASSIC III/IIID  
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G-12  
G-12  
Notes  
CLASSIC III/IIID  
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