Lincoln Electric SVM 137-A

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TROUBLESHOOTING & REPAIR

F-40 F-40

Classic III and IIID

ALTERNATOR ROTOR REMOVAL

AND REPLACEMENT (continued)

FIGURE F.16 – ROTOR REMOVAL

STATOR

FRAME

NUT SLEEVE

COLLAR

"BENT"

WASHER

BRUSH

HOLDER

ASSEMBLY

See Figure F.16 for steps 6 - 8.

6. With the 7/16" wrench, remove the two bolts,

nuts and washers mounting the brush holder

assembly to the stator frame.

7. Bend the flat washer away from the rotor lock-

ing nut.

8. With the 1-5/8" socket wrench, remove the

rotor locking nut, washer and sleeve collar.

NOTE: The sleeve collar will have to be removed

with a gear puller. Be careful not to damage the

rotor slip ring assembly. Remove the rotor by

pulling it free of the generator shaft.

Contents

Main SVM 137-A January, 1998 Safety Depends on You CLASSIC III/IIID Gasoline & Diesel Engine Driven DC Arc Welding Power Source i i FOR ENGINE powered equipment. WARNING ELECTRIC AND MAGNETIC FIELDS may be dangerous ii ii ARC RAYS can burn. ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. iii WELDING SPARKS can cause fire or explosion. iv iv PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Mar.93 MASTER TABLE OF CONTENTS FOR ALL SECTIONS - INSTALLATION SECTION - TECHNICAL SPECIFICATIONS - CLASSIC III AND IIID INPUT - ENGINE Manufacturer Description Speed Displacement Ignition Capacities RATED OUTPUT - WELDER Duty Cycle Amps Volts at Rated Amperes OUTPUT - WELDER AND GENERATOR SAFETY PRECAUTIONS LOCATION AND VENTILATION STORING STACKING TILTING PRE-OPERATION ENGINE SERVICE OIL FUEL BATTERY CONNECTIONS COOLING SYSTEM MUFFLER EXHAUST SPARK ARRESTER TRAILER ELECTRICAL OUTPUT CONNECTIONS WELDING CABLE CONNECTIONS MACHINE GROUNDING AUXILIARY POWER RECEPTACLES, PLUGS, AND HAND-HELD EQUIPMENT CIRCUIT BREAKERS Page - OPERATION SECTION - OPERATING INSTRUCTIONS SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. FUMES AND GASES can be dan- gerous. WELDING SPARKS can cause fire or explosion. RECOMMENDED APPLICATIONS WELDER Welding GENERATOR OPERATIONAL FEATURES AND CONTROLS WELDING CAPABILITY LIMITATIONS Welding Operation WELDER/GENERATOR CONTROLS CONTROLS AND SETTINGS CONTROL OF WELDING CURRENT CURRENT RANGE SELECTOR FINE CURRENT ADJUSTMENT GASOLINE ENGINE CONTROLS (CLASSIC III) Engine DIESEL ENGINE CONTROLS (CLASSIC IIID) ENGINE OPERATION BEFORE STARTING THE ENGINE Figure D.1 STARTING THE CLASSIC III CONTINEN- TAL TM27 GASOLINE ENGINE STARTING THE CLASSIC IIID CONTINEN- TAL TMD27 ENGINE STOPPING THE ENGINE (GASOLINE OR DIESEL) BREAK-IN PERIOD WELDING OPERATION TO USE THE CLASSIC III OR CLASSIC IIID FOR DC CONSTANT CURRENT STICK OR TIG WELDING: 2 1 7 6 5 4 3 Page AUXILIARY POWER Accessories Figure B.1. Page - ACCESSORIES - OPTIONS/ACCESSORIES TIG WELDING ACCESSORIES SEMIAUTOMATIC WELDING ACCESSORIES CONNECTION OF THE LN-7 TO THE USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.1.) CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS CONNECTION OF THE LN-7 TO THE USING K584 INPUT CABLE ASSEMBLY (SEE FIGURE C.2.) CONNECTION OF THE LN-25 TO THE USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.3.) CONNECTION OF THE LN-25 TO THE ACROSS THE ARC (SEE FIGURE C.4.) CONNECTION OF THE LN-23P TO THE WITH K623-1 WIRE FEED MODULE) USING THE K-350-1 ADAPTER KIT (SEE FIGURE C.5) Page Page -MAINTENANCE- SAFETY PRECAUTIONS ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE Change the Oil { Table D.1 How to Eliminate Air from the Fuel System. Table D.1 Page Page Page Page BATTERY MAINTENANCE WELDER/GENERATOR MAINTENANCE IDLER MAINTENANCE Page Page Page -THEORY OF OPERATION SECTION- GENERAL DESCRIPTION Page BATTERY, STARTER,ENGINE ALTERNATOR AND PROTECTION CIRCUITRY (CLASSIC IIID) ENGINE, GENERATOR ARMATURE AND FRAME, ALTERNATOR STATOR AND ROTOR EXCITATION (FLASHING) AUXILIARY AND FIELD FEEDBACK COILS INTERPOLE AND SERIES COILS CURRENT RANGE SELECTOR FINE CURRENT ADJUSTMENT ENGINE IDLER CIRCUIT DC GENERATOR MACHINES Page TROUBLESHOOTING & REPAIR SECTION HOW TO USE TROUBLESHOOTING GUIDE PC BOARD TROUBLESHOOTING PROCEDURES Flashing the Fields Alternator Rotor Test. Shunt Field Winding Test. Field Shunt Winding Test. Page Idler Solenoid Test. Page Page ENGINE PROBLEMS Page WELDING PROBLEMS ALTERNATOR ROTOR TEST Page Page Page FIELD SHUNT WINDING TEST FIELD SHUNT WINDING TEST (continued) Figure F.5. PLUG P10 FIELD SHUNT WINDING TEST (continued) PIN 3 PIN 5 TAB FLASHING THE FIELDS FLASHING THE FIELDS (continued) Troubleshooting Guide + _ IDLER SOLENOID TEST IDLER SOLENOID TEST (continued) LEADS 56 & 57 SOLENOID ENGINE THROTTLE ADJUSTMENT TEST - CLASSIC IIID (DIESEL) Page NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY) HIGH IDLE - NO LOAD Page ENGINE THROTTLE ADJUSTMENT TEST - CLASSIC III (GASOLINE) Page Page NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY) HIGH IDLE - NO LOAD Page NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) HIGH IDLE NO LOAD FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE NO LOAD FINE CURRENT CONTROL RHEOSTAT AND SELECTOR SWITCH AT MAXIMUM TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM MACHINE LOADED SELECTOR SWITCH AT MAXIMUM POSITION ALTERNATOR ROTOR REMOVAL AND REPLACEMENT Page See Figure F.15 for steps 3 - 5. Page Page ALTERNATOR STATOR REMOVAL AND REPLACEMENT ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued) PROCEDURE Figure F.18 and F.19. Alternator Rotor Removal Figure F.18. Page GENERNATOR BRUSH HOLDER/COIL CABLES (4) BRUSH HOLDER DRILL SPOT LOCATION STATOR/END BRACKET MOUNTING BOLT STATOR END BRACKET DRILL SPOT Alternator Rotor Removal and Replacement GENERATOR FRAME REMOVAL AND REPLACEMENT Page See Figure F.23 for steps 10 - 13. See Figure F.24 for steps 14 - 16. ENGINE/GENERATOR MOUNTING HOLES ROPE SLING See Figure F.25 for steps 17 - 20. See steps 14 - 16. Alternator Stator Removal and Replacement Alternator Rotor Removal and Replacement GENERATOR ARMATURE REMOVAL AND REPLACEMENT GENERATOR ARMATURE REMOVAL Alternator Rotor Removal Generator Frame Removal Alternator Stator Removal ROPE SLING RETEST AFTER REPAIR Page Page Page G-3 G-3 Wiring Diagram- Classic IIID ** 10-31-97L L9260 +- + - Page G-5 G-5 Wiring Diagram- Classic III ** * 10-31-97L +- Page G-7 G-7 Wiring Diagram - Wire Feed Module - L9259 CLEVELAND, OHIO U.S.A. 3-18-94 Page Idler PC Board Schematic Page G-11 G-11 Idler PC Board Layout M13708-3 Q2 R8 DZ1