Lincoln Electric 137-A User Manual

SVM 137-A January, 1998Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, your overall s

STACKINGClassic III and Classic IIID machines CANNOT bestacked.TILTINGPlace the machine on a secure, level surface whenev-er you use it or store it. A

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ALTERNATOR STATOR REMOVAL AND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repair

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GENERATOR FRAME REMOVAL AND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs

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See Figure F.23 for steps 10 - 13.10. Cut all necessary cable ties.11. Disconnect the blue and the brown wires at the in-line connectors. See Figure F

COOLING SYSTEMThe cooling system has been filled at the factory with a50-50 mixture of ethylene glycol antifreeze and water.Check the radiator level a

See Figure F.24 for steps 14 - 16.14. With the 9/16" wrench, remove the four bolts andlock washers holding the case front to the welderframe. The

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27. Re-attach the positive output terminal cable.28. Set the fuel tank into position on the rails andsecure it with the four bolts, washers, and nuts.

GENERATOR ARMATUREREMOVAL AND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repair

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NOTESF-56 F-56Classic III and IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return t

ELECTRICAL DIAGRAMSG-1 G-1CLASSIC III/IIIDReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCElectrical Diagrams Secti

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ELECTRICAL DIAGRAMSG-3 G-3CLASSIC III/IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

ELECTRICAL OUTPUT CONNECTIONSSee Figure A.1 for the location of the 115 and 230 voltreceptacles, weld output terminals, and ground stud.WELDING CABLE

NotesG-4 G-4CLASSIC III/IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

ELECTRICAL DIAGRAMSG-5 G-5CLASSIC III/IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

NotesG-6 G-6CLASSIC III/IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

ELECTRICAL DIAGRAMSG-7 G-7CLASSIC III/IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

NotesG-8 G-8CLASSIC III/IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

ELECTRICAL DIAGRAMSG-9 G-9CLASSIC III/IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

NotesG-10 G-10CLASSIC III/IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

ELECTRICAL DIAGRAMSG-11 G-11CLASSIC III/IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TO

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MACHINE GROUNDINGAccording to the United States National ElectricalCode, the frame of this portable generator is notrequired to be grounded and is per

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Section B-1 Section B-1Classic III and IIIDTABLE OF CONTENTS- OPERATION SECTION -Operation...

OPERATING INSTRUCTIONSRead and understand this entire section before operat-ing your Classic III or Classic IIID.SAFETY INSTRUCTIONSDo not attempt to

RECOMMENDED APPLICATIONSWELDERThe Classic III and Classic IIID provide excellent con-stant current DC welding output for stick (SMAW) weld-ing and for

WELDING CAPABILITYThe Classic III and Classic IIID are rated 300 amps, 32volts constant current DC at 50% duty cycle based ona ten minute time period

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SAFETYi iClassic III and IIIDFOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance wo

CONTROL OF WELDING CURRENT• DO NOT turn the CURRENT RANGE SELECTORwhile welding because the current may arc betweenthe contacts and damage the switch

GASOLINE ENGINE CONTROLS (CLASSIC III)See Figure B.3 for the location of the following features:1. IDLER CONTROL TOGGLE SWITCH: Adjusts therunning spe

OPERATIONB-8DIESEL ENGINE CONTROLS (CLASSIC IIID)See Figure B.4 for the location of the following features:1. IDLER CONTROL TOGGLE SWITCH: Adjusts the

ENGINE OPERATIONDO NOT RUN THE ENGINE AT EXCESSIVESPEEDS. The maximum allowable high idle speed forthe Classic III and Classic IIID is 1800 RPM, no lo

STOPPING THE ENGINE(GASOLINE OR DIESEL)1. Place the IGNITION switch in the OFF position.At the end of each day’s welding, drain accumulateddirt and wa

WELDING OPERATIONTO USE THE CLASSIC III OR CLASSIC IIIDFOR DC CONSTANT CURRENT STICK ORTIG WELDING:1. Remove the flange nuts from the weld output ter-

TO USE THE CLASSIC III OR CLASSICIIID FOR DC WIRE FEED WELDING(CONSTANT VOLTAGE WITH WIRE FEEDMODULE):1. Connect the LN-25, LN-23P, or LN-7 Wire Feede

AUXILIARY POWERBe sure that any electrical equipment plugged into thegenerator AC power receptacles can withstand a ±10%voltage and a ±3% frequency va

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TABLE OF CONTENTS- ACCESSORIES -Accessories...

SAFETYii iiClassic III and IIIDARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays

OPTIONS/ACCESSORIESThe following options/accessories are available for yourClassic III or Classic IIID from your local LincolnDistributor.Trailer (K91

TIG WELDING ACCESSORIESK930-2 TIG Module - The TIG Module is an accessorythat provides high frequency & shielding gas control forDC GTAW (TIG) wel

CONNECTION OF THE LN-7 TO THE CLASSIC III OR CLASSIC IIID (EQUIPPEDWITH K623-1 WIRE FEED MODULE)USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.1.)1. Shut

CONNECTION OF THE LN-7 TO THE CLASSIC III OR CLASSIC IIID (EQUIPPEDWITH K623-1 WIRE FEED MODULE)USING K584 INPUT CABLE ASSEMBLY(SEE FIGURE C.2.)1. Sh

CONNECTION OF THE LN-25 TO THE CLASSIC III OR CLASSIC IIID (EQUIPPEDWITH K623-1 WIRE FEED MODULE)USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.3.)1. Shu

CONNECTION OF THE LN-25 TO THE CLASSIC III OR CLASSIC IIID (EQUIPPEDWITH K623-1 WIRE FEED MODULE)“ACROSS THE ARC” (SEE FIGURE C.4.)1. Shut the welder

CONNECTION OF THE LN-23P TO THE CLASSIC III OR CLASSIC IIID (EQUIPPEDWITH K623-1 WIRE FEED MODULE) USINGTHE K-350-1 ADAPTER KIT (SEE FIGUREC.5)1. Shut

CONNECTION OF THE K488 SG CONTROLMODULE AND K487 MAGNUM SPOOL GUNTO THE CLASSIC III OR CLASSIC IIID(EQUIPPED WITH K623-1 WIRE FEEDMODULE) (SEE FIGURE

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection D-1 Section D-1Classic III and IIIDTABLE OF CONTENTS-MAINTE

Classic III and IIIDFOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipm

SAFETY PRECAUTIONS• Have qualified personnel do all maintenance andtroubleshooting work.• Turn the engine off before working inside themachine.• Re

CHANGE THE OIL FILTER: Change the oil filter thefirst time between 25 and 50 hours of operation. Then,under normal operating conditions, change the oi

FUEL FILTER - DIESEL ENGINE (CLASSIC IIIDCODES ABOVE 10061 WITH STANADYNE FUELFILTER):The diesel engine fuel filter is a metal canister ele-ment type.

HOW TO ELIMINATE AIR FROM THE FUEL SYSTEM– DIESEL ENGINE (CLASSIC IIID)The following procedure is for Classic IIID dieselengines with a Stanadyne type

COOLING SYSTEM: The Continental engine, gaso-line or diesel, is water cooled. Check the coolant levelat the radiator filler daily. Add a 50-50 mixture

TIGHTENING THE FAN BELT: Fan belts tend toloosen after the first 50 hours of operation. If the fanbelts are loose, the engine can overheat and the ba

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BATTERY MAINTENANCEGASES FROM BATTERY can explode.• Keep sparks, flame, and cigarettes awayfrom battery.BATTERY ACID can burn eyes and skin.• Wear g

WELDER/GENERATOR MAINTENANCESTORAGE: Store the Classic III or Classic IIID inclean, dry, protected areas.CLEANING: Blow out the generator and controls

IDLER MAINTENANCE1. The solenoid plunger must work freely becausebinding can cause engine surging. If surgingoccurs, be sure the plunger is properly l

SAFETYiv ivClassic III and IIIDPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection E-1 Section E-1Classic III and IIIDTheory of Operation ...

THEORY OF OPERATIONE-2 E-2Classic III and IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

THEORY OF OPERATIONE-3 E-3Classic III and IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master

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MASTER TABLE OF CONTENTS FOR ALL SECTIONSv vClassic III and IIIDPageSafety...

NOTESE-8 E-8Classic III and IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection F-1 Section F-1Classic III and IIIDTroubleshooting & Re

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TABLE OF CONTENTS- INSTALLATION SECTION -Section A-1 Section A-1Classic III and IIIDInstallationTechnical Specifications...

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TROUBLESHOOTING & REPAIRF-12 F-12Classic III and IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn

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FIELD SHUNT WINDING TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on th

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FLASHING THE FIELDSService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this eq

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IDLER SOLENOID TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this eq

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TROUBLESHOOTING & REPAIRF-29 F-29Classic III and IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn

Read this entire installation section before youstart installation.SAFETY PRECAUTIONSDo not attempt to use this equipment until you havethoroughly rea

TROUBLESHOOTING & REPAIRF-30 F-30Classic III and IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn

TROUBLESHOOTING & REPAIRF-31 F-31Classic III and IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn

TROUBLESHOOTING & REPAIRF-32 F-32Classic III and IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn

INSTALLATIONF-33 F-33Classic III and IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC R

TROUBLESHOOTING & REPAIRF-34 F-34Classic III and IIIDReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn

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ALTERNATOR ROTOR REMOVAL AND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs

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