SVM134-A
October, 2000
TM
CLASSIC I
For use with machine code numbers 10068 to 10069
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS MAN-
UAL AND THE SAFETY PRE-
CAUTIONS
THROUGHOUT.
CONTAINED
And, most
importantly, think before you act
and be careful.
SERVICE MANUAL
Copyright © 2000 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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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 I
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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 I
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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 I
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v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
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-7
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-3
Limitations .................................................................................................................................B-3
Controls and Settings..................................................................................................................B-4
Engine Operation ........................................................................................................................B-7
Welding Operation.......................................................................................................................B-9
Auxiliary Power..........................................................................................................................B-10
Accessories ..........................................................................................................................Section C
Maintenance..........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance.............................................................................................D-2
Major Component Locations.......................................................................................................D-9
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair ................................................................................................Section F
Electrical Diagrams..............................................................................................................Section G
Parts Manual................................................................................................................................P-292
CLASSIC I
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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
Trailers .................................................................................................................................A-5
Machine Grounding ..............................................................................................................A-6
Electrical Output Connections.....................................................................................................A-7
Welding Cable Connections .................................................................................................A-7
Cable Installation and Cable Sizes..........................................................................A-7
Auxiliary Power Receptacle, Plugs, and Hand-held Equipment...........................................A-7
CLASSIC I
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - CLASSIC I
INPUT - DIESEL ENGINE
Manufacturer Description
Speed
Displacement
Ignition
Capacities
Continental
TM27
4 cyl., 4 cycle
Water-cooled
gasoline
1450 RPM
Full load
164.7 cu. in.
(2700 cc)
Distributor
Type
Electronic
Fuel: 15 gal.
(57 liters)
38 HP @
1450 RPM
1600 RPM
High idle
Oil: 6.0 qt.
(5.7 liters)
1000 RPM
Low idle
Coolant: 9.3 qt.
(8.8 liters)
RATED OUTPUT - WELDER
Amps
Duty Cycle
Volts at Rated Amperes
60% Duty Cycle
200 DC Constant Current
40V(1)
OUTPUT - WELDER AND GENERATOR
Welding Ranges Max. Open Circuit Voltage
Auxiliary Power
40-300 Amps DC
95
1.75 kw
15 Amps @ 120V DC
PHYSICAL DIMENSIONS
Height
Width
Depth
Weight
40.9 in.
1040 mm
24 in.
610 mm
67.5 in.
1714 mm
1370 lb.
621 kg
1
Lincoln rating. Nema rating at 60% duty cycle is 200 DC amps / 28V.
CLASSIC I
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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 I 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. This will help protect you from
the dangers of moving parts, hot metal surfaces, and
live electrical devices.
SAFETY PRECAUTIONS
WARNING
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.
Whenever you use the Classic I, be sure that clean
cooling air can flow through the machine’s gasoline
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, outside area.
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrodes with your
skin or wet clothing.
The Classic I may be used outdoors. Do not set the
machine in puddles or otherwise submerge it in water.
Such practices pose safety hazards and cause improp-
er operation and corrosion of parts.
• Insulate yourself from the work
and ground.
• Always wear dry insulating
gloves.
STORING
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 SAE 30 or
40 oil. Run the engine for two 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
MOVING PARTS can injure.
place.
See Battery Maintenance in the
• Do not operate this equipment
with any of its doors open or
guards off.
Maintenance section of this manual.
4. See your engine operation manual for further infor-
mation on fuel and engine preservation. See also
“short” or “long” term storage in the Engine manual.
• 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 I
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A-4
A-4
INSTALLATION
STACKING
WARNING
Classic I 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 gasoline engine is designed to run in a level posi-
tion 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 condition. Also, fuel capacity will be a little less at
an angle.
• Keep sparks and flame away from the fuel tank.
OIL
The Classic I is shipped with the engine
filled with SAE 10W-30 oil. This should be
fine for most ambient operating temperature condi-
tions. See the engine operation manual for specific
recommendations. CHECKTHE OIL LEVEL BEFORE
YOU START THE ENGINE. This is an added precau-
tion. When full, the oil level should be up to but not over
the FULL mark on the dipstick. If it is not full, add
enough oil to fill it to the full mark. DO NOT overfill.
LIFTING
The Classic I weighs 1370 lb./621 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 lift bail if
it is equipped with a heavy accessory
such as a trailer.
Fill the fuel tank with clean, gasoline only.
The Classic I has 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 machine is stable when lifting.
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 I is 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 disconnected 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 gaso-
line engine in the Operation and Maintenance sec-
tions of this manual before you operate the Classic I.
CLASSIC I
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A-5
A-5
INSTALLATION
COOLING SYSTEM
TRAILERS
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 the 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
engines be equipped with exhaust spark arresters
when they are operated in certain locations where
unarrested sparks may present a fire hazard. The stan-
dard mufflers included with these welders do not qual-
ify as spark arresters. When required by local regula-
tions, a suitable spark arrester 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 I
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A-6
A-6
INSTALLATION
MACHINE GROUNDING
FIGURE A.1 - GROUND STUD LOCATION
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 receptacle.
When the Classic I is 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.1. The ground stud is marked with the ground
symbol.
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
particular situation and follow them explicitly. A
machine grounding stud marked with the symbol
is provided on the welding generator frame foot. See
Figure A.1. (If an older portable welder does not have
a grounding stud, connect the ground wire to an
unpainted frame screw or bolt).
1
1. Ground Stud
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.
WARNING
Do not ground the machine to a pipe that carries explo-
sive or combustible material.
CLASSIC I
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A-7
A-7
INSTALLATION
ELECTRICAL OUTPUT
CONNECTIONS
CAUTION
• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.
See Figure A.2 for the location of the 115V DC volt
receptacle, weld output terminals, and ground stud.
• Do not cross the welding cables at the output termi-
nal connection. Keep the cables isolated and sepa-
rate from one another.
WELDING CABLE CONNECTIONS
CABLE INSTALLATION AND CABLE SIZES
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.
With the engine off, route the electrode and work
cables through the strain relief bracket on the base and
connect to the terminals located below the fuel tank
mounting rail. (See size recommendations below.) For
positive polarity, connect the electrode cable to the ter-
minal marked Positive (+). For Negative polarity, con-
nect the electrode cable to the Negative (-) terminal.
These connections should be checked periodically and
tightened if necessary.
Lincoln Electric offers a welding accessory kit with the
properly specified welding cables. See the Accessories
section of this manual for more information.
AUXILIARY POWER RECEPTACLE,
PLUGS, AND HAND-HELD EQUIPMENT
The DC auxiliary power, supplied as a standard, has a
rating of 1.75 kw of 120V DC.
FIGURE A.2 - CLASSIC I OUTPUT CONNECTIONS
1
3
2
4
1. 120 VOLT DC RECEPTACLE
2. WELD OUTPUT TERMINALS (2)
3. GROUND STUD (LOCATION)
4. CABLE STRAIN RELIEF BRACKET
TABLE A.1 - RECOMMENDED COPPER WELDING CABLE SIZE AND LENGTH
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES
Cable size for combined length of
electrode plus work cable
Amps
200
Duty Cycle
Up to 200 ft.
200 to 250 ft.
60%
1
1/0
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A-8
A-8
NOTES
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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-3
Limitations .................................................................................................................................B-3
Controls and Settings..................................................................................................................B-4
Welder/Generator Controls...................................................................................................B-4
Control of Welding Current ...................................................................................................B-5
Gasoline Engine Controls.....................................................................................................B-6
Engine Operation ........................................................................................................................B-7
Before Starting the Engine ...................................................................................................B-7
Starting the Engine...............................................................................................................B-7
Stopping the Engine .............................................................................................................B-8
Cold Weather Starting ..........................................................................................................B-8
Break-in Period.....................................................................................................................B-8
Welding Operation.......................................................................................................................B-9
Classic I DC Constant Current Stick or TIG Welding ...........................................................B-9
Classic I DC Wire Feed Welding (Constant Voltage)..........................................................B-10
Auxiliary Power..........................................................................................................................B-10
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B-2
B-2
OPERATION
WARNING
OPERATING INSTRUCTIONS
Read and understand this entire section before operat-
ing your Classic I.
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 I is a heavy duty engine driven DC arc
welding power source capable of providing DC con-
stant current output for stick welding or DC TIG weld-
ing. The Classic I is wound with all copper coils for bet-
ter arc stability and precise welding control. With the
addition of the optional Wire Feed Module or CV
adapter, the Classic I will provide constant voltage out-
put for running the LN-25 wire feeder.
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 I has a current range of 40-300 DC amps.
It provides 1.75 kw of 120V DC auxiliary power.
WELDING SPARKS can cause
fire or explosion.
This unit uses the four cylinder Continental TM27
industrial, water-cooled gasoline engine.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
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B-3
B-3
OPERATION
RECOMMENDED APPLICATIONS
DESIGN FEATURES
• Constant current DC Stick welding (SMAW) process
capability with output range from 40 - 300 DC amps.
WELDER
The Classic I provides excellent constant current DC
welding output for stick (SMAW) welding and for DC
TIG welding. For more details on using the machine as
a welder, see Welding Operation in the Operation
section of this manual.
• Work and Electrode welding cable mounting termi-
nals.
• Separate ground stud for safe connection of case to
earth ground.
GENERATOR
• 115 volt DC auxiliary power receptacle.
• Electric starting.
The Classic I is also capable of providing 1.75 kw of
115V DC auxiliary power.
• Distributor type electronic ignition.
• Battery Charging Ammeter.
• Engine Hour Meter for determining periodic mainte-
nance.
OPERATIONAL FEATURES AND
CONTROLS
• Top-of-the-line 38 HP Continental gasoline engine.
The Classic I was designed for simplicity. Therefore, it
has very few operating controls. Two switches are used
for welding operations:
• Top-mounted 15 gallon (57.0 litter) fuel tank with con-
venient top fill.
• Automatic engine idler goes to low idle approximate-
ly 15 seconds after welding for greater fuel economy;
includes high idle switch.
• 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)
WELDING CAPABILITY
• A FINE CURRENT ADJUSTMENT control for fine
adjustment of current from minimum to maximum
within each range
The Classic I is rated 200 amps, 40 volts constant cur-
rent DC at 60% duty cycle based on a ten minute time
period. Longer duty cycles at lower output currents are
possible.
Controls for the gasoline engine control include a two-
position IGNITION ON/OFF toggle switch, a START
pushbutton, and a two-position IDLER switch that
selects engine speed for welding or auxiliary power
applications. See Engine Operation in the Operation
section of this manual for details about starting, run-
ning, stopping, and breaking in the gasoline engine.
The current is continuously variable from 40 to 300
amps DC.
LIMITATIONS
The Classic I is not recommended for any processes
besides those that are normally performed using DC
stick welding (SMAW) and DC TIG welding. Specific
limitations on using the Classic I for these processes
are described in the Welding Operation section of this
manual. Constant voltage welding is available with the
optional Wire Feed Module.
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B-4
B-4
OPERATION
CONTROLS AND SETTINGS
the case front. Welding output terminals and ground
stud are located on the machine right side, under the
door. See Figure B.1, B.2 and B.3 and the explanations
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
1
2
4
5
3
6
1. CURRENT RANGE SELECTOR
2. FINE CURRENT ADJUSTMENT
3. 115 VOLT DC RECEPTACLE
4. WELD OUTPUT TERMINAL (–)
5. WELD OUTPUT TERMINAL (+)
6. GROUND STUD
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. WELD OUTPUT TERMINAL (–) WITH FLANGE
NUT: Provides the connection point for either the
electrode holder or the work cable.
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. GROUND STUD: Provides a connection point for
connecting the machine case to earth ground. See
Machine Grounding in the Installation section of
this manual.
3. 120 VOLT DC RECEPTACLE: Connection point for
supplying 120V DC power to operate DC electrical
devices.
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B-5
B-5
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 to 120
position 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
60
50
190-120
240-160
130-80
40
30
20
70
80
90
220
MAX.
90
MIN.
100
10
FINE CURRENT
ADJUSTMENT
OIL
PRESSURE
START
CHOKE
IDLER
IGNITION
REMOTE
CONTROL
CURRENT
RANGE
SELECTOR
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B-6
B-6
OPERATION
FIGURE B.3 – GASOLINE ENGINE CONTROLS
FINE CURRENT
ADJUSTMENT
60
CURRENT RANGE
SELECTION
50
190-120
40
70
240-160
130-80
80
30
20
220
MAX
90
MIN
90
10
100
1. IDLER CONTROL TOGGLE SWITCH
2. IGNITION TOGGLE SWITCH
3. OIL PRESSURE LIGHT
4. START PUSHBUTTON
5. CHOKE CONTROL
5
4
6
1
OIL
PRESSURE
START
CHOKE
IDLER
IGNITION
REMOTE
CONTROL
6. ENGINE HOUR METER
7. AMMETER
2
3
7
GASOLINE ENGINE CONTROLS
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:
4. START PUSHBUTTON: Press this button to start
the gasoline engine. The IGNITION switch must be
in the ON position.
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.
NOTE: If you press the START pushbutton when
the engine is running, you may damage the engine
flywheel gear or starter motor.
Auxiliary Power: The engine accelerates to high
speed when power is drawn at the receptacle for
lights or tools. The engine returns to low idle
approximately 15 seconds after demand for
auxiliary power stops.
6. ENGINE HOUR METER: Records engine running
time. Use the meter to determine when to
perform required maintenance.
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 engine can be started by
pressing the START pushbutton. When the switch
is placed in the OFF position, the engine stops.
3. OIL PRESSURE LIGHT: Lights when the engine
oil pressure drops to an unsafe level. If the light
comes on within 30 seconds after startup, the
engine should be stopped by placing the IGNITION
switch in the OFF position.
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B-7
B-7
OPERATION
Check and fill the engine fuel tank:
1. Remove the fuel tank cap.
ENGINE OPERATION
WARNING
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.
DO NOT RUN THE ENGINE AT EXCESSIVE
SPEEDS. The maximum allowable high idle speed for
the Classic I is 1550 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.
3. Replace the fuel tank cap and tighten securely.
WARNING
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.
Read and understand all safety instructions included in
the Continental engine instruction manual that is
shipped with your Classic I.
BEFORE STARTING THE ENGINE
Check and fill the engine oil level:
1. Be sure the machine is on a level
surface.
NOTE: USE GASOLINE ONLY. Purchase gasoline in
quantities that will be used within 30 days, to assure
freshness.
2. Remove the engine oil dipstick and wipe it with a
clean cloth. Reinsert the dipstick and check the
level on the dipstick.
See Figure D.1 in the
Maintenance section of this manual.
3. Add oil (if necessary) to bring the level up to the full
mark. Do not overfill.
STARTING THE ENGINE
NOTE: Remove all loads connected to the DC power
receptacle before starting the engine. Make sure the
fuel valve on the sediment bowl is in the open position.
4. Replace the dipstick.
1. Place the IDLER switch in the "HIGH" position and
the IGNITION switch in the ON position. Pull out
the choke cable and then press the START button.
NOTE: If the engine fails to start in 60 seconds, wait 30
seconds before repeating Step 1.
2. 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.
3. As the engine warms, slowly return the choke con-
trol to the in (off) position.
4. Allow the engine to run at high idle speed for sev-
eral minutes to warm up before welding. Cold
engines tend to run at a speed too slow to supply
the voltage required for proper idler operation.
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B-8
B-8
OPERATION
STOPPING THE ENGINE
COLD WEATHER STARTING
1. Remove all welding and generator power loads
and let the engine cool by running it for several
minutes at low idle.
Follow the instructions on the nameplate and in the
engine manual shipped with the welder. With a fully
charged battery and the proper weight oil, the engine
should start satisfactorily even when the air tempera-
ture is down to about 0oF (-18oC).
2. Place the IGNITION switch in the OFF position.
It is important to follow the engine manufacturer’s rec-
ommendations for oil and fuel to obtain satisfactory
cold weather performance. Consult the Engine manu-
al and the Maintenance section of this manual.
The engine controls were properly set at the factory
and should require no adjusting when received.
At the end of each day’s welding, refill the fuel tank to
minimize moisture condensation in the tank. Also, run-
ning out of fuel tends to draw dirt into the fuel system.
BREAK-IN PERIOD
Check the crankcase oil level.
Any engine will use a small amount of oil during its
break-in period.
When hauling the welder between job sites, close the
fuel feed valve beneath the fuel tank. Failure to turn the
fuel off when traveling can cause carburetor 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 50 hours of oper-
ation. Also change the fuel filter cartridge. For more
details, see the Maintenance section of this manual.
Also see the Engine manual.
CAUTION
During break-in, subject the Classic I to moderate to
heavy loads. Avoid long periods running at idle. Before
stopping the engine, remove all loads and allow the
engine to cool several minutes.
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B-9
B-9
OPERATION
7. Set the CURRENT RANGE SELECTOR to a set-
ting equal to or slightly higher than the desired
welding current.
WELDING OPERATION
TO USE THE CLASSIC I FOR DC
CONSTANT CURRENT STICK OR TIG
WELDING:
8. Set the FINE CURRENT ADJUSTMENT to the
setting that gives the best arc characteristics for
the range selected. See Control of Welding
Current in this section of the manual.
1. Remove the flange nuts from the weld output ter-
minals and place the work and electrode welding
cables over the terminals. For positive electrode,
connect the electrode cable to the + terminal and
the work cable to –. For negative electrode,
reverse the electrode and work cables at the
welder’s output terminals. See Figure B.4.
Replace and tighten the flange nuts securely. Be
sure the connections are tight.
9. Strike an arc and begin welding.
After you finish welding:
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."
FIGURE B.4 – WELDING CIRCUIT CONNECTIONS FOR STICK WELDING
1. OUTPUT TERMINALS
2. ELECTRODE CABLE
3. ELECTRODE HOLDER
4. ELECTRODE
5. WORK PIECE
6. WORK CLAMP
7. WORK CABLE
1
2
3
4
5
6
7
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B-10
B-10
OPERATION
4. Set the Idler Switch to "AUTO."
TO USE THE CLASSIC I FOR DC WIRE
FEED WELDING (CONSTANT VOLTAGE)
WITH WIRE FEED MODULE:
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.
1. Connect the LN-25 Wire Feeder. Follow the instal-
lation instructions provided with the wire feeder.
6. Set the VOLTAGE ADJUSTMENT to the setting
that gives the best arc characteristics for the range
selected.
2. Set the wire feeder and Classic I for CV operation.
3. Start the engine. See Engine Operation in this
7. Pull the gun trigger.
section of the manual.
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
75 to 120 Amps
120 to 170 Amps
125 to 210 Amps
AUXILIARY POWER
WARNING
Be sure that any electrical equipment plugged into the
generator DC power receptacle can withstand a ±10%
voltage variation.
The DC auxiliary power, supplied as a standard, has a
rating of 1.75 kw of 120V DC power.
The rating of 1.75 kw permits a maximum continuous
current of 15 amps to be drawn from the 120 volt recep-
tacle.
An optional power plug kit is available. See the
Accessories section of this manual.
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Section C-1
Section C-1
TABLE OF CONTENTS
- ACCESSORIES -
Accessories...........................................................................................................................Section C
Options/Accessories ...................................................................................................................C-2
Semiautomatic Welding Accessories ...................................................................................C-2
Connection of Lincoln Electric Wire Feeders..............................................................................C-3
Connection of the LN-25 “Across the Arc” ...........................................................................C-3
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C-2
C-2
ACCESSORIES
Accessory Kit (K702) - Includes the following:
OPTIONS/ACCESSORIES
The following options/accessories are available for your
Classic I from your local Lincoln Distributor.
• Electrode cable
• Work cable
• Headshield
Trailer (K768) - For in-plant or yard towing at speeds
• Work clamp
under 10 m.p.h. Not intended for highway towing.
• Insulated electrode holder
Trailer (K780) - Two-wheeled trailer with brakes, lights,
and fenders. For highway use, consult applicable fed-
eral, state and local laws.
Remote Control - (K888-4) - Includes a control box
with 100 ft. (30.5 meters) of cable. Allows output to be
controlled remotely. K888-3 has only 25 ft. (7.6 meters)
of cable. (For K6090 through -4 only.)
Trailer (K913) - Two-wheeled trailer for in-plant and
yard towing. For highway use, consult applicable fed-
eral, state, and local laws. Various hitches and acces-
sories are available.
Remote Control Kit - (K924-1) - Includes a control box
with 100 ft. (30.5 meters) of cable. Allows output to be
controlled remotely. (For K6090-5 and above.)
Power Plug Kit (K802-A) - Provides auxiliary plug for
115VDC receptacle.
CV Adapter - (K384) - Provides constant voltage out-
put for semiautomatic welding. (For K6090 through -4
only.)
SEMIAUTOMATIC WELDING ACCESSORIES
LN-25 Wire Feeder - This portable wire feeder is capa-
ble of CC/CV wire feed welding.
Wire Feed Module - (K623-1) - Provides constant volt-
age output for semiautomatic welding. For LN-25 wire
feeder. (For K6090-5 and above.)
NOTE: Gas-shielded welding requires a Magnum Gun.
Gasless welding requires an Innershield Gun.
Linc Thaw™ Control Unit (L2964-1) - Includes meter
and fuses to protect the welder when thawing frozen
water pipes.
WARNING
PIPE THAWING IS NOT a CSA approved procedure.
If not done properly, it can result in fire, explosion,
damage to wiring which may make it unsafe, dam-
age to pipes, burning up the welder, or other haz-
ards.
Do not use a welder to thaw pipe before reviewing
Lincoln Bulletin E695.1 (dated October 1987 or later.)
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C-3
C-3
ACCESSORIES
CONNECTION OF LINCOLN
ELECTRIC WIRE FEEDERS
The Lincoln Electric LN-25 wire feeder is recommend-
ed for wire feed welding with the Classic I.
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.
CONNECTION OF THE LN-25 TO THE
CLASSIC I “ACROSS THE ARC”WITH
WIRE FEED MODULE (SEE FIGURE C.1.)
5. Place the IDLER switch in the “HIGH” position.
6. Adjust wire feed speed and voltage at the LN-25.
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.
NOTE: Welding cable must be sized for current
and duty cycle of application.
NOTE: Figure C.1 shows the electrode connect-
ed for positive polarity. To change polari-
ty, shut the welder off and reverse the
electrode and work cables at the Classic I
output terminals. Reverse the LN-25
polarity switch.
FIGURE C.1
CLASSIC I/LN-25 ACROSS THE ARC CONNECTION DIAGRAM
14 PIN
AMPHENOL
+
LN-25 WIRE FEEDER
WITH K444-2 REMOTE
VOLTAGE CONTROL OPTION
CV-
ELECTRODE CABLE
TO
WORK
WORK CLIP
LEAD TO WORK
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C-4
C-4
NOTES
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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
Oil ............................................................................................................................D-2
Engine Maintenance Schedule................................................................................D-2
Change the Oil ........................................................................................................D-3
Change the Oil Filter ...............................................................................................D-3
Fuel..........................................................................................................................D-3
Fuel Filter.................................................................................................................D-4
Air Cleaner...............................................................................................................D-4
Cooling System .......................................................................................................D-4
Fan Belt ...................................................................................................................D-5
Spark Plugs .............................................................................................................D-5
Battery Maintenance ......................................................................................................D-6
Cleaning the Battery................................................................................................D-6
Checking Specific Gravity........................................................................................D-6
Checking Electrolyte Level ......................................................................................D-6
Charging the Battery ...............................................................................................D-6
Welder/Generator Maintenance .....................................................................................D-7
Storage ....................................................................................................................D-7
Cleaning ..................................................................................................................D-7
Nameplates .............................................................................................................D-7
Generator Commutator and Brushes ......................................................................D-7
Bearings ..................................................................................................................D-7
Current Range Selector Contacts ...........................................................................D-8
Receptacle...............................................................................................................D-8
Cable Connections ..................................................................................................D-8
Idler Maintenance...........................................................................................................D-8
Major Component Locations.......................................................................................................D-9
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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 I.
OIL: Check the oil level after every 10
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 fan, and all other
moving parts when starting, operating, or repairing this
machine.
Change the oil the first time after 50 hours of opera-
tion. Then, under normal operating conditions, change
the oil as specified in Table D.1. If the engine is operat-
ed under heavy load or in high ambient temperatures,
change the oil more frequently.
TABLE D.1
CONTINENTAL ENGINE MAINTENANCE SCHEDULE
FREQUENCY
MAINTENANCE REQUIRED
Daily or Before
Starting Engine
• Visual Inspection.
• Fill fuel tank.
• Check oil level.
• Check air cleaner for dirty, loose, or damaged parts.
• Check radiator level.
First 50 Hours
Every 50 Hours
• Check air filter.
• Change engine oil.
• Change oil filter.
• Change fuel filter.
• Check battery.
• Check fan belt.
• Change engine oil and filter.
• Service air cleaner (clean element).
• Check fan belt tension.
• Check battery electrolyte level and connections.
Every 250 Hours • Repeat 50-hour checks.
• Clean spark plugs and check gap.
• Check distributor cap.
• Check ignition wires.
• Replace air cleaner element.
Refer to your engine Owner's Manual for details and periodic maintenance at 500 hours and beyond.
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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
1
5. DIPSTICK LEVELS
3. Apply a thin coat of new oil to the rubber gasket on
the new oil filter.
CHANGE THE OIL: Change the oil, while the engine
is still warm, as follows:
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.
1 . Drain the oil from the drain plug located on the
engine bottom, as shown in Figure D.1.
2. Replace the plug and tighten it securely.
3. Remove the oil fill cap and add oil until the level
reaches the upper dash full mark on the dipstick.
Use high quality oil viscosity grade 10W30.
Consult the engine manual for oil specifications.
Always check the level with the dipstick before
adding more oil.
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 I back in service.
4. Reinstall the oil fill cap and the dipstick.
6. If there are no leaks, stop the engine and recheck
the oil level. If necessary, add oil to bring the level
up to the upper dash mark, but do not overfill.
CHANGE THE OIL FILTER: Change the oil filter the
first time after 50 hours of operation. Then, under nor-
mal operating conditions, change the oil filter after
every 50 hours of operation. If the engine is operated
under heavy load or in high ambient temperatures,
change the oil filter more frequently. See Table D.1 for
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.
recommended maintenance intervals.
Continental oil filters from your local Continental ser-
vice center.
Order
Refer to your engine operation manual for
recommended grade of fuel.
Change the oil filter as follows:
1 . Drain the oil from the engine and allow the oil filter
to drain.
2. Remove the old filter (spin it off) and discard it.
Wipe off the filter mounting surface and adapter.
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D-4
D-4
MAINTENANCE
FUEL FILTER: Inspect the in-line fuel filter daily. When
necessary remove the sediment bowl from beneath the
gas tank and clean out any accumulated dirt and water.
Change the fuel filter after the first 50 hours of opera-
tion and every 500 hours thereafter.
5. If necessary, flush the system with clean water.
6. Replace 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. (Capacity: 9.3
quarts/8.8 liters.)
AIR CLEANER: The Continental engine is equipped
with a dry type air filter. Inspect the air cleaner daily -
more often in dusty conditions. Never remove the air
filter while the engine is running. Never apply oil to the
air cleaner. Clean every 50 hours. Every 250 hours
(more frequently in extreme dust conditions) replace
the air cleaner as follows:
FIGURE D.2A – ENGINE COOLANT DRAIN PLUG
1. Loosen the wing nut and remove the cover and the
filter element. Do not allow dirt to fall into the
exposed carburetor. Gently tap the element flat on
a smooth surface.
2. 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 2 bar (30 psi).
3. Check the element for damage before reassem-
bling the air cleaner. Replace the element if it
appears damaged. The air cleaner element part
number is Donaldson #181050 or Nelson
#70206N.
FIGURE D.2B – RADIATOR DRAIN COCK
COOLING SYSTEM: The Continental engine 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 system, do the following:
1. Ensure that the machine is on level ground.
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.
2. Remove the radiator filler cap.
3. Remove the drain plug or cock from the side of the
cylinder block in order to drain the engine. Ensure
that the drain hole is not restricted. See Figure
D.2A.
4. Open the radiator drain cock at the bottom of the
radiator in order to drain the radiator. See Figure
D.2B.
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D-5
D-5
MAINTENANCE
FAN BELT: Fan belts tend to loosen after the first 50
hours of operation. If the fan belt is loose, the engine
can overheat and the battery can lose its charge.
Check belt tightness by pressing on the belt midway
between the pulleys. The belt should deflect no more
than 13 mm (0.5 in.). See Figure D.3.
SPARK PLUGS: Clean or replace the spark plugs
after every 250 hours of operation as follows.
1. Before removing the plugs, clean the base area to
keep dirt from falling into the engine through the
plug hole.
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
scraping or by using a wire brush. Wash the plugs
with a commercial solvent.
To adjust the fan belt, loosen the alternator bolts, then
push the alternator outward until the correct belt ten-
sion is achieved. Retighten the alternator bolts. See
Figure D.3.
FIGURE D.3 – TIGHTENING THE FAN BELT
3. After cleaning or when installing a new spark plug,
set the terminal gap with a feeler gauge or gapping
tool. See Figure D.4.
Gap Specifications: 0.032 inch (.8 mm).
4. Tighten plugs to 30 ft-lbs (40 N·m).
1
2
3
4
5
6
7
FIGURE D.4 – SET SPARK PLUG GAP
8
9
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D-6
D-6
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 I is 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 Classic I 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.
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D-7
D-7
MAINTENANCE
Periodically inspect the commutators and brushes by
removing the covers. DO NOT remove these covers
while the machine is running.
WELDER/GENERATOR
MAINTENANCE
STORAGE: Store the Classic I in clean, dry, protected
areas.
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.
CLEANING: Blow out the generator and controls peri-
odically with low pressure air. Do this at least once a
week in particularly dirty areas.
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.
NAMEPLATES: Whenever routine maintenance is per-
formed 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.
GENERATOR COMMUTATOR AND BRUSHES: The
generator brushes are properly adjusted when the
welder is shipped. They require no particular attention.
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.
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
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.
BEARINGS: The Classic I is equipped with double-
shielded ball bearings having sufficient grease to last
indefinitely under normal service. Where the welder is
used constantly or in excessively 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.
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.
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D-8
D-8
MAINTENANCE
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.
IDLER MAINTENANCE
CAUTION
Before doing electrical work on the idler printed circuit
board, disconnect the battery.
Put a drop of oil on the CURRENT RANGE SELEC-
TOR shaft at least once every month.
RECEPTACLE: Keep the electrical receptacle in good
condition. Remove any dirt, oil, or other debris from
surfaces and holes.
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 carburetor lever. Dust the plunger about once a
year with graphite powder.
CABLE CONNECTIONS: Check the welding cable
connections at the weld output terminals often. Be
sure that the connections are always tight.
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). The reed switch and battery must also be
grounded properly.
4. If desired, the welder can be used without automat-
ic idling by setting the “Idler” switch to the “High Idle”
position.
5. When installing a new battery or using a jumper bat-
tery to start the engine, be sure the battery polarity
is connected properly. The correct polarity is nega-
tive ground. Damage to the engine alternator and
the printed circuit board can result from incorrect
connection.
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D-9
D-9
MAINTENANCE
FIGURE D.5 - MAJOR COMPONENT LOCATIONS
1. RIGHT CASE SIDE (DOOR)
2. BASE (WITH BATTERY)
3. EXCITER BRUSHES
4. EXCITER
5. GENERATOR
6. GENERATOR BRUSHES
7. OUTPUT TERMINALS
8. FUEL TANK
12
9. CASE FRONT WITH CONTROL PANEL
10. LEFT CASE SIDE
11. CASE TOP
11
12. CASE BACK
13. RADIATOR
14. GASOLINE ENGINE
15. AIR CLEANER
16. IDLER CONTROL
13
10
9
14
15
8
7
6
16
5
4
2
3
1
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D-10
D-10
NOTES
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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 Circuit .....................................................E-2
Engine, Main Generator Armature and Frame and DC Exciter.............................................E-3
Excitation (Flashing)........................................................................................................E-3
Main Shunt, Interpole and Series Coils ..........................................................................E-3
Current Range Selector ..................................................................................................E-4
Fine Current Adjustment ................................................................................................E-4
Engine Idler Circuit..........................................................................................................E-4
DC Generator Machines........................................................................................................E-5
SELECTOR
SWITCH
REED
RELAY
CR2
IDLER
BOARD
NEGATIVE
OUTPUT
TERMINAL
OIL
PRESSURE
LIGHT
ENGINE
HOUR
METER
IDLER
SOLENOID
OIL
PRESSURE
SWITCH
GENERATOR
FRAME
SERIES
COILS
RESIDUAL
MAGNETISM
FUEL
SHUTDOWN
SHUNT
FIELD
DC
EXCITER
ARMATURE
GENERATOR
ARMATURE
MECHANICAL
COUPLING
115 VDC
RECEPTACLE
ENGINE
ARMATURE
SHAFT
ENGINE
IGNITION
IGNITION
SWITCH
ENGINE
ALTERNATOR
SERIES
FIELD
INTERPOLE
COILS
STARTER
MOTOR
FIELD
SHUNT
WINDINGS
BATTERY
GENERATOR
FIELD CONTROL
POSITIVE
OUTPUT
TERMINAL
FIGURE E.1 – CLASSIC I BLOCK LOGIC DIAGRAM
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 – BATTERY, STARTER, ENGINE ALTERNATOR AND OIL SWITCH CIRCUIT
SELECTOR
SWITCH
REED
RELAY
CR2
IDLER
BOARD
NEGATIVE
OUTPUT
TERMINAL
OIL
PRESSURE
LIGHT
ENGINE
HOUR
METER
IDLER
SOLENOID
OIL
PRESSURE
SWITCH
GENERATOR
FRAME
SERIES
COILS
RESIDUAL
MAGNETISM
FUEL
SHUTDOWN
SHUNT
FIELD
DC
EXCITER
ARMATURE
GENERATOR
ARMATURE
MECHANICAL
COUPLING
115 VDC
RECEPTACLE
ENGINE
ARMATURE
SHAFT
ENGINE
IGNITION
IGNITION
SWITCH
ENGINE
ALTERNATOR
SERIES
FIELD
INTERPOLE
COILS
STARTER
MOTOR
FIELD
SHUNT
WINDINGS
BATTERY
GENERATOR
FIELD CONTROL
POSITIVE
OUTPUT
TERMINAL
GENERAL DESCRIPTION
BATTERY, STARTER, ENGINE
ALTERNATOR AND OIL SWITCH
CIRCUIT
The Classic I is a heavy duty, engine driven, DC arc
welding power source capable of providing constant
current output for stick welding or DC TIG welding.
Also, a total of 1750 watts of auxiliary power is available
at the 115VDC receptacle. The Classic I is manufac-
tured with all copper windings.
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 will not function.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3 – ENGINE, MAIN GENERATOR ARMATURE AND FRAME AND DC EXCITER
SELECTOR
SWITCH
REED
RELAY
CR2
IDLER
BOARD
NEGATIVE
OUTPUT
TERMINAL
OIL
PRESSURE
LIGHT
ENGINE
HOUR
METER
IDLER
SOLENOID
OIL
PRESSURE
SWITCH
GENERATOR
FRAME
SERIES
COILS
RESIDUAL
MAGNETISM
FUEL
SHUTDOWN
SHUNT
FIELD
DC
EXCITER
ARMATURE
GENERATOR
ARMATURE
MECHANICAL
COUPLING
115 VDC
RECEPTACLE
ENGINE
ARMATURE
SHAFT
ENGINE
IGNITION
IGNITION
SWITCH
ENGINE
ALTERNATOR
SERIES
FIELD
INTERPOLE
COILS
STARTER
MOTOR
FIELD
SHUNT
WINDINGS
BATTERY
GENERATOR
FIELD CONTROL
POSITIVE
OUTPUT
TERMINAL
MAIN SHUNT, INTERPOLE AND SERIES
COILS
ENGINE, MAIN GENERATOR
ARMATURE AND FRAME AND DC
EXCITER
The generator armature rotates within the magnetic
field created by the shunt field windings. A DC voltage
is induced in the armature and is transferred, through
the armature commutator and brushes, to the series
and interpole coils. The interpole coils, which are con-
nected in series with the positive output terminal, are
located so as to counteract any magnetic influences
that could cause mechanical distortion in the rotating
armature. The series coils are designed to oppose or
"buck" the DC voltage that is generated in the arma-
ture.
EXCITATION (FLASHING)
The main generator armature and the exciter arma-
ture are mechanically coupled to the engine. When
the engine is started and running, the residual mag-
netism that is stored in the exciter pole pieces is
induced upon the exciter armature. This causes the
exciter to "build-up" and produce a DC output volt-
age. This DC voltage is applied, via the field rheostat
control, to the main generator shunt field coils. The
exciter output is also connected to the 115VDC recep-
tacle.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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E-4
E-4
THEORY OF OPERATION
ENGINE IDLER CIRCUIT
ENGINE, MAIN GENERATOR
ARMATURE AND FRAME AND DC
EXCITER (CONTINUED)
The idler solenoid is mechanically connected to the
engine governor linkage. When welding current is
being drawn, the reed switch CR2 is closed. This
signals the idler PC board to release (deactivate) the
idler solenoid, which then lets the machine go to a high
speed condition. Also, when auxiliary power (115VDC)
is being used, the current is passed through a reed
switch coil located on the idler PC board, which signals
the PC board to release the idler solenoid.
CURRENT RANGE SELECTOR
The selector switch acts as a course current adjust-
ment by allowing varying amounts of series windings to
be included in the welding current path. The series
coils and selector switch are connected in series with
the negative output terminal.
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 acti-
vates the idler solenoid, and the machine will return to
a low idle speed condition.
FINE CURRENT ADJUSTMENT
The field rheostat control functions as a fine output cur-
rent adjustment by controlling the current through the
shunt windings, thus controlling the amount of magnet-
ism created in the shunt field windings. Open circuit
weld voltage can also be controlled by the field rheo-
stat control.
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E-5
E-5
THEORY OF OPERATION
DC GENERATOR MACHINES
C
U
R
R
E
N
T
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 excited by direct
current.
F
I
E
L
D
SHUNT FIELD WINDINGS
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. When the armature rotates
through the magnetic field produced by the stationary
field winding, it induces a coil voltage in the armature
winding. The voltage induced in an individual armature
coil is an alternating (AC) voltage, which must be recti-
fied. In a conventional DC generator machine, rectifi-
cation is provided mechanically by means of a com-
mutator. A commutator is a cylinder formed of copper
segments insulated from each other and mounted on,
but insulated from, the rotating shaft. Stationary car-
bon brushes held against the commutator surface con-
nect the armature windings to external terminals. The
commutator provides full-wave rectification, transform-
ing the voltage waveform between brushes and mak-
ing available a DC voltage to the external circuit.
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
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E-6
E-6
NOTES
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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..................................................................................................F4 - F-12
Test Procedures...................................................................................................................F-13
DC Exciter Test..............................................................................................................F-13
Idler Solenoid Test.........................................................................................................F-17
Main Generator Shunt Field Winding Test.....................................................................F-19
Engine Throttle Adjustment Test....................................................................................F-22
Flashing the Fields ........................................................................................................F-26
Oscilloscope Waveforms......................................................................................................F-29
Normal Open Circuit Voltage Waveform (115VDC Supply)...........................................F-29
Normal Open Circuit DC Weld Voltage Waveform.........................................................F-30
Typical DC Weld Voltage Waveform, Machine Loaded..................................................F-31
Removal and Replacement Procedures ..............................................................................F-32
DC Exciter Armature and Field Coils Removal and Replacement................................F-32
Main Generator Frame Removal and Replacement......................................................F-35
Main Generator Armature Removal and Replacement.................................................F-46
Retest After Repair ..............................................................................................................F-48
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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 con-
ducted without removing the case top and doors
assembly.
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 1-800-833-9353.
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F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
• 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.
WARNING
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.
• 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.
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:
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 tem-
perature.
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 ohm
resistive cord connected to a
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
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 prevent stat-
ic build-up. Be sure not to touch
any electrically live parts at the
same time.
NOTE: Following this procedure and writing on the
Workstations
warranty
report,
“INSTALLED
AND
SWITCHED PC BOARDS TO VERIFY PROB-
LEM,” 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.
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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 for loose or missing 1. Check for loose or broken wires
rect speed, but there is no, or very
low, welder output voltage. There
is no DC auxiliary output voltage.
brushes in the DC exciter.
between the exciter brushes
and the DC receptacle and the
fine current control field
rheostat. See the Wiring Diagram.
2. The exciter may need “flashing.”
See Flashing the Fields in this
section.
2. Perform the DC Exciter Test.
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 1-800-833-9353.
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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 the 1. Check the welding cables for 1. Check the fine current control
correct speed but there is no, or
very low, welder output. The DC
auxiliary output voltage is normal.
loose or faulty connections.
field rheostat for resistance and
proper operation. Normal resis-
tance is 64 ohms. Check asso-
ciated wires for loose or faulty
connections. See the Wiring
Diagram.
2. Check for loose or missing
brushes in the welding genera-
tor.
2. Perform the Main Generator
Shunt Field Winding Test.
3. Check the continuity of the inter-
pole coils. They should show
continuity from the positive
brusholders to the positive out-
put 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
brusholders, through the current
selector switch, to the negative
output terminal and should NOT
be grounded to the generator
frame.
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 1-800-833-9353.
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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. Check for loose or faulty weld- 1. Check the fine current control
mally. The auxiliary output remains
constant. The engine is operating
correctly.
ing cables.
field rheostat for resistance and
proper operation. Normal resis-
tance is 64 ohms. Check asso-
ciated wires for loose or faulty
connections. See the Wiring
Diagram.
2. This may be a normal condition.
The machine will normally lose
some output as the components
are heated.
3. Check for loose, worn, dirty or
poorly seated main DC genera-
tor brushes.
2. Perform the Main Generator
Shunt Field Winding Test.
3. Check the current range
selector switch and contacts for
proper operation.
4. The main armature commutator
may need cleaning.
4. While the machine is loaded,
check the interpole and series
coils for signs of “arcing.” This
condition would indicate short-
ed 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 1-800-833-9353.
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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 DC receptacle and 1. Check for loose or faulty con-
correct speed, but there is no DC
auxiliary output voltage at the
115VDC receptacle. The welding
generator is functioning correctly.
plug for loose or faulty connec-
tions.
nections or wires at the 115
VDC receptacle and associated
circuitry.
Diagram.
See the Wiring
2. Check the 15 Amp fuse. CSA
machines only.
The actual welding current is much 1. Check the welding cables for 1. The engine RPM may be low. If
less than is indicated on the dials.
loose or faulty connections.
necessary perform the Engine
Throttle Adjustment Test.
2. The welding cables may be
excessively long or coiled.
2. Perform the DC Exciter Test.
3. Check the main DC generator 3. Check the fine current control
brushes for good commutation
and alignment. Contact the
Lincoln Electric Service Dept.
1-800-833-9353 (WELD).
field rheostat for resistance and
proper operation. Normal resis-
tance is 64 ohms. Check asso-
ciated wires for loose or faulty
connections. See the Wiring
Diagram.
4. Check the current range selec-
tor switch and contacts for prop-
er operation.
5. Perform the Main Generator
Shunt Field Winding Test.
6. 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 1-800-833-9353.
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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
OUTPUT PROBLEMS
The actual welding current is much 1. Check the main DC generator 1. The engine operating speed
greater than is indicated on the
dials.
brushes for good commutation
and alignment. Contact the
Lincoln Electric Service Dept.
1-800-833-9353 (WELD).
may be too high. If necessary
perform the Engine Throttle
Adjustment Test.
2. While the machine is loaded,
check the series coils for signs
of “arcing.” This condition could
point to shorted turns in the
series coils.
3. Perform the DC Exciter Test.
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 1-800-833-9353.
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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 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. Perform the Idler Solenoid
Test.
4. While the engine is running, if
the oil pressure light is NOT lit, 4. Check for loose or faulty con-
the oil pressure switch may be
faulty. See the Wiring Diagram.
nections at the idler PC board.
5. 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 1-800-833-9353.
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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 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 DC auxiliary
power receptacle.
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.
See the Wiring Diagram.
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 black “B” leads con-
speed when a load is applied to the
DC auxiliary receptacle. 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.
nected to the idler PC board and
associated connections. See
the Wiring Diagram.
2. The load may be too small. The
load must be above 150 watts.
2. The idler PC board may be
faulty.
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 1-800-833-9353.
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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. Make sure the ignition switch is 1. Check the ignition switch for
start.
in the ON position.
proper operation. Check the
associated leads for loose or
faulty connections. See the
Wiring Diagram.
2. Check for adequate fuel supply.
2. Check the fuel solenoid. Make
sure it is opening when +12VDC
is applied to the red lead. See
the Wiring Diagram.
3. The engine distributor or carbu-
retor may need servicing.
The oil pressure light does not light 1. Make sure the correct grade 1. The oil pressure switch may be
while the engine is running.
and amount of oil is in the
engine crankcase. See the
Maintenance Section of this
manual.
faulty. Replace.
2. If the engine hour meter and
alternator function properly, the
oil pressure switch is closing.
The oil pressure light may be
faulty. See the Wiring Diagram.
3. The engine may not have ade-
quate oil pressure and may be
in need of repair.
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 1-800-833-9353.
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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
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 1600
RPM. If necessary perform the
Engine Throttle Adjustment
Test.
2. The polarity may be wrong for
the electrode and process.
2. Check the main DC generator
brushes for good commutation
and alignment. Contact the
Lincoln Electric Service Dept. at
1-800-833-9353 (WELD).
The welding arc frequently “pops 1. The fine current control field 1. Check the engine speed. High
out.”
rheostat may be set too low for
the process and electrode.
idle speed should be 1600
RPM. If necessary perform the
Engine Throttle Adjustment
Test.
2. Check the welding cables for
loose or faulty connections.
2. The current range selector
switch may be faulty. Check for
proper operation and contact.
3. Check the DC generator brushes
for good commutation and align-
ment.
Contact the Lincoln
Electric Service Dept. at 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 1-800-833-9353.
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F-13
F-13
TROUBLESHOOTING & REPAIR
DC EXCITER 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 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will help determine whether or not the DC exciter is operating correctly. If oper-
ation is not correct, the test will also determine what component(s) may be faulty.
MATERIALS NEEDED
3/8" Nut driver
Volt/ohmmeter (Multimeter)
Wiring Diagram
This procedure takes approximately 30 minutes to perform.
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F-14
F-14
TROUBLESHOOTING & REPAIR
DC EXCITER TEST (continued)
FIGURE F.1 – 120VDC RECEPTACLE
SERIES COIL CONNECTION
POINT (NEGATIVE)
POSITIVE
TEST PROCEDURE
2. Start the engine and put the idler switch in
the HIGH idle position.
1. Turn off the engine and remove all external
loads to the welder terminals and auxiliary
receptacle.
3. Using the volt/ohmmeter, carefully check the
DC voltage at the 120V receptacle.
(Observe proper polarity. The large slot of
the receptacle is negative. See Figure F.1.)
Normal voltage is 125 - 135VDC, no load,
with the engine at the high idle speed of
1600 RPM. If the voltage is normal, the DC
exciter is functioning correctly. If the voltage
is low or not present, proceed to the next
step.
WARNING
MOVING PARTS can injure.
• Remove guards only when
necessary to perform service,
and replace them when the
service requiring their removal
is complete.
• Keep hands, hair, clothing and tools away
from V-belts, gears, fans, and all other moving
parts when starting, operating, or repairing
equipment.
• If fan guards are missing from a machine,
obtain replacements from
a
Lincoln
Distributor. (See Parts List.) Always use
greatest care when working near moving
parts.
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F-15
F-15
TROUBLESHOOTING & REPAIR
DC EXCITER TEST (continued)
FIGURE F.2 – EXCITER COVER REMOVAL
WARRANTY
+
CHECK VOLTAGE
AT BRUSH
HOLDERS HERE
(RIGHT SIDE IS +)
EXITER
COVER
4. Turn off the engine. Using the 3/8” nut driver,
remove the exciter cover. See Figure F.2.
5. Start the engine. Using the volt/ohmmeter,
carefully check the DC voltage at the brush
holders. See Figure F.2. The right side
brush holder is positive polarity. Normal DC
voltage is 125 - 135VDC with the engine at
the high idle speed of 1600 RPM.
WARNING
MOVING PARTS can injure.
6. If the DC voltage is normal at the brush hold-
ers, the DC exciter armature and shunt coils
are OK.
• Remove guards only when
necessary to perform service,
and replace them when the
service requiring their removal
is complete.
a. If the voltage is low or not present, pro-
ceed with the shunt coil and series coil
resistance tests.
• Keep hands, hair, clothing and tools away
from V-belts, gears, fans, and all other moving
parts when starting, operating, or repairing
equipment.
b. If the correct DC voltage is present at the
brush holders but not at the 120VDC
receptacle, the series coil or associated
leads may be faulty. See the Wiring
Diagram. Proceed with the shunt coil and
series coil resistance tests.
• If fan guards are missing from a machine,
obtain replacements from
a
Lincoln
Distributor. (See Parts List.) Always use
greatest care when working near moving
parts.
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F-16
F-16
TROUBLESHOOTING & REPAIR
DC EXCITER TEST (continued)
FIGURE F.3 – BRUSH HOLDER LEADS
WARRANTY
WHITE
FLEX
LEAD
SMALL
FLEX
LEAD
SOLID
LEAD
Shunt Coil and Series Coil Resistance Tests
7. Turn the engine OFF.
10. Using the volt/ohmmeter, check the series
coil resistance.
8. Using the 3/8" nut driver, disconnect the two
leads from the left side brush holder. See
Figure F.3. Separate the two leads. One
will be a larger "solid" lead (series coil).
The other will be a smaller flex lead (shunt
coil).
a. Check from the larger solid lead (left
side) to the 120VDC receptacle. (Check
at the longer slot opening. See Figure
F.1.) Normal resistance is less than 1
ohm.
9. Using the 3/8" nut driver, remove the two
flex leads from the right side brush holder.
Note lead placement for reassembly.
Using the volt/ohmmeter, check the shunt
coil resistance. Check from the left side
small flex lead to the right side white flex
lead. See Figure F.3. Normal resistance is
120 - 130 ohms. If the resistance is very
high or "open," the shunt coils are faulty.
Replace them. If the resistance is very low,
the shunt coils are "shorted.” Replace
them.
b. Also measure the resistance from the
solid lead (left side) to machine ground.
See Figure F.3. This resistance should
be very high - at least 500,000 ohms. It
may be necessary to disconnect the
series coil from the 120VDC receptacle
to isolate the series coil from the rest of
the circuitry. See the Wiring Diagram.
11. If the shunt and series coils are good, and
the exciter is not operating properly, the
exciter armature may be faulty. Replace the
exciter armature.
Also measure the resistance from either
lead to machine ground. This resistance
should be very high - at least 500,000
ohms.
12. After the test and repairs are completed,
install the exciter cover using the 3/8” nut
driver.
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F-17
F-17
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 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine whether or not the idler solenoid can function when it is energized with
12VDC.
MATERIALS NEEDED
External 12VDC supply
Wiring Diagram
Volt/ohmmeter (Multimeter)
This procedure takes approximately 15 minutes to perform.
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F-18
F-18
TROUBLESHOOTING & REPAIR
IDLER SOLENOID TEST (continued)
FIGURE F.4 – IDLER SOLENOID CONNECTIONS
QUICK
CONNECT
LEADS
TEST PROCEDURE
7. If the solenoid does not operate properly,
check for a mechanical restriction in the link-
age or for a missing spring.
1. Turn the engine OFF.
2. Unlatch and secure the right side door.
3. Locate the idler solenoid and the two leads
with quick connects. See Figure F.4.
8. If the linkage is intact and the solenoid does
not operate correctly when 12VDC is
applied, the idler solenoid may be faulty.
Replace the idler solenoid.
4. Disconnect the two solenoid leads at the
quick connection splices.
NOTE: Normal solenoid coil resistance is
approximately 25 ohms.
5. Using the external power supply, apply
12VDC to the idler solenoid leads. The
solenoid should activate.
9. After the test and repairs are completed,
close and latch the right side door.
6. The solenoid should deactivate when the
12VDC is removed.
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F-19
F-19
TROUBLESHOOTING & REPAIR
MAIN GENERATOR SHUNT FIELD 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 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will help determine whether or not the main shunt field coils are shorted, open, or
grounded.
MATERIALS NEEDED
Volt/ohmmeter (Multimeter)
Wiring Diagram
This procedure takes approximately 25 minutes to perform.
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F-20
F-20
TROUBLESHOOTING & REPAIR
MAIN GENERATOR SHUNT FIELD WINDING TEST (continued)
FIGURE F.5 – PLUG P10 LOCATION
PLUG P10
TEST PROCEDURE
1. Turn the engine OFF.
2. Unlatch, lift and secure the right side door.
3. Locate plug P10. See Figure F.5.
4. Remove plug P10.
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F-21
F-21
TROUBLESHOOTING & REPAIR
MAIN GENERATOR SHUNT FIELD WINDING TEST (continued)
FIGURE F.6 – PLUG P10 PIN ASSIGNMENTS
PIN 3
PIN 5
TAB
5. Locate the blue (U) (pin 3) and the brown (N)
(pin 5) leads in the harness plug. See
Figure F.6.
9. If the plug and associated leads are okay,
the shunt field coils may be faulty. Replace
the shunt field coils.
6. Using the volt/ohmmeter, measure the resis-
tance between the blue and the brown lead.
Normal resistance is approximately 40
ohms.
10. If the test does meet the resistance specifi-
cations, the main shunt coils are okay.
11. Replace plug P10, making sure the leads
and plug are secure.
7. Also measure the resistance from either
lead (blue or brown) to ground. This resis-
tance should be at least 500,000 ohms.
12. After the test and repairs are completed,
close and latch the right side door.
8. If the test does not meet the resistance
specifications, then check the harness plug
for loose connections or shorted leads.
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F-22
F-22
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT 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 1-800-833-9353 (WELD).
TEST DESCRIPTION
If the machine output is low or high, this test will determine whether or not the engine is oper-
ating at the correct speed (RPM) during both HIGH and LOW idle conditions. Directions for
adjusting the throttle to the correct RPM are given.
MATERIALS NEEDED
White or red marking pencil
7/16” Wrench
3/8” Wrench
This procedure takes approximately 35 minutes to perform.
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F-23
F-23
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.7 – BLOWER PADDLE MARK LOCATION
BLOWER
PADDLE
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 a
mark on one of the blower paddles. See
Figure F.7.
6. With the machine at HIGH IDLE, the tach
should read between 1550 and 1650 RPM.
With the machine at LOW IDLE, the tach
should read between 1000 and 1050 RPM.
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F-24
F-24
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.8 – HIGH IDLE ADJUSTMENT
GOVERNOR
LOCKING
NUT
ADJUSTMENT
SCREW
Adjust High Idle
a. Make sure there is no load on the machine.
b. Set the Idler switch to the HIGH position.
c. Locate the governor on the left side of the
engine. See Figure F.8.
d. Using the 3/8” wrench to turn the adjustment
screw and locking nut, adjust the high idle
speed to between 1550 - 1650 RPM. It may
not be necessary to remove the seal. See
Figure F.8.
e. If further adjustments are necessary, consult
the Engine Manual.
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F-25
F-25
TROUBLESHOOTING & REPAIR
ENGINE THROTTLE ADJUSTMENT TEST (continued)
FIGURE F.9 – LOW IDLE ADJUSTMENT
SPEED
ADJUSTMENT
SCREW
IDLER
ROD
LOCKING
NUT
Adjust Low Idle
a. Make sure there is no load on the machine.
f. Tighten the locking nut to the ball joint. The
low idle RPM should now be slightly less
than the bottom value of the range.
b. Set the Idler switch to AUTO and wait for the
engine to change to low idle speed.
g. Using the speed adjustment screw on the
carburetor, set the low RPM to within the
range (1000 - 1050 RPM). See Figure F.9.
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
locking nut. This is located on the idler rod
between the carburetor ball joint and the
idler solenoid. See Figure F.9.
e. Adjust the idler rod stickout from the ball
joint to set the low idle speed to the bottom
of the range (1000 RPM). The flattened por-
tion of the idler rod must be vertical. This
ensures free pivoting of the idler rod in the
idler solenoid plunger. To achieve this, turn
the idler rod into the ball joint (no more than
one-half turn).
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F-26
F-26
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 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will magnetize the exciter pole pieces. The exciter can then “build-up” when
the engine is started.
MATERIALS NEEDED
12-volt battery
Two jumper wires with alligator clips on each end
Wiring Diagram
3/8” Wrench
This procedure takes approximately 15 minutes to perform.
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F-27
F-27
TROUBLESHOOTING & REPAIR
FLASHING THE FIELDS (continued)
FIGURE F.10 – EXCITER COVER REMOVAL
EXITER
COVER
PROCEDURE
1. Turn the engine OFF.
2. Using the 3/8” wrench, remove the exciter
cover. See Figure F.10.
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F-28
F-28
TROUBLESHOOTING & REPAIR
FLASHING THE FIELDS (continued)
FIGURE F.11 - BRUSH HOLDER/BATTERY JUMPER CONNECTIONS
WARRANTY
+
RAISE
EXCITER
BRUSH OFF
COMMUTATOR
TO NEGATIVE
TO POSITIVE
BATTERY
TERMINAL
BATTERY
TERMINAL
3. Raise one exciter brush off the armature com-
mutator.
6. Remove both leads from the brush holders
and the battery.
4. Using the jumper leads and the 12VDC bat-
tery, first attach the clip of one lead to the
POSITIVE terminal of the battery. Attach the
other end of this same lead to the right side
brush holder. See Figure F.11.
7. Install the brush removed in step 3.
8. Install the exciter cover using the 3/8” nut
driver.
9. Start the engine. The exciter should produce
DC output voltage.
5. Carefully attach one clip of the other lead to
the NEGATIVE terminal of the battery. Attach
the other end of the same lead to the left side
brush holder for approximately five seconds.
Pull the lead away quickly to minimize arcing.
See Figure F.11.
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F-29
F-29
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VDC SUPPLY)
HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM
0 volts
2 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
represents 2 milliseconds in time.
Note: Scope probes connected at
machine 115VDC receptacle.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....2 ms/Div.
Coupling.............................DC
Trigger.........................Internal
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F-30
F-30
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AND SELECTOR
SWITCH AT MAXIMUM
0 volts
50 volts
5 ms
This is the typical DC welding output
voltage generated from a properly
operating machine. Note that each
vertical division 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
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F-31
F-31
TROUBLESHOOTING & REPAIR
TYPICAL DC WELD VOLTAGE WAVEFORM
MACHINE LOADED – SELECTOR SWITCH AT MAXIMUM
0 volts
5 ms
20 volts
MACHINE LOADED TO 200 AMPS AT 40VDC
This is the typical DC welding output
voltage generated from a properly
operating machine. Note that each
vertical division 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
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F-32
F-32
TROUBLESHOOTING & REPAIR
DC EXCITER ARMATURE AND FIELD COILS
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 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the exciter armature
and field coils.
MATERIALS NEEDED
3/8” Wrench
1/2” Wrench
1-5/8” Socket wrench
Wiring Diagram
This procedure takes approximately 1.5 hours to perform.
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F-33
F-33
TROUBLESHOOTING & REPAIR
DC EXCITER ARMATURE AND FIELD COILS
REMOVAL AND REPLACEMENT (continued)
FIGURE F.12 – EXCITER COVER REMOVAL
POLE PIECE BOLTS (4)
EXITER FRAME
BRUSH HOLDER
ASSEMBLY (2)
ARMATURE
SLEEVE COLLAR
FLAT WASHER
ARMATURE LOCKING NUT
EXITER COVER
PROCEDURE
Reassembly:
DC Exciter Armature Removal Procedure
7. Upon reassembly, the armature locking nut
should be torqued to 170 ft.-lbs. Install a
new sleeve collar if necessary (Part number
T5345). Bend the flat washer against the
locking nut.
1. Turn the engine OFF.
2. Using the 3/8” nut driver, remove the exciter
cover. See Figure F.12.
3. Using the 3/8” wrench, remove the two brush
holder assemblies. Note insulator placement
for reassembly.
8. Install the brush holder assemblies. Note
insulator placement.
4. Bend the flat washer away from the armature
locking nut.
9. Check the armature air gap. Minimum gap
should be .025”.
5. Using the 1-5/8” socket wrench, remove the
armature locking nut, washer, and sleeve col-
lar.
10. Install the exciter cover.
6. Carefully remove the armature by sliding it
from the shaft.
NOTE: The sleeve collar may have to be
removed with a gear puller. Be careful not to
damage the armature commutator.
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F-34
F-34
TROUBLESHOOTING & REPAIR
DC EXCITER ARMATURE AND FIELD COILS
REMOVAL AND REPLACEMENT (continued)
Field Coils Removal Procedure
Reassembly:
1. Perform the DC Exciter Armature Removal
7. Assemble the new coils to their respective
pole pieces.
Procedure.
2. Using the 3/8” wrench, remove the leads from
the brush holder. Note lead placement for
reassembly.
8. Assemble the coil and pole pieces to the
exciter frame with four bolts.
9. Make the necessary lead connections to the
idler board and 115VDC receptacle. Wrap
the slices with tape.
3. Using the 1/2” wrench, remove the four bolts
(two on each side) holding the pole pieces to
the exciter frame. See Figure F.12.
10. Assemble the armature and brushes.
See the DC Exciter Armature Removal
Procedure.
4. Label and remove the tape and splices from
the black and red leads that go to the idler
board and 115VDC receptacle. See the
Wiring Diagram.
5. Carefully slide the coils and pole pieces from
the exciter frame.
6. Remove the coils from the pole pieces.
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F-35
F-35
TROUBLESHOOTING & REPAIR
MAIN 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 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the main DC
generator frame.
MATERIALS NEEDED
Rope sling
Wood or steel blocks
Pry bars
9/16” Wrench
1/2” Wrench
7/16” Wrench
3/4” Wrench
Slot head screw driver
Wiring Diagram
This procedure takes approximately 8 hours to perform.
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F-36
F-36
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.13 – BATTERY PANEL REMOVAL
NEGATIVE
BATTERY
CABLE
PROCEDURE
3. Using the 1/2” wrench, remove the negative
battery cable.
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.13.
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F-37
F-37
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.14 – TOP AND DOORS ASSEMBLY DETAILS
BOLT / NUT (4)
'L' DOOR
HOOKS (4)
4. Using the 1/2” wrench, remove the four nuts
and bolts holding the case top and doors
assembly to the welder frame. Remove the
rubber gasket from the top. Carefully lift up
and remove the top and doors assembly.
Carefully remove the “L” shaped door hooks.
See Figure F.14.
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F-38
F-38
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.15 – FUEL TANK MOUNTING DETAILS
BOLTS / NUTS /
WASHERS (4)
FUEL LINE
FUEL BOWL
FUEL TANK
RAILS
5. Perform the DC Exciter Armature Removal
7. Using the 9/16” wrench, remove the four nuts,
bolts, and washers holding the fuel tank
assembly to the rails. See Figure F.15.
Procedure.
6. Turn off the fuel supply at the fuel bowl and
remove the fuel line. Plug the line to avoid
spillage.
8. Carefully remove the fuel tank and set it aside
in a safe area.
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F-39
F-39
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.16 – SELECTOR SWITCH LEAD REMOVAL
SELECTOR
SWITCH
TERMINAL
LEAD (5)
C
B
A
9. Using the 1/2” wrench, remove the five heavy
flex leads from the selector switch terminals.
Label the leads for reassembly. See Figure
F.16.
FIGURE F.17 – OUTPUT TERMINAL LEAD REMOVAL
COPPER STRAP AND
REED SWITCH ASSEMBLY
POSITIVE OUTPUT
TERMINAL AND LEAD
C
B
A
10. Using the 3/4” wrench, remove the copper
strap lead and reed switch assembly from
the negative output terminal. See Figure
F.17.
11. Using the 3/4” wrench, remove the heavy
lead from the positive output terminal. See
Figure F. 17.
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F-40
F-40
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.18 – CHOKE CONTROL CABLE REMOVAL
LOOSEN
HERE
CHOKE
CABLE
12. Using the slot head screw driver, remove the
choke control cable from the engine carbure-
tor assembly. Mark cable replacement for
reassembly. See Figure F.18.
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F-41
F-41
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.19 – FRONT PANEL WIRING CONNECTIONS
14. BLACK LEAD TO
IDLER PC BOARD
18. WHITE LEAD
22. BROWN LEAD TO
IDLER SWITCH
21. YELLOW LEAD
TO IDLER SWITCH
D
17. RED LEADS TO
IGNITION SWITCH
16. "H" LEAD TO
START BUTTON
19.
{
20. BLUE AND BLACK
LEADS TO AMMETER
15. SHUNT LEADS
13. RED LEAD TO
DC RECEPTACLE
QUICK DISCONNECT
13. Using the slot head screw driver, remove the
18. Remove the white lead from the idler PC
board. See Figure F.19 and the Wiring
Diagram.
red lead connecting the 115VDC receptacle
to the DC exciter. See Figure F.19 and the
Wiring Diagram. Cut any necessary cable
ties.
19. Using the 3/8” nut driver, remove the blue
lead from the ammeter. Label for reassem-
bly. See Figure F.19 and the Wiring Diagram.
14. Remove the black lead connecting the idler
PC board to the DC exciter. See Figure F.19
and the Wiring Diagram. Cut any necessary
cable ties.
20. Using the 3/8” nut driver, remove the black
lead from the ammeter. Label for reassem-
bly. See Figure F.19 and the Wiring Diagram.
15. Disconnect the blue and brown main shunt
leads from their quick disconnect splices.
See the Wiring Diagram.
21. Label and remove the yellow lead from the
idler switch. The yellow lead connects the
idler switch to the oil pressure switch. See
Figure F.19 and the Wiring Diagram.
16. Disconnect the “H” lead from the START but-
ton switch. See Figure F.19 and the Wiring
Diagram.
22. Label and remove the brown lead from the
idler switch. The brown lead connects the
idler switch to the idler solenoid. See Figure
F.19 and the Wiring Diagram.
17. Remove the two red leads from the ignition
switch. Label for reassembly. See Figure
F.19 and the Wiring Diagram.
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F-42
F-42
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.20 – FRONT PANEL FASTENER REMOVAL
BOLTS / NUTS / WASHERS (2)
MIDDLE SCREW (1)
BASE MOUNTING BOLTS (4)
23. Using the 1/2” wrench, remove the two bolts,
nuts, and washers that hold the front panel
assembly to the horizontal rails. (There is
one on each side.) See Figure F.20.
25. Using the 3/8” nut driver, remove the screw
from the lower middle of the front panel. See
Figure F.20.
26. Carefully remove the front panel assembly.
24. Using the 9/16” wrench, remove the four
bolts, nuts, and washers from the bottom of
the front panel assembly. These four bolts
mount the front to the base. (There are two
on each side.) See Figure F.20.
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F-43
F-43
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.21 – BRUSH BRACKET WRAP-AROUND COVER
BRUSH BRACKET
REMOVE (2) NUTS,
WASHERS, AND SCREWS
WRAP- AROUND COVER
27. Using the slot head screw driver, remove the
two screws and nuts from the brush bracket
wrap-around cover. Remove the cover. See
Figure F.21.
FIGURE F.22 – MAIN GENERATOR BRUSH BRACKET CLAMPING BOLT
CLAMPING BOLT
BRUSHES (8)
BRUSH BRACKET
28. Lift the eight brushes from the main commu-
tator. Note their positions for reassembly.
29. Using the 7/16” wrench, loosen (do not
remove) the main generator brush bracket
clamping bolt. Note the position of the drill
spot for reassembly. See Figure F.22.
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F-44
F-44
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
FIGURE F.23 – MAIN GENERATOR FEET MOUNTING
MAIN GENERATOR
FEET (2)
REMOVE MOUNTING
NUTS, WASHERS,
AND BOLTS
30. Using the 3/4” wrench, remove the frame
mounting bolts, nuts, and washers from the
feet of the main generator. See Figure F.23.
FIGURE F.24 – MAIN GENERATOR ENGINE MOUNTING
SLING
ENGINE / GENERATOR
MOUNTING HOLES
31. With the rope sling around the main genera-
tor frame, carefully lift the frame a small dis-
tance. Slide the wood or steel blocks under
the engine. See Figure F.24.
32. Using the 9/16” wrench, remove the bolts
and lock washers mounting the generator
frame to the engine. See Figure F.24.
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F-45
F-45
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
33. 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.
8. Connect the white wire to the idler PC board.
Connect the two red wires to the ignition
switch. Connect the “H” lead to the START
button switch. Connect the blue and brown
main shunt leads at their quick disconnect
splices. Connect the black lead between the
idler PC board and the DC exciter.
NOTE: The exciter frame is also removed with the
main generator frame.
9. Using the slot head screw driver, connect the
red lead between the 115VDC receptacle
and the DC exciter. Replace any cable ties
cut during disassembly.
Reassembly: Refer to Figures F.13 - F.24 as
needed.
1. Using the rope sling, carefully lift and “wiggle”
the generator frame onto the engine and
armature assembly. Be careful to support the
generator frame as you position it.
10. Using the slot head screw driver, install the
choke control cable to the engine carburetor
assembly, noting placement mark.
11. Using the 3/4” wrench, install the heavy lead
to the positive output terminal and the copper
strap lead and reed switch assembly to the
negative output terminal.
2. Using the 9/16” wrench, install the bolts and
lock washers mounting the generator frame to
the engine. Using the 3/4” wrench, install the
frame mounting bolts, nuts, and washers to
the feet of the main generator. Check air gap
– min. .035” for main generator.
12. Using the 1/2” wrench, install the five heavy
flex leads to the selector switch as labeled
during disassembly.
3. Using the 7/16” wrench, tighten the main gen-
erator brush bracket clamping bolt. Note the
position of the drill spot.
13. Carefully position the fuel tank to the mount-
ing rails. Using the 9/16” wrench, install the
four nuts, bolts, and washers holding the fuel
tank assembly to the rails. Remove the plug
from the fuel line and attach it to the fuel
bowl.
4. Install the eight brushes against the main
commutator. Observe the positions you noted
during disassembly.
5. Using the slot head screw driver, install the
brush bracket wrap-around cover with two
nuts and screws.
14. Perform the DC Exciter Armature
Reassembly Procedure.
15. Carefully set the top and doors assembly into
place. Install the “L” shaped door hooks.
Using the 1/2” wrench, install the four nuts
and bolts holding the case top and doors
assembly to the welder frame. Install the
rubber gasket to the top.
6. Carefully set the front panel assembly into
position. Using the 3/8” nut driver, install the
screw for the lower middle of the front panel.
Using the 9/16” wrench, install the four bolts,
nuts, and washers for the bottom of the front
panel assembly. Then install the two bolts,
nuts, and washers that hold the front panel
assembly to the horizontal rails.
16. Using the 1/2” wrench, install the negative
battery cable. Slide the battery mounting
panel back into place and, using the 7/16”
wrench, install the two bolts and washers
that secure the panel.
7. Using the 3/8” nut driver, connect the yellow
wire from the oil pressure switch and the
brown wire from the idler solenoid to the idler
switch. Connect the blue wire and the black
wire to the ammeter. See the Wiring Diagram.
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F-46
F-46
TROUBLESHOOTING & REPAIR
MAIN 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
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F-47
F-47
TROUBLESHOOTING & REPAIR
MAIN GENERATOR ARMATURE REMOVAL
AND REPLACEMENT (continued)
FIGURE F.25 – MAIN GENERATOR ARMATURE MOUNTING
SLING
BLOWER PADDLE
MOUNTING BOLTS /
LOCK WASHERS (8)
PROCEDURE
Replacement: Refer to Figure F.25
1. Turn the engine OFF.
1. Support the armature with the rope sling.
Mount the armature to the engine, rotating it
1/8 turn in either direction to achieve attach-
ment. Before removing the rope sling, be
careful to support the armature with the wood
or steel blocks under the engine. With the 5/8”
wrench, install the eight bolts and lock wash-
ers that attach the blower paddles and the
armature to the engine flywheel.
2. Perform the DC Exciter Armature Removal
procedure.
3. Perform the Main Generator Frame Removal
procedure.
4. Using the rope sling, support the armature.
5. Make sure the engine supported with the
wood or steel blocks.
6. Using 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.25.
2. Perform other replacement procedures
according to each of the following:
Generator
Replacement
Frame
Removal
and
7. With the armature supported and “balanced”
in the rope sling, carefully rotate the armature
1/8 turn in either direction to release it.
DC Exciter Armature Removal and
Replacement
CAUTION
The armature is now free to be removed from
the engine.
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F-48
F-48
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
1000-1050
1550-1650
Load RPM
NA
1440-1500
WELDER DC OUTPUT
Current Control
Rheostat
Current Selector
Open Circuit
Voltage
Load Volts
Load Amps
300
Switch
Maximum
Maximum
88-95
33-39
DC AUXILIARY POWER RECEPTACLE OUTPUT
Open Circuit Voltage
Load Volts
Load Amps
123-132
115-125
15.0
FIELD AMPS AND VOLTS
(Current Rheostat at Maximum)
Exciter DC Volts
Main Shunt Field Amps
RPM
123 - 132
2.35-2.65
1440-1560
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G-1
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
ELECTRICAL DIAGRAMS SECTION
Electrical Diagrams Section ..........................................................................................Section G
Wiring Diagram ...........................................................................................................................G-2
Wiring Diagram Wire Feed Module .............................................................................................G-3
Idler PC Board Schematic ...........................................................................................................G-4
Idler PC Board Layout .................................................................................................................G-5
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G-2
G-2
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - CLASSIC I
CLASSIC I - WIRING DIAGRAM
ELECTRICAL SYMBOLS
ALTERNATE IGNITION CIRCUIT
(WITH RESISTOR) SUPPLIED
ON EARLIER ENGINES
PER E1537
CONTROL PANEL COMPONENTS
SHOWN AS VEIWED FROM REAR.
P10
J5
LEAD COLOR CODE
IDLER
P.C.
BOARD
9
8
2
1
11
6
5
4
12
7
3
10
R-RED
B-BLACK
U-BLUE
OR GREY
W-WHITE
Y-YELLOW
G-GREEN
N-BROWN
B
B
+
-
+
N
-
W B
B
R
Y
U
IGNITION
COIL
IGNITION
COIL
IGNITION
RESISTOR
610
BAT
DISTRIBUTOR
DISTRIBUTOR
R
R
602B
R
B
41
1
CARBURETOR
2
3
FUSE IN CIRCUIT
ENGINE
ON C.S.A. VERSION
W
R
R
42
HOUR
FUEL SHUT-OFF
Y
F1
15A.
OIL
ONLY.
METER
602A
4
5
PRESSURE
LIGHT
IDLER
SOLENOID
600B
START
-
+
N
RHEOSTAT
600A
B
IGNITION
SWITCH
IDLER
SWITCH
6
G
P9
J8
R
G
SELECTOR
SWITCH
U
Y
OIL PRESSURE
SWITCH
50A
R
B
AUX POWER
W
Y
B
RECEPTACLE
GENERATOR
R
ALTERNATOR
S
-
A
B
TO EXCITER
OUTPUT
E
E
B
EXC
+
R
+
FOR REMOTE
OPTION
5
4
3
2
1
+
-
+
A
STARTING
MOTOR
CR2 REED
RELAY
WELDER
GROUND
TO BASE
LEAD BLOCK
U
N
GROUND
R
U
TO ENGINE
N
POSITIVE
(CC+) & (CV+ WITH WFM OPTION)
NEGATIVE
(CC-)
P11
K924-4 REMOTE CONTROL (OPTIONAL)
K924-1 REMOTE CONTROL (OPTIONAL)
WIRE FEED MODULE (OPTIONAL)
PLUG FOR REMOTE
*
*
SEE
REMOTE CONTROL RECEPTACLE & SWITCH
CONTROL POTENTIOMETER
BELOW
ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
REMOTE CONTROL RECEPTACLE & SWITCH
1
2
3
RESISTORS
G
X
PLUG FOR REMOTE
CONTROL POTENTIOMETER
Y
B
R
X
SEE
*
BELOW
B
R
X
SEE
*
INLINE
BELOW
1
2
3
41
4
5
RESISTORS
G
X
Y
PLUG
(P5)
CONNECTORS
600
42
W
Y
W
1
2
3
W.F.M.
CONTROL
PANEL
B
41
SEE
BELOW
*
6
7
8
600
42
Y
4
5
602
SEE
BELOW
*
R
W
B
4
5
602
WIRE
#8 LEAD
6
9
10
POS.
NEG.
CONNECT TO POS. & NEG.
OUTPUT TERMINALS
W
P8
FEED
6
11
12
CONNECT
TO CASE
REMOTE CONTROL
POTENTIOMETER BOX
P8
SWITCH FOR LOCAL OR
REMOTE CONTROL SHOWN
IN LOCAL POSITION.
MODULE
NEGATIVE CV
OUTPUT TERMINAL
PANEL
SWITCH FOR LOCAL OR
REMOTE CONTROL SHOWN
IN LOCAL POSITION.
#2 HEAVY LEAD
609
CONNECT
TO CASE
REMOTE CONTROL
POTENTIOMETER BOX
608
WITH MACHINE OFF, REMOVE PLUG "P9" ON MACHINE FROM CONNECTOR "J8". THEN CONNECT PLUG "P8"
ON REMOTE CONTROL KIT TO CONNECTOR "J8" ON MACHINE.
*
CONNECT TO NEG.
BRUSH HOLDER
WITH MACHINE NOT RUNNING, REMOVE PLUG "P9" ON
MACHINE FROM CONNECTOR "J8". THEN CONNECT
PLUG "P8" ON REMOTE CONTROL TO
*
IF A WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISPOSE OF THE UNCONNECTED
PLUG "P10" (IF ONE IS ON THE MACHINE). FASTEN THE NEW PLUG "P11" NEARBY, LEAVING IT
UNCONNECTED.
* *
#2 HEAVY LEAD
CONNECTOR "J8" ON MACHINE.
200 AMP
IF NO WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISCONNECT PLUG "P10" ON THE
MACHINE FROM CONNECTOR "J5". CONNECT PLUG "P11" FROM THE REMOTE CONTROL KIT TO CONNECTOR
"J5" ON THE MACHINE.
*
MACHINE MUST NOT BE RUNNING
WHEN MAKING THESE CONNECTIONS.
THERMOSTAT
ASSEMBLY
CONNECT RED AND BLACK LEADS ON REMOTE TO
RED AND BLACK LEADS ON MACHINE.
DAMAGE CAN OCCUR TO THE REMOTE CONTROL SWITCH IF IT IS USED WITHOUT THE "P11"
CAUTION:
PLUG INSTALLED OR A WIRE FEED MODULE INSTALLED.
ON CLASSIC I MACHINES CONNECT RED AND BLACK LEADS ON REMOTE TO RED AND BLACK LEADS ON
MACHINE.
7-28-2000F
L9262
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.
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G-3
G-3
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - WIRE FEED MODULE
WIRE FEED MODULE - WIRING DIAGRAM
ELECTRICAL SYMBOLS PER E1537
CONTROL BOARD
Y
1
2
FLASHING
LEADS
MOLEX CONNECTORS
W
218
219
1
2
J3
J1
J2
J4
503
602
509
610
3
J1
P1
SHUNT
TO
4
CONNECTOR CAVITY NUMBERING
SEQUENCE VIEWED FROM
FIELD
RHEOSTAT
5
634
667
2
1
2
COMPONENT SIDE OF BOARD.
6
+
CONNECTS TO
ENGINE WELDER
RECEPTACLE J5
115V
DC
N.A. LEADS 31, 32 AND 602 DO NOT GO INSIDE WIRE FEED MODULE BOX.
N.B. COMPONENTS VIEWED FROM REAR
7
3
600
8
-
4
4
9
621
633
75A
76
5
1
5
9
3
4
8
2
6
GND
31
10
11
12
6
7
7
115V
AC
12
10
11
32
8
P5
P5
N.A.
77
9
CONNECTOR CAVITY NUMBERING
SEQUENCE VIEWED FROM
LEAD SIDE OF CONNECTOR
GND
31
75
10
GND
31
1
2
3
4
5
6
7
8
9
J2
P2
CC/CV SWITCH S1
SHOWN IN CV MODE
510 602
32
501
1
2
3
4
5
6
32
CV CONTROL
609
610A
510
501
503A
602
609
610A
510
501
503A
509
77A
R501
75
610A
503A
503A
10K
631
630
503
76A
501
609
J4
P4
602
J6
REMOTE CONNECTOR
P6
W
610A
Y
1
2
3
4
5
6
7
8
31
J
115 VAC
75
76
77
2
75
76
77
2
1
2
3
4
5
6
A
B
C
D
E
32
GND
2A
GROUND
600
608
610
CONTACTOR
4A
77B
76B
75A
1
4
4
REMOTE
F
75A
75A
P7
G
J7
510
AMPHENOL
J3
P3
77
4A
2
76B
2A
4
77B
219
+
218
-
76
LOCAL/REMOTE SWITCH S2
SHOWN IN LOCAL MODE
621
667
300 AMP
SHUNT
76A
77A
633
608
609
CR4
666
634
+
+
+
250
TO NEG
BRUSH HOLDER
CC
-
CC
+
CV
-
25W
CR3
C501
C502
C503
CONTACTOR
631
630
622
CONTACTOR
30000 MFD
75 VOLT
EACH
3-18-94
L9259
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.
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G-4
G-4
ELECTRICAL DIAGRAMS
SCHEMATIC - IDLER PC BOARD
M
1 6 9 9 0
NOT USED
11
9
X1 -D
X1 -C
D2
R8
13
YEL
14
R9
R15
15.0
Y
TO BATTERY
TO SOLENOID
10
B3
B4
8
+
t
15.0
56
D1
GND
GND
W
WHITE
3
16
DZ1
10V
5W
C3
C4
50
C1
X2
X1
15V
LM2901
12
4536B
8
10K
GND
TO REED SW.
RED
GND
GND
R
B
R13
B5
13.7K
C10
.047
47.5K
D7
100V
10K
22.1K
R20
D
S
T13157-14
33.2K
R6
C8
511
B1
Q1
10K
R5
133K
15A
60V
G
CR1
16
5
4
1
DZ3
SET
V
DD
15V
1W
DZ2
27V
5W
7
6
CR1
X1 -A
2
2
3
4
5
6
7
15
14
13
12
11
RESET
MONO IN
OSC INH
1
X1
-B
X2
IN
1
R17
B2
B
OUT
OUT
1
DECODE
1.00K
R12
2
D
C
B
26.7K
8
BY-PASS
R
C9
10
CLOCK INH
VSS
D5
1N4936
8
9
A
D8
3.32K
4536B
C2
C6
18
15V
22.1K
.5
5W
P.C.BOARD IS CONNECTED DIRECTLY
TO FRAME GND THRU MOUNTING SCREW
GND
M16990-2BA
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
LEAD COLOR CODE
R- 20
C- 10
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
1/4W
UNLESS OTHERWISE SPECIFIED)
UNLESS OTHERWISE SPECIFIED)
D-
8
LABELS
=
Ohms
(
B
Y
BLACK
YELLOW
RED
=
1A, 400V
(UNLESS OTHERWISE SPECIFIED)
SUPPLY
VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
NOTES :
R
W
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
COMPLETE BOARD, THIS DIAGRAM MAY
WITHOUT AFFECTING THE INTERCHANGEABILITY OF
A
FRAME CONNECTION
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
WHITE
EARTH GROUND CONNECTION
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLES SIZES PER E-2056
Ch'ge.Sht.No.
10-29-93A
EQUIP.
TYPE
CLASSIC SA200
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.O2
.OO2
IDLER PCB SCHEMATIC
SUBJECT
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
NONE
SCALE
MATERIAL TOLERANCE ("t") TO AGREE
WITH PUBLISHED STANDARDS
SHT.
AUSTRALIA
CANADA
FRANCE
S20334
I.E.B.
2/10/93
CHK.
SUP'S'D'G.
M
16990
DR.
DATE
NO.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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G-5
G-5
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - IDLER PC BOARD
+.05
-.02
2.40
DZ1
M16723-2
R11
C4
IDLER
R20
R13
1.80
R8
C10
6
X1
X2
7
CR1
Q1
.85
B5
B3
5
B4
B2
B1
4
0
+.05
3.25
3.25 -.02
0
1.00
1
3
2
ITEM
PART NO.
DESCRIPTION
REQ’D
P.C. BOARD BLANK
TAB TERMINAL
1
5
1
M16723-B
T13157-14
CS000290
T13344-3
T13344-2
T12012-4
CJ000015
1
2
3
4
5
6
7
E1724-#10-2.10
REED SWITCH COIL
REED SWITCH COIL
REED SWITCH
1
1
1
2
E2387-#20-1.50
5-5-95A
M16723-2
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 pro-
vided 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.
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