Lincoln Electric SVM134-A manual

CLA SSIC I SVM134-A October , 2000 For use with machine code numbers 10068 to 10069 TM RETURN TO MAIN INDEX SER VICE MANUAL Safety Depends on Y ou 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 [...]

SAFETY i i CLASSIC I FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Operate engines in open, well-v entilated areas or vent the engine e xhaust fumes outdoors. _______________________[...]

SAFETY ii ii CLASSIC I ARC RA YS can burn. 4.a. Use a shield with the proper filter and cov er plates to protect your e yes from sparks and the ra ys of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b . Use suitab le clothing made from durable flame-resistant material to pr[...]

CLASSIC I FOR ELECTRICALL Y powered equipment. 8.a. T ur n off input power using the disconnect switch at the fuse bo x before working on the equipment. 8.b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manuf acturer’ s recommendations. 8.c. Ground the equipment in accordance with the U.S . Nati[...]

SAFETY iv iv CLASSIC I PRÉCA UTIONS DE SÛRETÉ P our 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: Sûreté P our Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. [...]

MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v CLASSIC I P age Safety .................................................................................................................................................i-iv Installation .....................................................................................................................[...]

T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 CLASSIC I Installation T echnical Specifications ..............................................................................................................A-2 Saf ety Precautions .................................................................................................[...]

INST ALLA TION A-2 A-2 CLASSIC I TECHNICAL SPECIFICA TIONS - CLASSIC I INPUT - DIESEL ENGINE Manufacturer Description Speed Displacement Ignition Capacities Continental 4 cyl., 4 cycle 1450 RPM 164.7 cu. in. Distributor Fuel: 15 gal. TM27 W ater-cooled Full load (2700 cc) T ype (57 liters) gasoline Electronic 38 HP @ 1600 RPM Oil: 6.0 qt. 1450 RPM [...]

Read this entire installation section before y ou start installation. SAFETY PRECA UTIONS Do not attempt to use this equipment until you ha ve thoroughly read all the operation and maintenance manuals supplied with y our machine. They include impor tant saf ety precautions; detailed engine star ting, operating, and maintenance instructions; and par[...]

ST A CKING Classic I machines CANNO T be stacked. TIL TING Place the machine on a secure, le vel surf ace whene v- er you use it or store it. Any surf aces you place it on other than the ground must be firm, non-skid, and structurally sound. The gasoline engine is designed to run in a lev el posi- tion f or best performance. If you do operate it at[...]

COOLING SYSTEM The cooling system has been filled at the f actory with a 50-50 mixture of eth ylene glycol antifreeze and w ater . Check the r adiator le v el and add a 50-50 solution as needed. (See the engine manual or antifreez e con- tainer f or alternate antifreeze recommendations.) MUFFLER This welder is supplied with an adjustab le rain cap [...]

MA CHINE GROUNDING According to the United States National Electrical Code, the fr ame of this por table gener ator is not required to be grounded and is permitted to ser v e as the grounding means f or cord connected equipment plugged into its receptacle. When the Classic I is mounted on a truck or a trailer , the machine generator ground stud MUS[...]

ELECTRICAL OUTPUT CONNECTIONS See Figure A.2 f or the location of the 115V DC v olt receptacle, weld output terminals, and ground stud. WELDING CABLE CONNECTIONS CABLE INST ALLA TION AND CABLE SIZES With the engine off , route the electrode and work cables through the str ain relief brac ket on the base and connect to the terminals located below th[...]

NO TES A-8 A-8 CLASSIC I Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Section B-1 Section B-1 CLASSIC I T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Saf ety Instructions .........................................................................................................[...]

OPERA TING INSTR UCTIONS Read and understand this entire section bef ore operat- ing your Classic I. SAFETY INSTR UCTIONS Do not attempt to use this equipment until you ha ve thoroughly read all the operation and maintenance manuals supplied with y our machine. They include impor tant saf ety precautions; detailed engine star ting, operating, and m[...]

RECOMMENDED APPLICA TIONS WELDER The Classic I provides e xcellent constant current DC welding output f or stic k (SMA W) welding and for DC TIG welding. For more details on using the machine as a welder , see W elding Operation in the Operation section of this manual. GENERA T OR The Classic I is also capable of pro viding 1.75 kw of 115V DC auxil[...]

OPERA TION B-4 B-4 CLASSIC I FIGURE B.1 – OUTPUT CONTROLS 1. CURRENT RANGE SELECTOR 2. FINE CURRENT ADJUSTMENT 3. 115 V OL T DC RECEPT ACLE 4. WELD OUTPUT TERMINAL (–) 5. WELD OUTPUT TERMINAL (+) 6. GROUND STUD WELDER/GENERA T OR CONTR OLS See Figure B.1 f or the location of the f ollo wing features: 1. CURRENT RANGE SELECT OR: Selects ranges o[...]

CONTROL OF WELDING CURRENT • DO NOT turn the CURRENT RANGE SELECT OR while welding because the current ma y arc between the contacts and damage the s witch. • DO NO T attempt to set the CURRENT RANGE SELECT OR between the fiv e points designated on the nameplate. See Figure B.2. The CURRENT RANGE SELECT OR provides fiv e o verlapping current ra[...]

GASOLINE ENGINE CONTROLS See Figure B.3 f or the location of the f ollowing f eatures: 1. IDLER CONTROL T OGGLE SWITCH: Adjusts the running speed of the engine. The s witch has two positions, "HIGH" and "A UT O ." In "HIGH," the engine runs continuously at high idle. In "A UT O," the idler control works as f [...]

ENGINE OPERA TION DO NO T R UN THE ENGINE A T EXCESSIVE SPEEDS. The maximum allo wab le high idle speed for the Classic I is 1550 RPM, no load. Do NO T increase the idle speed on the engine. Se v ere personal injur y and damage to the machine can result if it is operated at speeds abov e the maximum r ated speed. Read and understand all saf ety ins[...]

ST OPPING THE ENGINE 1. Remove all w elding and generator po wer loads and let the engine cool by running it f or se v eral minutes at lo w idle. 2. Place the IGNITION switch in the OFF position. The engine controls were properly set at the factory and should require no adjusting when receiv ed. At the end of each da y’ s welding, refill the fuel[...]

WELDING OPERA TION T O USE THE CLASSIC I FOR DC CONST ANT CURRENT STICK OR TIG WELDING: 1. Remove the flange n uts from the weld output ter- minals and place the work and electrode welding cables o v er the terminals. For positiv e electrode, connect the electrode cable to the + terminal and the work cable to –. F or negativ e electrode, re v ers[...]

OPERA TION B-10 B-10 CLASSIC I T ABLE B.1 RANGE SETTINGS FOR WIRE SIZE/SPEED Diameter (inches) Wire Speed Range Appropriate Curr ent Range (inches/minute) .035 80-110 75 to 120 Amps .045 70-130 120 to 170 Amps .068 40-90 125 to 210 Amps T O USE THE CLASSIC I FOR DC WIRE FEED WELDING (CONST ANT V OL T A GE) WITH WIRE FEED MODULE: 1. Connect the LN-2[...]

T ABLE OF CONTENTS - A CCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories ...................................................................................................................C-2 Semiautomatic W elding Access[...]

OPTIONS/A CCESSORIES The f ollowing options/accessories are av ailable f or your Classic I from your local Lincoln Distrib utor . T railer (K768) - For in-plant or y ard towing at speeds under 10 m.p .h. Not intended f or highwa y towing. T railer (K780) - T wo-wheeled trailer with brak es, lights, and f enders. F or highwa y use, consult applicabl[...]

The Lincoln Electric LN-25 wire feeder is r ecommend- ed for wire feed welding with the Classic I. CONNECTION OF THE LN-25 T O THE CLASSIC I “A CROSS THE ARC” WITH WIRE FEED MODULE (SEE FIGURE C.1.) 1. Shut the welder off. 2. Connect the electrode cable fr om the LN-25 to the “+” terminal of the welder . Connect the work cable to the “CV?[...]

NO TES C-4 C-4 CLASSIC I Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Section D-1 Section D-1 CLASSIC I T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Saf ety Precautions ......................................................................................................................D[...]

SAFETY PRECA UTIONS • Ha ve qualified personnel do all maintenance and troubleshooting w ork. • T ur n the engine off before w orking inside the machine. • Remov e cov ers or guards only when necessar y to perf orm maintenance and replace them when the maintenance requiring their remov al is complete. • If covers or guards are missing from [...]

CHANGE THE OIL: Change the oil, while the engine is still warm, as follo ws: 1 . Drain the oil from the dr ain 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 le vel reaches the upper dash full mark on the dipstick. Use high quality oil viscos[...]

FUEL FIL TER: Inspect the in-line fuel filter daily . When necessar y remo v e the sediment bo wl from beneath the gas tank and clean out any accum ulated dir t and water . Change the fuel filter after the first 50 hours of opera- tion and e v er y 500 hours thereafter . AIR CLEANER: The Continental engine is equipped with a dr y type air filter . [...]

F AN BEL T : 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. T o adjust the fan belt, loosen the alterna[...]

B A TTER Y MAINTENANCE GASES FROM BA TTER Y can e xplode. • K eep sparks, flame , and cigarettes a way from batter y . BA TTER Y ACID can b urn eyes and skin. • Wear glo ves and e ye protection and be careful when working near a batter y . F ollow the instructions printed on the batter y . T o pre v ent EXPLOSION when: • INST ALLING A NEW BA [...]

WELDER/GENERA T OR MAINTENANCE ST ORA GE: Store the Classic I in clean, dr y , protected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air . Do this at least once a week in par ticularly dir ty areas. NAMEPLA TES : Whene v er routine maintenance is per- f ormed on this machine - or at least yearly - inspect a[...]

CURRENT RANGE SELECT OR CONT ACTS: The contacts should not be greased. T o keep the contacts clean, rotate the current control handle through its entire range frequently . Good practice is to tur n the handle from maximum to minimum setting twice each morning before star ting to weld. Nev er rotate the han- dle while the machine is under load. Put [...]

MAINTENANCE D-9 D-9 CLASSIC I FIGURE D .5 - MAJOR COMPONENT LOCA TIONS 11 12 9 8 15 14 16 13 7 6 5 3 4 2 1 10 1. RIGHT CASE SIDE (DOOR) 2. BASE (WITH BA TTER Y) 3. EXCITER BRUSHES 4. EXCITER 5. GENERA TOR 6. GENERA TOR BR USHES 7. OUTPUT TERMINALS 8. FUEL T ANK 9. CASE FRONT WITH CONTROL P ANEL 10. LEFT CASE SIDE 11. CASE TOP 12. CASE BACK 13. RADI[...]

NO TES D-10 D-10 CLASSIC I Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Section E-1 Section E-1 CLASSIC I Theory of Operation ............................................................................................................. Section E General Description ...............................................................................................................E-2 Batter y , Star ter , Engine Alternator a[...]

GENERAL DESCRIPTION The Classic I is a heavy duty , engine driven, DC arc welding pow er source capable of pro viding constant current output f or stick w elding or DC TIG welding. Also , a total of 1750 watts of auxiliary power is a v ailable at the 115VDC receptacle. The Classic I is manuf ac- tured with all copper windings. B A TTER Y , ST AR TE[...]

ENGINE, MAIN GENERA T OR ARMA TURE AND FRAME AND DC EXCITER EXCIT A TION (FLASHING) The main generator armature and the exciter arma- ture are mechanically coupled to the engine. When the engine is star ted and running, the residual mag- netism that is stored in the e xciter pole pieces is induced upon the e xciter armature. This causes the e xcite[...]

ENGINE, MAIN GENERA TOR ARMA TURE AND FRAME AND DC EXCITER (CONTINUED) 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. FINE CURREN[...]

DC GENERA TOR MACHINES 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. The armature coil sides are placed at opposite points on the rotating shaft with the conductors par[...]

NO TES E-6 E-6 CLASSIC I Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Section F-1 Section F-1 CLASSIC I T roubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide .......................................................................................F-2 PC Board T roubleshooting Procedures ........................[...]

HOW T O USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained 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 safet[...]

ELECTRIC SHOCK can kill. Hav e an electr ician install and service this equipment. T ur n the machine OFF bef ore working on equipment. Do not touch electrically hot par ts. Sometimes machine f ailures appear to be due to PC board f ailures. These problems can sometimes be traced to poor electrical connections. T o a v oid prob- lems when troublesh[...]

TROUBLESHOOTING & REP AIR F-4 F-4 CLASSIC I Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. 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 b[...]

TROUBLESHOOTING & REP AIR F-5 F-5 CLASSIC I TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. 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 b[...]

TROUBLESHOOTING & REP AIR F-6 F-6 CLASSIC I Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. 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 b[...]

TROUBLESHOOTING & REP AIR F-7 F-7 CLASSIC I TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. 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 b[...]

TROUBLESHOOTING & REP AIR F-8 F-8 CLASSIC I Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. 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 b[...]

TROUBLESHOOTING & REP AIR F-9 F-9 CLASSIC I TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. 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 b[...]

TROUBLESHOOTING & REP AIR F-10 F-10 CLASSIC I Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. 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[...]

TROUBLESHOOTING & REP AIR F-11 F-11 CLASSIC I TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. 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[...]

F-12 F-12 CLASSIC I TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. 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[...]

TROUBLESHOOTING & REP AIR F-13 F-13 CLASSIC I DC EXCITER TEST W ARNING 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 ele[...]

TR OUBLESHOO TING & REP AIR F-14 F-14 CLASSIC I SERIES COIL CONNECTION POINT (NEGA TIVE) POSITIVE FIGURE F .1 – 120VDC RECEPT ACLE DC EXCITER TEST (continued) TEST PROCEDURE 1. T urn off the engine and remov e all e xternal loads to the welder terminals and auxiliar y receptacle. MO VING P ARTS can injure. • Remov e guards only when necessa[...]

TR OUBLESHOO TING & REP AIR F-15 F-15 CLASSIC I DC EXCITER TEST (continued) EXITER COVER WARRANTY CHECK VOLTAGE A T BRUSH HOLDERS HERE (RIGHT SIDE IS +) + FIGURE F .2 – EXCITER COVER REMOV AL 4. T urn off the engine. Using the 3/8” nut driver , remov e the e xciter cover . See Figure F .2. MO VING P ARTS can injure. • Remov e guards only [...]

TR OUBLESHOO TING & REP AIR F-16 F-16 CLASSIC I WHITE FLEX LEAD SMALL FLEX LEAD SOLID LEAD WARRANTY FIGURE F .3 – BRUSH HOLDER LEADS Shunt Coil and Series Coil Resistance T ests 7. T ur n the engine OFF . 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[...]

TROUBLESHOOTING & REP AIR F-17 F-17 CLASSIC I W ARNING IDLER SOLENOID TEST 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[...]

TR OUBLESHOO TING & REP AIR F-18 F-18 CLASSIC I IDLER SOLENOID TEST (continued) FIGURE F .4 – IDLER SOLENOID CONNECTIONS QUICK CONNECT LEADS TEST PROCEDURE 1. T urn 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. 4. Disconnect the two solenoid l[...]

TROUBLESHOOTING & REP AIR F-19 F-19 CLASSIC I W ARNING MAIN GENERA TOR SHUNT FIELD WINDING TEST 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 you[...]

TR OUBLESHOO TING & REP AIR F-20 F-20 CLASSIC I MAIN GENERA T OR SHUNT FIELD WINDING TEST (continued) FIGURE F .5 – PLUG P10 LOCA TION PLUG P10 TEST PROCEDURE 1. T urn the engine OFF . 2. Unlatch, lift and secure the right side door . 3. Locate plug P10. See Figure F .5. 4. Remov e plug P10. Return to Section TOC Return to Section TOC Return [...]

TROUBLESHOOTING & REP AIR F-21 F-21 CLASSIC I MAIN GENERA TOR SHUNT FIELD WINDING TEST (continued) FIGURE F .6 – PLUG P10 PIN ASSIGNMENTS PIN 3 PIN 5 TA B 5. Locate the blue (U) (pin 3) and the brown (N) (pin 5) leads in the harness plug. See Figure F .6. 6. Using the volt/ohmmeter , measure the resis- tance between the blue and the brown lea[...]

TROUBLESHOOTING & REP AIR F-22 F-22 CLASSIC I W ARNING ENGINE THROTTLE ADJUSTMENT TEST 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 [...]

TR OUBLESHOO TING & REP AIR F-23 F-23 CLASSIC I ENGINE THR O TTLE ADJUSTMENT TEST (continued) FIGURE F .7 – BLOWER P ADDLE MARK LOCA TION BLOWER P ADDLE MARK TEST PROCEDURE Strobe T ach Method 1. Conduct this procedure with the engine OFF . 2. Unlatch, lift, and secure the right and left side doors. 3. With the white or red marking pencil, pl[...]

TR OUBLESHOO TING & REP AIR F-24 F-24 CLASSIC I ENGINE THR O TTLE ADJUSTMENT TEST (continued) 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 gov ernor on the left side of the engine. See Figure F .8. d. Using the 3/8” wrench to tur n the adjustment screw and loc kin[...]

TR OUBLESHOO TING & REP AIR F-25 F-25 CLASSIC I ENGINE THR O TTLE ADJUSTMENT TEST (continued) FIGURE F .9 – LOW IDLE ADJUSTMENT SPEED ADJUSTMENT SCREW LOCKING NUT IDLER ROD Adjust Low Idle a. Make sure there is no load on the machine . b . Set the Idler switch to A UT O and w ait f or the engine to change to low idle speed. c. Check the align[...]

TROUBLESHOOTING & REP AIR F-26 F-26 CLASSIC I W ARNING FLASHING THE FIELDS 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[...]

TR OUBLESHOO TING & REP AIR F-27 F-27 CLASSIC I FLASHING THE FIELDS (continued) FIGURE F .10 – EXCITER CO VER REMO V AL EXITER COVER PROCEDURE 1. T urn the engine OFF . 2. Using the 3/8” wrench, remov e the exciter cov er . See Figure F .10. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Ma[...]

TR OUBLESHOO TING & REP AIR F-28 F-28 CLASSIC I FLASHING THE FIELDS (continued) FIGURE F .11 - BRUSH HOLDER/B A TTER Y JUMPER CONNECTIONS + RAISE EXCITER BRUSH OFF COMMUT A T OR TO POSITIVE BA TTERY TERMINAL TO NEGATIVE BA TTERY TERMINAL WARRANTY 3. Raise one e xciter brush off the ar mature com- mutator . 4. Using the jumper leads and the 12VD[...]

TR OUBLESHOO TING & REP AIR F-29 F-29 CLASSIC I This is the typical auxiliar y output v oltage generated from a properly operating machine . Note that each v er tical division represents 50 volts and that each horizontal division represents 2 milliseconds in time. Note: Scope probes connected at machine 115VDC receptacle. SCOPE SETTINGS V olts/[...]

TR OUBLESHOO TING & REP AIR F-30 F-30 CLASSIC I This is the typical DC welding output v oltage generated from a properly operating machine . Note that each v er tical division represents 50 volts and that each horizontal division represents 5 milliseconds in time. Note: Scope probes connected at machine output terminals. SCOPE SETTINGS V olts/D[...]

TR OUBLESHOO TING & REP AIR F-31 F-31 CLASSIC I This is the typical DC welding output v oltage generated from a properly operating machine . Note that each v er tical 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 [...]

TROUBLESHOOTING & REP AIR F-32 F-32 CLASSIC I W ARNING DC EXCITER ARMA TURE AND FIELD COILS REMOV AL AND REPLACEMENT 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 facto[...]

TR OUBLESHOO TING & REP AIR F-33 F-33 CLASSIC I DC EXCITER ARMA TURE AND FIELD COILS REMO V AL AND REPLA CEMENT (continued) FIGURE F .12 – EXCITER CO VER REMO V AL ARMA TURE BRUSH HOLDER ASSEMBL Y (2) EXITER FRAME POLE PIECE BOL TS (4) EXITER COVER ARMA TURE LOCKING NUT FLA T W ASHER SLEEVE COLLAR PROCEDURE DC Exciter Armature Remov al Pr oce[...]

TR OUBLESHOO TING & REP AIR F-34 F-34 CLASSIC I DC EXCITER ARMA TURE AND FIELD COILS REMO V AL AND REPLA CEMENT (continued) Field Coils Remov al Pr ocedure 1. P erform the DC Exciter Armature Remov al Procedure. 2. Using the 3/8” wrench, remove the leads from the brush holder . Note lead placement f or reassembly . 3. Using the 1/2” wrench,[...]

TROUBLESHOOTING & REP AIR F-35 F-35 CLASSIC I W ARNING MAIN GENERA TOR FRAME REMOV AL AND REPLACEMENT 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 . F[...]

TR OUBLESHOO TING & REP AIR F-36 F-36 CLASSIC I MAIN GENERA T OR FRAME REMO V AL AND REPLA CEMENT (continued) FIGURE F .13 – BA TTER Y P ANEL REMOV AL NEGA TIVE BA TTERY CABLE PROCEDURE 1. T urn the engine OFF . 2. Using the 7/16” wrench, remov e the two bolts and washers and par tially slide out the battery mounting panel. See Figure F .13[...]

TR OUBLESHOO TING & REP AIR F-37 F-37 CLASSIC I MAIN GENERA T OR FRAME REMO V AL AND REPLA CEMENT (continued) FIGURE F .14 – TOP AND DOORS ASSEMBL Y DET AILS BOL T / NUT (4) 'L' DOOR HOOKS (4) 4. Using the 1/2” wrench, remove the f our nuts and bolts holding the case top and doors assembly to the w elder frame . Remove the rubber [...]

TR OUBLESHOO TING & REP AIR F-38 F-38 CLASSIC I MAIN GENERA T OR FRAME REMO V AL AND REPLA CEMENT (continued) FIGURE F .15 – FUEL T ANK MOUNTING DET AILS BOL TS / NUTS / W ASHERS (4) FUEL T ANK FUEL BOWL RAILS FUEL LINE 5. P erform the DC Exciter Armature Remov al Procedure. 6. T urn off the fuel supply at the fuel bowl and remov e the fuel l[...]

TR OUBLESHOO TING & REP AIR F-39 F-39 CLASSIC I FIGURE F .16 – SELECTOR SWITCH LEAD REMOV AL SELECTOR SWITCH TERMINAL LEAD (5) A C B D E 9. Using the 1/2” wrench, remove the fiv e heavy fle x leads from the selector s witch terminals. Label the leads f or reassembly . See Figure F .16. FIGURE F .17 – OUTPUT TERMINAL LEAD REMOV AL COPPER S[...]

TR OUBLESHOO TING & REP AIR F-40 F-40 CLASSIC I FIGURE F .18 – CHOKE CONTROL CABLE REMOV AL LOOSEN HERE CHOKE CABLE 12. Using the slot head screw driv er , remove the choke control cab le from the engine carb ure- tor assembly . Mark cable replacement f or reassembly . See Figure F .18. MAIN GENERA T OR FRAME REMO V AL AND REPLA CEMENT (conti[...]

TR OUBLESHOO TING & REP AIR F-41 F-41 CLASSIC I FIGURE F .19 – FRONT P ANEL WIRING CONNECTIONS A C B D E 15. SHUNT LEADS QUICK DISCONNECT 13. RED LEAD TO DC RECEPT ACLE 19. 20. BLUE AND BLACK LEADS TO AMMETER 17. RED LEADS TO IGNITION SWITCH 21. YELLOW LEAD TO IDLER SWITCH 22. BROWN LEAD TO IDLER SWITCH 16. "H" LEAD TO ST ART BUTTON[...]

TR OUBLESHOO TING & REP AIR F-42 F-42 CLASSIC I FIGURE F .20 – FRONT P ANEL F ASTENER REMOV AL BOL TS / NUTS / W ASHERS (2) BASE MOUNTING BOL TS (4) MIDDLE SCREW (1) 23. Using the 1/2” wrench, remov e the two bolts , nuts, and w ashers that hold the front panel assembly to the horizontal r ails. (There is one on each side.) See Figure F .20[...]

TR OUBLESHOO TING & REP AIR F-43 F-43 CLASSIC I FIGURE F .21 – BRUSH BRACKET WRAP-AROUND COVER BRUSH BRACKET WRAP- AROUND COVER REMOVE (2) NUTS, W ASHERS, AND SCREWS 27. Using the slot head screw driv er , remove the two scre ws and nuts from the brush brack et wrap-around cov er . Remov e the cov er . See Figure F .21. MAIN GENERA T OR FRAME[...]

TR OUBLESHOO TING & REP AIR F-44 F-44 CLASSIC I FIGURE F .23 – MAIN GENERA TOR FEET MOUNTING MAIN GENERA T OR REMOVE MOUNTING NUTS, WASHERS, AND BOL TS FEET (2) 30. Using the 3/4” wrench, remov e the frame mounting bolts, nuts , and w ashers from the f eet of the main generator . See Figure F .23. MAIN GENERA T OR FRAME REMO V AL AND REPLA [...]

TR OUBLESHOO TING & REP AIR F-45 F-45 CLASSIC I 33. Using the rope sling and pr y bars, carefully lift and “wiggle” the gener ator frame a wa y from the engine and ar mature assembly . Be careful to suppor t the generator fr ame as you remov e it. NO TE: The exciter fr ame is also remov ed with the main generator frame . Reassembl y: Ref er[...]

TR OUBLESHOO TING & REP AIR F-46 F-46 CLASSIC I W ARNING MAIN GENERA T OR ARMA TURE REMO V AL AND REPLA CEMENT Ser vice and repair should be perf or med b y only Lincoln Electric factory trained personnel. Unauthorized repairs perf ormed on this equipment may result in danger to the technician or machine operator and will in v alidate your f ac[...]

TR OUBLESHOO TING & REP AIR F-47 F-47 CLASSIC I MAIN GENERA T OR ARMA TURE REMO V AL AND REPLA CEMENT (continued) FIGURE F .25 – MAIN GENERA TOR ARMA TURE MOUNTING MOUNTING BOL TS / LOCK W ASHERS (8) BLOWER P ADDLE SLING PROCEDURE 1. T urn the engine OFF . 2. P erform the DC Exciter Armature Remov al procedure. 3. P erf or m the Main Generato[...]

TR OUBLESHOO TING & REP AIR F-48 F-48 CLASSIC I RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for an y reason that requires y ou to remov e any mechanical par t which could aff ect the machine’ s electr ical characteristics. OR • If you repair or replace an y electrical components. ENGINE OUTPUT Mode No Load RPM Lo[...]

ELECTRICAL DIAGRAMS G-1 G-1 CLASSIC I Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Electrical Diagrams Section .......................................................................................... Section G Wiring Diagram ....................................................................................[...]

ELECTRICAL DIAGRAMS G-2 G-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-2 CLASSIC I WIRING DIAGRAM - CLASSIC I MOTOR + GROUND GROUND TO BASE TO ENGINE EXC ALTERNATOR S B + STARTING OIL PRESSURE SWITCH[...]

ELECTRICAL DIAGRAMS G-3 CLASSIC I WIRING DIAGRAM - WIRE FEED MODULE 3-18-94 L9259 AMPHENOL 1 A D F 510 602 610A 503A 609 501 CONTACTOR CONTACTOR ++ + 622 666 633 75A 76 77 75 R501 630 631 CV CONTROL 4 667 634 J2 J3 501 631 600 608 610A 509 503A 630 503 J4 2 1 GND 31 32 609 610A 510 501 503A 602 75 76 77 2 4 J1 E G J 32 31 4A GND 2A 77B 76B 75A 76B [...]

ELECTRICAL DIAGRAMS G-4 CLASSIC I SCHEMA TIC - IDLER PC BOARD EARTH GROUND CONNECTION M VOLTAGE NET FRAME CONNECTION 8 R- 20 NO. 10 COMMON CONNECTION TO SOLENOID LAST NO. USED TO BATTERY EQUIP. SUBJECT Y 16990 M B TO FRAME GND THRU MOUNTING SCREW GENERAL INFORMATION NONE (UNLESS OTHERWISE SPECIFIED) 2/10/93 ELECTRICAL SYMBOLS PER E1537 UNLESS OTHER[...]

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 troub[...]