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Lincoln Electric CLASSIC I SVM134-A Service Manual

Lincoln electric welder user manual
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RETURN TO MAIN INDEX
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
CONTAINED
THROUGHOUT.
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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Summary of Contents for Lincoln Electric CLASSIC I SVM134-A

  • Page 1 RETURN TO MAIN INDEX SVM134-A October, 2000 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 ...

  • Page 2: Safety

    Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    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.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent 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.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ 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: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS 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...
  • Page 7 Section A-1 - INSTALLATION SECTION - Installation 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...

  • Page 8: Installation

    TM27 Water-cooled gasoline 38 HP @ 1450 RPM Duty Cycle 60% Duty Cycle OUTPUT - WELDER AND GENERATOR Welding Ranges Max. Open Circuit Voltage 40-300 Amps DC Height 40.9 in. 1040 mm Lincoln rating. Nema rating at 60% duty cycle is 200 DC amps / 28V.

  • Page 9: Safety Precautions

    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.

  • Page 10: Pre-Operation Engine Service

    Lift only with equipment of adequate lifting capacity. Be sure machine is stable when lifting. HIGH ALTITUDE OPERATION It may be necessary to derate welder output at higher altitudes. Some engine adjustment may be required. Contact a Continental Service Representative.

  • Page 11: Cooling System

    (See the engine manual or antifreeze con- tainer for alternate antifreeze recommendations.) 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.

  • Page 12: Machine Grounding

    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).

  • Page 13: Electrical Output Connections

    Cable diameters are increased for long cable lengths to reduce voltage drops. Lincoln Electric offers a welding accessory kit with the properly specified welding cables. See the Accessories section of this manual for more information.
  • Page 14 NOTES CLASSIC I...
  • Page 15 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...

  • Page 16: Operation

    OPERATING INSTRUCTIONS Read and understand this entire section before operat- ing your Classic I. SAFETY INSTRUCTIONS 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;...

  • Page 17: Recommended Applications

    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. GENERATOR The Classic I is also capable of providing 1.75 kw of...

  • Page 18: Controls And Settings

    CONTROLS AND SETTINGS The welder/generator controls are located on the Output Control Panel of the machine case front. Engine idler control and start/stop controls are also on WELDER/GENERATOR CONTROLS See Figure B.1 for the location of the following features: 1. CURRENT RANGE SELECTOR: Selects ranges...

  • Page 19: Control Of Welding Current

    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.

  • Page 20: Gasoline Engine Controls

    FIGURE B.3 – GASOLINE ENGINE CONTROLS 1. IDLER CONTROL TOGGLE SWITCH 2. IGNITION TOGGLE SWITCH 3. OIL PRESSURE LIGHT 4. START PUSHBUTTON 5. CHOKE CONTROL 6. ENGINE HOUR METER 7. AMMETER GASOLINE ENGINE CONTROLS See Figure B.3 for the location of the following features: 1.

  • Page 21: Engine Operation

    ENGINE OPERATION WARNING 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.

  • Page 22: Stopping The Engine

    Check the crankcase oil level. 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.

  • Page 23: Welding Operation

    + terminal and the work cable to –. For negative electrode, reverse the electrode and work cables at the welder’s output terminals. Replace and tighten the flange nuts securely. Be sure the connections are tight. 2. Select the appropriate electrode.

  • Page 24: Auxiliary Power

    B-10 TO USE THE CLASSIC I FOR DC WIRE FEED WELDING (CONSTANT VOLTAGE) WITH WIRE FEED MODULE: 1. Connect the LN-25 Wire Feeder. Follow the instal- lation instructions provided with the wire feeder. 2. Set the wire feeder and Classic I for CV operation. 3.
  • Page 25 Section C-1 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 TABLE OF CONTENTS - ACCESSORIES - CLASSIC I Section C-1...
  • Page 26 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.)

  • Page 27: Connection Of Lincoln Electric Wire Feeders

    CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS The Lincoln Electric LN-25 wire feeder is recommend- ed for wire feed welding with the Classic I. CONNECTION OF THE LN-25 TO THE CLASSIC I “ACROSS THE ARC” WITH WIRE FEED MODULE (SEE FIGURE C.1.) 1.
  • Page 28 NOTES CLASSIC I...
  • Page 29 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...

  • Page 30: Safety Precautions

    SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. •...

  • Page 31: Fuel

    CHANGE THE OIL: Change the oil, while the engine is still warm, as follows: 1 . Drain the oil from the drain plug located on the engine bottom, as shown in Figure D.1. 2. Replace the plug and tighten it securely. 3.

  • Page 32: Fuel Filter

    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. AIR CLEANER: The Continental engine is equipped with a dry type air filter.

  • Page 33: Fan Belt

    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.

  • Page 34: Battery Maintenance

    GROUND - Damage to the engine alternator and the printed circuit board can result from incorrect connection. • 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.

  • Page 35: Welder/Generator Maintenance

    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. CAUTION DO NOT SHIFT THE BRUSHES or adjust the rocker setting.

  • Page 36: Current Range Selector Contacts

    (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.

  • Page 37: Major Component Locations

    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 9. CASE FRONT WITH CONTROL PANEL 10. LEFT CASE SIDE 11.
  • Page 38 D-10 D-10 NOTES CLASSIC I...
  • Page 39 Section E-1 -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...

  • Page 40: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 – BATTERY, STARTER, ENGINE ALTERNATOR AND OIL SWITCH CIRCUIT IDLER BOARD ENGINE PRESSURE HOUR LIGHT METER PRESSURE SWITCH FUEL SHUTDOWN ENGINE ENGINE IGNITION IGNITION ENGINE SWITCH ALTERNATOR STARTER MOTOR BATTERY GENERAL DESCRIPTION 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.

  • Page 41: Engine, Main Generator Armature And Frame And Dc Exciter

    THEORY OF OPERATION FIGURE E.3 – ENGINE, MAIN GENERATOR ARMATURE AND FRAME AND DC EXCITER IDLER BOARD ENGINE PRESSURE HOUR LIGHT METER PRESSURE SWITCH FUEL SHUTDOWN ENGINE ENGINE IGNITION IGNITION ENGINE SWITCH ALTERNATOR STARTER MOTOR BATTERY ENGINE, MAIN GENERATOR ARMATURE AND FRAME AND DC EXCITER EXCITATION (FLASHING) The main generator armature and the exciter arma-...

  • Page 42: Current Range Selector

    THEORY OF OPERATION ENGINE, MAIN GENERATOR ARMATURE 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.

  • Page 43: Dc Generator Machines

    THEORY OF OPERATION DC GENERATOR 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.
  • Page 44 NOTES CLASSIC I...
  • Page 45 Section F-1 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...

  • Page 46: Troubleshooting And Repair

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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.

  • Page 47: Pc Board Troubleshooting Procedures

    • 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.

  • Page 48: Troubleshooting Guide

    DC auxiliary output voltage. 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.
  • Page 49 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.
  • Page 50 The engine is operating correctly. 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. POSSIBLE AREAS OF...
  • Page 51 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.
  • Page 52 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. POSSIBLE AREAS OF...
  • Page 53 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. detailed in the beginning of this manual.
  • Page 54 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. POSSIBLE AREAS OF...
  • Page 55 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.
  • Page 56 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. detailed in the beginning of this manual.

  • Page 57: Dc Exciter Test

    F-13 TROUBLESHOOTING & REPAIR 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.
  • Page 58 F-14 TROUBLESHOOTING & REPAIR DC EXCITER TEST (continued) TEST PROCEDURE 1. Turn off the engine and remove all external loads to the welder terminals and auxiliary receptacle. WARNING MOVING PARTS can injure. • Remove guards only when necessary to perform service,...
  • Page 59 F-15 TROUBLESHOOTING & REPAIR DC EXCITER TEST (continued) EXITER COVER 4. Turn off the engine. Using the 3/8” nut driver, remove the exciter cover. See Figure F.2. WARNING MOVING PARTS can injure. • Remove guards only when necessary to perform service, and replace them when the service requiring their removal is complete.
  • Page 60 F-16 TROUBLESHOOTING & REPAIR DC EXCITER TEST (continued) Shunt Coil and Series Coil Resistance Tests 7. Turn 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 will be a larger "solid"...

  • Page 61: Idler Solenoid Test

    F-17 TROUBLESHOOTING & REPAIR 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.
  • Page 62 F-18 TROUBLESHOOTING & REPAIR IDLER SOLENOID TEST (continued) FIGURE F.4 – IDLER SOLENOID CONNECTIONS QUICK CONNECT LEADS TEST PROCEDURE 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.

  • Page 63: Main Generator Shunt Field Winding Test

    TROUBLESHOOTING & REPAIR MAIN GENERATOR 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 your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 64 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.
  • Page 65 F-21 TROUBLESHOOTING & REPAIR MAIN GENERATOR SHUNT FIELD WINDING TEST (continued) FIGURE F.6 – PLUG P10 PIN ASSIGNMENTS PIN 5 5. Locate the blue (U) (pin 3) and the brown (N) (pin 5) leads in the harness plug. Figure F.6. 6.

  • Page 66: Engine Throttle Adjustment Test

    TROUBLESHOOTING & REPAIR 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 and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 67 F-23 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.7 – BLOWER PADDLE MARK LOCATION BLOWER PADDLE MARK TEST PROCEDURE Strobe Tach Method 1. Conduct this procedure with the engine OFF. 2. Unlatch, lift, and secure the right and left side doors.
  • Page 68 F-24 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.8 – HIGH IDLE ADJUSTMENT GOVERNOR 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.
  • Page 69 F-25 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.9 – LOW IDLE ADJUSTMENT IDLER LOCKING Adjust Low Idle a. Make sure there is no load on the machine. b. Set the Idler switch to AUTO and wait for the engine to change to low idle speed.

  • Page 70: Flashing The Fields

    F-26 TROUBLESHOOTING & REPAIR 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.
  • Page 71 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. CLASSIC I F-27...
  • Page 72 F-28 TROUBLESHOOTING & REPAIR FLASHING THE FIELDS (continued) FIGURE F.11 - BRUSH HOLDER/BATTERY JUMPER CONNECTIONS TO NEGATIVE BATTERY TERMINAL 3. Raise one exciter brush off the armature com- mutator. 4. Using the jumper leads and the 12VDC bat- tery, first attach the clip of one lead to the POSITIVE terminal of the battery.

  • Page 73: Normal Open Circuit Voltage Waveform (115Vdc Supply

    F-29 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VDC SUPPLY) HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM 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.

  • Page 74: Normal Open Circuit Dc Weld Voltage Waveform

    F-30 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AND SELECTOR SWITCH AT MAXIMUM 50 volts 5 ms This is the typical DC welding output voltage generated from a properly operating machine.

  • Page 75: Typical Dc Weld Voltage Waveform, Machine Loaded

    F-31 TROUBLESHOOTING & REPAIR TYPICAL DC WELD VOLTAGE WAVEFORM MACHINE LOADED – SELECTOR SWITCH AT MAXIMUM 20 volts MACHINE LOADED TO 200 AMPS AT 40VDC 5 ms 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.

  • Page 76: Dc Exciter Armature And Field Coils Removal And Replacement

    DC EXCITER ARMATURE AND FIELD COILS REMOVAL 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. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 77 F-33 TROUBLESHOOTING & REPAIR DC EXCITER ARMATURE AND FIELD COILS REMOVAL AND REPLACEMENT (continued) FIGURE F.12 – EXCITER COVER REMOVAL EXITER COVER PROCEDURE DC Exciter Armature Removal Procedure 1. Turn the engine OFF. 2. Using the 3/8” nut driver, remove the exciter cover.
  • Page 78 F-34 TROUBLESHOOTING & REPAIR DC EXCITER ARMATURE AND FIELD COILS REMOVAL AND REPLACEMENT (continued) Field Coils Removal Procedure 1. Perform the DC Exciter Armature Removal Procedure. 2. Using the 3/8” wrench, remove the leads from the brush holder. Note lead placement for reassembly.

  • Page 79: Main Generator Frame Removal And Replacement

    TROUBLESHOOTING & REPAIR REMOVAL 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. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 80 F-36 TROUBLESHOOTING & REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.13 – BATTERY PANEL REMOVAL NEGATIVE BATTERY CABLE PROCEDURE 1. Turn the engine OFF. 2. Using the 7/16” wrench, remove the two bolts and washers and partially slide out the battery mounting panel.
  • Page 81 FIGURE F.14 – TOP AND DOORS ASSEMBLY DETAILS 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.
  • Page 82 F-38 TROUBLESHOOTING & REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.15 – FUEL TANK MOUNTING DETAILS FUEL TANK 5. Perform the DC Exciter Armature Removal Procedure. 6. Turn off the fuel supply at the fuel bowl and remove the fuel line. Plug the line to avoid spillage.
  • Page 83 F-39 TROUBLESHOOTING & REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.16 – SELECTOR SWITCH LEAD REMOVAL SELECTOR SWITCH TERMINAL LEAD (5) 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.
  • Page 84 F-40 TROUBLESHOOTING & REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.18 – CHOKE CONTROL CABLE REMOVAL 12. Using the slot head screw driver, remove the choke control cable from the engine carbure- tor assembly. Mark cable replacement for reassembly.
  • Page 85 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 21. YELLOW LEAD TO IDLER SWITCH 17. RED LEADS TO IGNITION SWITCH 16.
  • Page 86 F-42 TROUBLESHOOTING & REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.20 – FRONT PANEL FASTENER REMOVAL MIDDLE SCREW (1) 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.
  • Page 87 F-43 TROUBLESHOOTING & REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.21 – BRUSH BRACKET 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.
  • Page 88 F-44 TROUBLESHOOTING & REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.23 – MAIN GENERATOR FEET MOUNTING 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 –...
  • Page 89 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. 16. Using the 1/2” wrench, install the negative battery cable.

  • Page 90: Main Generator Armature Removal And Replacement

    MAIN GENERATOR ARMATURE REMOVAL 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. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 91 F-47 TROUBLESHOOTING & REPAIR MAIN GENERATOR ARMATURE REMOVAL AND REPLACEMENT (continued) FIGURE F.25 – MAIN GENERATOR ARMATURE MOUNTING PROCEDURE 1. Turn the engine OFF. 2. Perform the DC Exciter Armature Removal procedure. 3. Perform the Main Generator Frame Removal procedure. 4.

  • Page 92: Retest After Repair

    Open Circuit Voltage 123-132 Exciter DC Volts 123 - 132 RETEST AFTER REPAIR ENGINE OUTPUT No Load RPM 1000-1050 1550-1650 WELDER DC OUTPUT Open Circuit Voltage 88-95 Load Volts 115-125 FIELD AMPS AND VOLTS (Current Rheostat at Maximum) Main Shunt Field Amps 2.35-2.65...
  • Page 93 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 CLASSIC I...
  • Page 94 WIRING DIAGRAM - CLASSIC I 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. ELECTRICAL DIAGRAMS ELECTRICAL DIAGRAMS CLASSIC I - WIRING DIAGRAM...
  • Page 95 ELECTRICAL DIAGRAMS WIRING DIAGRAM - WIRE FEED MODULE WIRE FEED MODULE - WIRING DIAGRAM NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. CLASSIC I...
  • Page 96 ELECTRICAL DIAGRAMS SCHEMATIC - IDLER PC BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. CLASSIC I...
  • Page 97 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.

This manual is also suitable for:

Classic i

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