Page 2 - SAFETY; CLASSIC I; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
SAFETY i i CLASSIC I FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine ex...
Page 3 - ii; ELECTRIC SHOCK can kill.
SAFETY ii ii CLASSIC I ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made fr...
Page 4 - iii
CLASSIC I FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equip...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
SAFETY iv iv CLASSIC I 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 cont...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
MASTER TABLE OF CONTENTS FOR ALL SECTIONS v v CLASSIC I Page Safety .................................................................................................................................................i-iv Installation ........................................................................
Page 7 - TABLE OF CONTENTS; Tilting
TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Section A-1 CLASSIC I Installation Technical Specifications ..............................................................................................................A-2 Safety Precautions .......................................................
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS - CLASSIC I
INSTALLATION A-2 A-2 CLASSIC I TECHNICAL SPECIFICATIONS - 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 Water-cooled Full load (2700 cc) Type (57 liters) gasoline Elect...
Page 9 - STORING
Read this entire installation section before youstart installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you havethoroughly read all the operation and maintenancemanuals supplied with your machine. They include important safety precautions; detailed engine starting,operating...
Page 10 - PRE-OPERATION ENGINE SERVICE; Operation and Maintenance sec-
STACKING Classic I machines CANNOT be stacked. TILTING Place the machine on a secure, level surface whenev-er you use it or store it. Any surfaces you place it onother than the ground must be firm, non-skid, andstructurally sound. The gasoline engine is designed to run in a level posi-tion for best ...
Page 11 - Design capacity of the trailer vs. the weight of the; CAUTION
COOLING SYSTEM The cooling system has been filled at the factory with a50-50 mixture of ethylene glycol antifreeze and water.Check the radiator level and add a 50-50 solution asneeded. (See the engine manual or antifreeze con-tainer for alternate antifreeze recommendations.) MUFFLER This welder is s...
Page 12 - MACHINE GROUNDING; See
MACHINE GROUNDING According to the United States National ElectricalCode, the frame of this portable generator is notrequired to be grounded and is permitted to serve asthe grounding means for cord connected equipmentplugged into its receptacle. When the Classic I is mounted on a truck or a trailer,...
Page 13 - WELDING CABLE CONNECTIONS; • Loose connections will cause the output terminals to
ELECTRICAL OUTPUT CONNECTIONS See Figure A.2 for the location of the 115V DC voltreceptacle, weld output terminals, and ground stud. WELDING CABLE CONNECTIONS CABLE INSTALLATION AND CABLE SIZES With the engine off, route the electrode and workcables through the strain relief bracket on the base andc...
Page 14 - NOTES
NOTES A-8 A-8 CLASSIC I Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC
Page 15 - Operation
Section B-1 Section B-1 CLASSIC I TABLE OF CONTENTS - OPERATION SECTION - Operation ............................................................................................................................... Section B Safety Instructions..............................................................
Page 16 - GENERAL DESCRIPTION; OPERATION
OPERATING INSTRUCTIONS Read and understand this entire section before operat-ing your Classic I. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you havethoroughly read all the operation and maintenancemanuals supplied with your machine. They include important safety precautions; deta...
Page 17 - RECOMMENDED APPLICATIONS; WELDER; Welding Operation in the Operation; GENERATOR; Engine Operation in the Operation; DESIGN FEATURES; Welding Operation section of this
RECOMMENDED APPLICATIONS WELDER The Classic I provides excellent constant current DCwelding output for stick (SMAW) welding and for DCTIG welding. For more details on using the machine asa welder, see Welding Operation in the Operation section of this manual. GENERATOR The Classic I is also capable ...
Page 18 - WELDER/GENERATOR CONTROLS; See Figure B.1 for the location of the following features:; CURRENT RANGE SELECTOR: Selects ranges; CONTROLS AND SETTINGS
OPERATION B-4 B-4 CLASSIC I FIGURE B.1 – OUTPUT CONTROLS 1. CURRENT RANGE SELECTOR2. FINE CURRENT ADJUSTMENT3. 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 R...
Page 19 - CONTROL OF WELDING CURRENT; • DO NOT turn the CURRENT RANGE SELECTOR; FIGURE B.2 – CURRENT CONTROLS
CONTROL OF WELDING CURRENT • DO NOT turn the CURRENT RANGE SELECTOR while welding because the current may arc betweenthe contacts and damage the switch. • DO NOT attempt to set the CURRENT RANGE SELECTOR between the five points designated onthe nameplate. See Figure B.2. The CURRENT RANGE SELECTORpr...
Page 20 - GASOLINE ENGINE CONTROLS
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 twopositions, "HIGH" and "AUTO." In "HIGH," theengine runs continuously at high idle. In "AUTO,"...
Page 21 - ENGINE OPERATION; BEFORE STARTING THE ENGINE; Check and fill the engine oil level:; STARTING THE ENGINE
ENGINE OPERATION DO NOT RUN THE ENGINE AT EXCESSIVESPEEDS. The maximum allowable high idle speed forthe Classic I is 1550 RPM, no load. Do NOT increasethe idle speed on the engine. Severe personal injuryand damage to the machine can result if it is operatedat speeds above the maximum rated speed. Re...
Page 22 - STOPPING THE ENGINE; Place the IGNITION switch in the OFF position.; COLD WEATHER STARTING; Maintenance section of this manual.; Also see the Engine manual.
STOPPING THE ENGINE 1. Remove all welding and generator power loadsand let the engine cool by running it for severalminutes at low idle. 2. Place the IGNITION switch in the OFF position. The engine controls were properly set at the factoryand should require no adjusting when received. At the end of ...
Page 23 - WELDING OPERATION
WELDING OPERATION TO USE THE CLASSIC I FOR DCCONSTANT CURRENT STICK OR TIGWELDING: 1. Remove the flange nuts from the weld output ter-minals and place the work and electrode weldingcables over the terminals. For positive electrode,connect the electrode cable to the + terminal andthe work cable to –....
Page 24 - AUXILIARY POWER; Accessories section of this manual.
OPERATION B-10 B-10 CLASSIC I TABLE B.1 RANGE SETTINGS FOR WIRE SIZE/SPEED Diameter (inches) Wire Speed Range Appropriate Current Range (inches/minute) .035 80-110 75 to 120 Amps .045 70-130 120 to 170 Amps .068 40-90 125 to 210 Amps TO USE THE CLASSIC I FOR DC WIREFEED WELDING (CONSTANT VOLTAGE)WIT...
Page 25 - Accessories
TABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories .......................................................................................................
Page 26 - SEMIAUTOMATIC WELDING ACCESSORIES; ACCESSORIES
OPTIONS/ACCESSORIES The following options/accessories are available for yourClassic I from your local Lincoln Distributor. Trailer (K768) - For in-plant or yard towing at speedsunder 10 m.p.h. Not intended for highway towing. Trailer (K780) - Two-wheeled trailer with brakes, lights,and fenders. For ...
Page 27 - NOTE: Welding cable must be sized for current
The Lincoln Electric LN-25 wire feeder is recommend-ed for wire feed welding with the Classic I. CONNECTION OF THE LN-25 TO THECLASSIC I “ACROSS THE ARC” WITHWIRE FEED MODULE (SEE FIGURE C.1.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-25 to the “+” terminal of the welder. Co...
Page 29 - Maintenance
Section D-1 Section D-1 CLASSIC I TABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Safety Precautions ..........................................................................
Page 30 - SAFETY PRECAUTIONS; ENGINE MAINTENANCE; MAINTENANCE; CONTINENTAL ENGINE MAINTENANCE SCHEDULE
SAFETY PRECAUTIONS • 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 themaintenance requiring their removal is complete. • If cove...
Page 31 - Change the Oil section,
CHANGE THE OIL: Change the oil, while the engineis 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. Remove the oil fill cap and add oil until the levelreaches the upper dash full mark o...
Page 32 - FIGURE D.2B – RADIATOR DRAIN COCK
FUEL FILTER: Inspect the in-line fuel filter daily. Whennecessary remove the sediment bowl from beneath thegas 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 equipp...
Page 34 - BATTERY MAINTENANCE; CLEANING THE BATTERY
BATTERY MAINTENANCE 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 thebattery. To prevent EXPLOSION when: • INS...
Page 36 - IDLER MAINTENANCE
CURRENT RANGE SELECTOR CONTACTS: Thecontacts should not be greased. To keep the contactsclean, rotate the current control handle through itsentire range frequently. Good practice is to turn thehandle from maximum to minimum setting twice eachmorning before starting to weld. Never rotate the han-dle ...
Page 39 - FIGURE E.1 – CLASSIC I BLOCK LOGIC DIAGRAM
Section E-1 Section E-1 CLASSIC I Theory of Operation ............................................................................................................. Section E General Description .............................................................................................................
Page 40 - The engine alternator supplies; THEORY OF OPERATION
GENERAL DESCRIPTION The Classic I is a heavy duty, engine driven, DC arcwelding power source capable of providing constantcurrent output for stick welding or DC TIG welding.Also, a total of 1750 watts of auxiliary power is availableat the 115VDC receptacle. The Classic I is manufac-tured with all co...
Page 43 - DC GENERATOR MACHINES
DC GENERATOR MACHINES The armature winding of a DC generator is located onthe rotating member. Current is conducted from it bymeans of carbon brushes. The field winding is locatedin the stator, which is stationary and excited by directcurrent. The armature coil sides are placed at opposite pointson ...
Page 46 - HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; The
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 machineoperator and will invalidate your factory warranty. For your safety and to avo...
Page 47 - PC BOARD TROUBLESHOOTING PROCEDURES
ELECTRIC SHOCK can kill. Have an electrician install and servicethis equipment. Turn the machine OFFbefore working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PCboard failures. These problems can sometimes be traced to poor electrical connections...
Page 48 - TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; OUTPUT PROBLEMS; Check for loose or missing
TROUBLESHOOTING & REPAIR 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 Departm...
Page 49 - Observe Safety Guidelines; Shunt Field Winding Test.
TROUBLESHOOTING & REPAIR 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 Departm...
Page 50 - The main armature commutator
TROUBLESHOOTING & REPAIR 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 Departm...
Page 52 - Check the main DC generator
TROUBLESHOOTING & REPAIR 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 Departm...
Page 53 - FUNCTION PROBLEMS
TROUBLESHOOTING & REPAIR 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 Departm...
Page 55 - ENGINE PROBLEMS
TROUBLESHOOTING & REPAIR 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 Depar...
Page 56 - WELDING PROBLEMS
F-12 F-12 CLASSIC I TROUBLESHOOTING & REPAIR 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 Depar...
Page 57 - DC EXCITER TEST; TEST DESCRIPTION; This procedure takes approximately 30 minutes to perform.
TROUBLESHOOTING & REPAIR F-13 F-13 CLASSIC I 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 technicianor machine operator and will invalidate your facto...
Page 58 - TEST PROCEDURE; MOVING PARTS can injure.
TROUBLESHOOTING & REPAIR F-14 F-14 CLASSIC I SERIES COIL CONNECTION POINT (NEGATIVE) POSITIVE FIGURE F.1 – 120VDC RECEPTACLE DC EXCITER TEST (continued) TEST PROCEDURE 1. Turn off the engine and remove all external loads to the welder terminals and auxiliaryreceptacle. MOVING PARTS can injure. •...
Page 59 - FIGURE F.2 – EXCITER COVER REMOVAL
TROUBLESHOOTING & REPAIR F-15 F-15 CLASSIC I DC EXCITER TEST (continued) EXITER COVER WARRANTY CHECK VOLTAGE AT BRUSH HOLDERS HERE(RIGHT SIDE IS +) + FIGURE F.2 – EXCITER COVER REMOVAL 4. Turn off the engine. Using the 3/8” nut driver, remove the exciter cover. See Figure F.2. MOVING PARTS can i...
Page 60 - FIGURE F.3 – BRUSH HOLDER LEADS; Replace; Figure; b. Also measure the resistance from the
TROUBLESHOOTING & REPAIR F-16 F-16 CLASSIC I WHITE FLEX LEAD SMALLFLEX LEAD SOLID LEAD WARRANTY FIGURE F.3 – BRUSH HOLDER LEADS 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. SeeFigur...
Page 61 - This procedure takes approximately 15 minutes to perform.
TROUBLESHOOTING & REPAIR F-17 F-17 CLASSIC I WARNING 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 ormachine operator and will invalidate your f...
Page 62 - IDLER SOLENOID TEST; FIGURE F.4 – IDLER SOLENOID CONNECTIONS
TROUBLESHOOTING & REPAIR F-18 F-18 CLASSIC I 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. See Figur...
Page 63 - This procedure takes approximately 25 minutes to perform.
TROUBLESHOOTING & REPAIR F-19 F-19 CLASSIC I WARNING 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 ormachine operator and wi...
Page 64 - MAIN GENERATOR SHUNT FIELD WINDING TEST; FIGURE F.5 – PLUG P10 LOCATION
TROUBLESHOOTING & REPAIR F-20 F-20 CLASSIC I 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. Retur n to Sect...
Page 65 - FIGURE F.6 – PLUG P10 PIN ASSIGNMENTS
TROUBLESHOOTING & REPAIR F-21 F-21 CLASSIC I 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. SeeFigure F.6. 6. Using the volt/ohmmeter, measure the resis-...
Page 66 - This procedure takes approximately 35 minutes to perform.
TROUBLESHOOTING & REPAIR F-22 F-22 CLASSIC I WARNING 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 ormachine operator and will inval...
Page 67 - ENGINE THROTTLE ADJUSTMENT TEST; FIGURE F.7 – BLOWER PADDLE MARK LOCATION; Strobe Tach Method
TROUBLESHOOTING & REPAIR F-23 F-23 CLASSIC I ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.7 – BLOWER PADDLE MARK LOCATION BLOWERPADDLE 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. 3. With...
Page 68 - Adjust High Idle; a. Make sure there is no load on the machine.; FIGURE F.8 – HIGH IDLE ADJUSTMENT; GOVERNOR
TROUBLESHOOTING & REPAIR F-24 F-24 CLASSIC I ENGINE THROTTLE 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 governor on the left side of the engine. See Figure F.8. d. Using the 3/8” wrench to...
Page 69 - FIGURE F.9 – LOW IDLE ADJUSTMENT
TROUBLESHOOTING & REPAIR F-25 F-25 CLASSIC I ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.9 – LOW IDLE ADJUSTMENT SPEEDADJUSTMENTSCREW LOCKINGNUT IDLER ROD 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 l...
Page 70 - DESCRIPTION
TROUBLESHOOTING & REPAIR F-26 F-26 CLASSIC I WARNING 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 ormachine operator and will invalidate your f...
Page 71 - FLASHING THE FIELDS; FIGURE F.10 – EXCITER COVER REMOVAL; PROCEDURE
TROUBLESHOOTING & REPAIR F-27 F-27 CLASSIC I 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. Retur n to Section TOC Retur n to Section TOC Retur n to Section TO...
Page 73 - SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VDC SUPPLY); HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM; volts
TROUBLESHOOTING & REPAIR F-29 F-29 CLASSIC I This is the typical auxiliary outputvoltage generated from a properlyoperating machine. Note that eachvertical division represents 50 voltsand that each horizontal division represents 2 milliseconds in time. Note: Scope probes connected atmachine 115V...
Page 74 - NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM; HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AND SELECTOR
TROUBLESHOOTING & REPAIR F-30 F-30 CLASSIC I This is the typical DC welding outputvoltage generated from a properlyoperating machine. Note that eachvertical division represents 50 voltsand that each horizontal division represents 5 milliseconds in time. Note: Scope probes connected atmachine out...
Page 75 - TYPICAL DC WELD VOLTAGE WAVEFORM; MACHINE LOADED – SELECTOR SWITCH AT MAXIMUM; MACHINE LOADED TO 200 AMPS AT 40VDC
TROUBLESHOOTING & REPAIR F-31 F-31 CLASSIC I This is the typical DC welding outputvoltage generated from a properlyoperating machine. Note that eachvertical division represents 20 voltsand that each horizontal division represents 5 milliseconds in time.The machine was loaded with a resistance gr...
Page 76 - This procedure takes approximately 1.5 hours to perform.
TROUBLESHOOTING & REPAIR F-32 F-32 CLASSIC I WARNING 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 ormac...
Page 77 - DC EXCITER ARMATURE AND FIELD COILS; Bend the flat washer away from the armature
TROUBLESHOOTING & REPAIR F-33 F-33 CLASSIC I DC EXCITER ARMATURE AND FIELD COILS REMOVAL AND REPLACEMENT (continued) FIGURE F.12 – EXCITER COVER REMOVAL ARMATURE BRUSH HOLDER ASSEMBLY (2) EXITER FRAME POLE PIECE BOLTS (4) EXITER COVER ARMATURE LOCKING NUT FLAT WASHER SLEEVE COLLAR PROCEDURE DC E...
Page 78 - Field Coils Removal Procedure
TROUBLESHOOTING & REPAIR F-34 F-34 CLASSIC I 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 reass...
Page 79 - This procedure takes approximately 8 hours to perform.
TROUBLESHOOTING & REPAIR F-35 F-35 CLASSIC I WARNING MAIN GENERATOR FRAME 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 ormachine operator a...
Page 80 - MAIN GENERATOR FRAME REMOVAL; FIGURE F.13 – BATTERY PANEL REMOVAL
TROUBLESHOOTING & REPAIR F-36 F-36 CLASSIC I MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.13 – BATTERY PANEL REMOVAL NEGATIVEBATTERYCABLE PROCEDURE 1. Turn the engine OFF. 2. Using the 7/16” wrench, remove the two bolts and washers and partially slide out the batterymounting...
Page 81 - FIGURE F.14 – TOP AND DOORS ASSEMBLY DETAILS
TROUBLESHOOTING & REPAIR F-37 F-37 CLASSIC I MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.14 – TOP AND DOORS ASSEMBLY DETAILS BOLT / NUT (4) 'L' DOORHOOKS (4) 4. Using the 1/2” wrench, remove the four nuts and bolts holding the case top and doorsassembly to the welder frame....
Page 82 - FIGURE F.15 – FUEL TANK MOUNTING DETAILS; Turn off the fuel supply at the fuel bowl and
TROUBLESHOOTING & REPAIR F-38 F-38 CLASSIC I MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) FIGURE F.15 – FUEL TANK MOUNTING DETAILS BOLTS / NUTS /WASHERS (4) FUEL TANK FUEL BOWL RAILS FUEL LINE 5. Perform the DC Exciter Armature Removal Procedure. 6. Turn off the fuel supply at the fu...
Page 83 - See Figure
TROUBLESHOOTING & REPAIR F-39 F-39 CLASSIC I FIGURE F.16 – SELECTOR SWITCH LEAD REMOVAL SELECTORSWITCH TERMINAL LEAD (5) A C B D E 9. Using the 1/2” wrench, remove the five heavy flex leads from the selector switch terminals.Label the leads for reassembly. See FigureF.16. FIGURE F.17 – OUTPUT TE...
Page 84 - Using the slot head screw driver, remove the
TROUBLESHOOTING & REPAIR F-40 F-40 CLASSIC I FIGURE F.18 – CHOKE CONTROL CABLE REMOVAL LOOSENHERE 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. MAIN GENERATOR FRAME RE...
Page 86 - Carefully remove the front panel assembly.
TROUBLESHOOTING & REPAIR F-42 F-42 CLASSIC I FIGURE F.20 – FRONT PANEL FASTENER REMOVAL BOLTS / NUTS / WASHERS (2) BASE MOUNTING BOLTS (4) MIDDLE SCREW (1) 23. Using the 1/2” wrench, remove the two bolts, nuts, and washers that hold the front panelassembly to the horizontal rails. (There isone o...
Page 87 - Using the slot head screw driver, remove the; FIGURE F.22 – MAIN GENERATOR BRUSH BRACKET CLAMPING BOLT; Lift the eight brushes from the main commu-
TROUBLESHOOTING & REPAIR F-43 F-43 CLASSIC I FIGURE F.21 – BRUSH BRACKET WRAP-AROUND COVER BRUSH BRACKET WRAP- AROUND COVER REMOVE (2) NUTS, WASHERS, AND SCREWS 27. Using the slot head screw driver, remove the two screws and nuts from the brush bracketwrap-around cover. Remove the cover. SeeFigu...
Page 88 - FIGURE F.24 – MAIN GENERATOR ENGINE MOUNTING; With the rope sling around the main genera-
TROUBLESHOOTING & REPAIR F-44 F-44 CLASSIC I FIGURE F.23 – MAIN GENERATOR FEET MOUNTING MAIN GENERATOR REMOVE MOUNTING NUTS, WASHERS, AND BOLTS FEET (2) 30. Using the 3/4” wrench, remove the frame mounting bolts, nuts, and washers from thefeet of the main generator. See Figure F.23. MAIN GENERAT...
Page 91 - MAIN GENERATOR ARMATURE REMOVAL; FIGURE F.25 – MAIN GENERATOR ARMATURE MOUNTING; DC Exciter Armature Removal
TROUBLESHOOTING & REPAIR F-47 F-47 CLASSIC I MAIN GENERATOR ARMATURE REMOVAL AND REPLACEMENT (continued) FIGURE F.25 – MAIN GENERATOR ARMATURE MOUNTING MOUNTING BOLTS / LOCK WASHERS (8) BLOWER PADDLE SLING PROCEDURE 1. Turn the engine OFF. 2. Perform the DC Exciter Armature Removal procedure. 3....
Page 92 - RETEST AFTER REPAIR; ENGINE OUTPUT
TROUBLESHOOTING & REPAIR F-48 F-48 CLASSIC I 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. E...
Page 93 - ELECTRICAL DIAGRAMS
ELECTRICAL DIAGRAMS G-1 G-1 CLASSIC I Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Electrical Diagrams Section ..........................................................................................Section G Wiring Diagram ..................................
Page 94 - WIRING DIAGRAM - CLASSIC I; CLASSIC I - WIRING DIAGRAM
ELECTRICAL DIAGRAMS G-2 G-2 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-2 CLASSIC I WIRING DIAGRAM - CLASSIC I M O T O R + G R O U N D G R O U...
Page 95 - WIRING DIAGRAM - WIRE FEED MODULE; WIRE FEED MODULE - WIRING DIAGRAM
ELECTRICAL DIAGRAMS G-3 CLASSIC I WIRING DIAGRAM - WIRE FEED MODULE 3 - 1 8 - 9 4 L 9 2 5 9 A M P H E N O L 1 A D F 5 1 0 6 0 2 6 1 0 A 5 0 3 A 6 0 9 5 0 1 C O N T A C T O R C O N T A C T O R + + + 6 2 2 6 6 6 6 3 3 7 5 A 7 6 7 7 7 5 R 5 0 1 6 3 0 6 3 1 C V C O N T R O L 4 6 6 7 6 3 4 J 2 J 3 5 0 1 ...
Page 96 - SCHEMATIC - IDLER PC BOARD
ELECTRICAL DIAGRAMS G-4 CLASSIC I SCHEMATIC - IDLER PC BOARD E A R T H G R O U N D C O N N E C T I O N M V O L T A G E N E T F R A M E C O N N E C T I O N 8 R - 2 0 N O . 1 0 C O M M O N C O N N E C T I O N T O S O L E N O I D L A S T N O . U S E D T O B A T T E R Y E Q U I P . S U B J E C T Y 1 6 9...
Page 97 - PC BOARD ASSEMBLY - IDLER PC BOARD
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....
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