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Lincoln Electric SVM134-A User's Manual

1. 4 2 2 5 ui S A 5 Exhaust Spark Arrester usines A 5 5 6 Electrical Output Connections sienne A 7 Welding Cable Connections iii A 7 O P Cable Installation and Cable A 7 9 Auxiliary Power Receptacle Plugs and Hand held A 7 3 tc o o g E 5 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC A 2 INSTALLATION TECHNICAL SPECIFICATIONS CLASSIC INPUT DIESEL ENGINE Manufacturer Description Continental TM27 4 cyl 4 cycle Water cooled gasoline 38 HP 1450 RPM Ignition 164 7 cu in Distributor 2700 cc Type Electronic Speed 1450 RPM Full load Displacement 1600 RPM High idle 1000 RPM Low idle A 2 Capacities Fuel 15 gal 57 liters Oil 6 0 qt 5 7 liters Coolant 9 3 qt 8 8 liters RATED OUTPUT WELDER Duty Cycle Amps Volts at Rated Amperes 60 Duty Cycle 200 DC Constant Current 40V Return to Section TOC Return to Master TOC OUTPUT WELDER AND GENERATOR Auxiliary Power 1 75 kw 15 Amps 120V DC Welding Ranges Max Open Circuit Voltage 40
2. 9 Classic DC Constant Current Stick or TIG B 9 5 Classic DC Wire Feed Welding Constant Voltage B 10 Auxiliary ac re tad B 10 g O g CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 3 tc Return to Section TOC Return to Master TOC o ZA OPERATION OPERATING INSTRUCTIONS Read and understand this entire section before operat ing your Classic 1 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 detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet clothing e Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dan gerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion
3. F 32 Main Generator Frame Removal and F 35 3 Main Generator Armature Removal and F 46 t THO 48 o O 9 gt 3 o o 9 gt g E 5 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 2 tc Return to Section TOC Return to Master TOC o O o 9 TROUBLESHOOTING REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunc tions Simply follow the three step procedure list ed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that
4. 3 4 OPERATION 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 the case front Welding output terminals and ground stud are located on the machine right side under the door See Figure B 1 B 2 and B 3 and the explanations that follow FIGURE B 1 OUTPUT CONTROLS WELDER GENERATOR CONTROLS See Figure B 1 for the location of the following features 1 CURRENT RANGE SELECTOR Selects ranges of continuous current output for constant current stick or TIG applications and constant voltage wire feed applications with optional Wire Feed Module See Control of Welding Current more informa tion FINE CURRENT ADJUSTMENT Allows fine adjustment of current within the selected output range Control of Welding more information 120 VOLT DC RECEPTACLE Connection point for supplying 120V DC power to operate DC electrical devices 4 CURRENT RANGE SELECTOR 1 2 FINE CURRENT ADJUSTMENT 3 115 VOLT DC RECEPTACLE 4 WELD OUTPUT TERMINAL 5 WELD OUTPUT TERMINAL 6 GROUND STUD WELD OUTPUT TERMINAL WITH FLANGE NUT Provides the connection point for either the electrode holder or the work cable WELD OUTPUT TERMINAL WITH FLANGE NUT Provi
5. Return to Section TOC Return to Master TOC CLASSIC LINCOLN 5 Section 1 Section 1 TABLE OF 5 ACCESSORIES ACCOSSOLIOS DE Section C Optiohns ACCeSSOTIGS eit bana ee 2 Semiautomatic Welding Accessories 2 0001 0000 C 2 Connection of Lincoln Electric Wire Feeders 3 Connection of the LN 25 Across the Arc C 3 Return to Master TOC Return to Master TOC 7 d 3 Return to Master CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 5 Return to Section Return to Master TOC 2 ACCESSORIES OPTIONS ACCESSORIES The following options accessories are available for your Classic from your local Lincoln Distributor Trailer K768 For in plant or yard towing at speeds under 10 m p h Not intended for highway towing Trailer K780 Two wheeled trailer with brakes lights and fenders For highway use consult applicable fed eral state and local laws Trailer K913 Two wheeled trailer for in plant and yard towing For highway use consult applicable fed e
6. Return to Master Section E 1 Section E 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION Theory of Op ration oerte duos d ersparen a ak aba env ida qe Section E General SEQ Fart uM epu E 2 Battery Starter Engine Alternator and Switch Circuit E 2 Engine Main Generator Armature and Frame and DC E 3 zy aai idana 3 Main Shunt Interpole and Series 3 Current Range Selector iii E 4 Fine Current E 4 Engine 4 DC Generator Machines iii E 5 SELECTOR SWITCH REED IDLER RELAY NEGATIVE Tap cre BOARD NO A C OUTPUT been ERMINAL ENGINE QIL BE ue IDLER ISOLENOID GENERATOR SWITCH FRAME SERIES RESIDUAL COILS MAGNETISM FUEL SHUTDOWN SHI ENGINE Mechanical GENERATOR r EXCITER mw 115 VDC IENTTION COUPLING ARMATURE m ARMATURE Mamm RECEPTACLE IGNITION IK ENGINE 5 SWITCH ALTERNATOR o INTERPOLE COILS STARTER MOTOR FIELD SHUNT WINDINGS BATTERY GENERATOR FIELD CONTROL POSITIVE OUTPUT TERMINAL FIGURE CLASSIC BLOCK LOGIC DIAGRAM CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Ret
7. T13157 14 VDD RESET xo MONO IN IN 1 OSC INH OUT 1 DECODE e OUT2 D 26 7K 8 BY PASS e CLOCK INH B 05 Vss 1N4936 4536B C6 vr 15V e e P C BOARD IS CONNECTED DIRECTLY TO FRAME GND THRU MOUNTING SCREW elo o FE E gt 219 5 2 a M16990 2BA GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 R 20 CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED C 10 B BLACK RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS DIODES 1A 400V UNLESS OTHERWISE SPECIFIED Y YELLOW SUPPLY VOLTAGE NET NOTES O POWER SUPPLY SOURCE POINT LEAD COLOR CODE R RED N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 5 COMMON CONNECTION WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY 77 FRAME CONNECTION W WHITE Nor HoW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE GROUND GONNEG UNLESS OTHERWISE SPECIFIED TOLERANCE Ch ge Sht No EQUIP ON HOLES SIZES PER E 2056 THE LINCOLN ELECTRIC CO CLASSIC SA200 ON 2 PLACE DECIMALS 15 02 10 29 93 ON PLACE DECIMALS IS 002 CLEVELAND U S A SUBJECT IDLER PCB SCHEMATIC ON ALL ANGLES IS 5 OF
8. 1 1 0 CLASSIC LINCOLN 5 A 8 NOTES CLASSIC LINCOLN 5 901 191SEN 901 191SEIN 0 901 J91Se N 01 901 J91Se N DOL uonoes oj DOL uonoes oj uumeg DOL uonoes DOL uonoes Section B 1 Section B 1 TABLE OF CONTENTS o OPERATION SECTION 8 PUER Section B Safety nien B 2 General Description 2 Recommended Applications B 3 B 3 3 Operational Features and Controls B 3 Design eS AUS ER E B 3 Welding B 3 B Miura B 3 Controls and B 4 5 Welder Generator Controls sr B 4 Control of Welding Current suisse B 5 2 Gasoline Engine Controls sires 6 Engine 8 87e IrziiToja EP B 7 Before Starting the Engine iii B 7 Starting the B 7 Stopping the B 8 Cold Weather Starting 8 8 T Welding
9. ojo 55 o 2 i 10 Using the 3 4 wrench remove the copper 11 Using the 3 4 wrench remove the heavy strap lead and reed switch assembly from lead from the positive output terminal See E E the negative output terminal See Figure Figure F 17 3 F17 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo O o 515 Oo PEN 2 2 5 5 1 Return to Section Return to Master TOC F 40 TROUBLESHOOTING amp REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT continued FIGURE F 18 CHOKE CONTROL CABLE REMOVAL C 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 CLASSIC LINCOLN 5 Kl 2 Ts A um N Fe te LATE F ES F 40 LOOSEN HERE F 41 F 41 TROUBLESHOOTING amp REPAIR o 2 5 2 2 tc Return to Section TOC Return to Master TOC o 14 red lead connecting the 115VDC to the DC exciter See Figure F 19 and the Wiring Diagram
10. dE JN FIEF 515 MOG 8 8 SRY MOUNTING BOLTS ala p LOCK WASHERS 8 d 52 PROCEDURE 1 Turn the engine OFF Replacement Refer to Figure 25 2 Perform the DC Exciter Armature Removal 1 Support the armature with the rope sling procedure Mount the armature to the engine rotating it 1 8 turn in either direction to achieve attach 3 Perform the Main Generator Frame Removal ment Before removing the rope sling be procedure careful to support the armature with the wood 4 Using the rope sling support the armature or steel blocks under the engine With the 5 8 wrench install the eight bolts and lock wash ers that attach the blower paddles and the armature to the engine flywheel 5 Make sure the engine supported with the wood or steel blocks 6 Using the 5 8 wrench remove the eight bolts and lock washers holding the blower paddles and the armature to the engine flywheel See 2 Perform other replacement procedures Figure F 25 according to each of the following 7 With the armature supported and balanced Generator __ __ in the rope sling carefully rotate the armature 1 8 turn in either direction to release it DC Exciter Armature Removal and A CAUTION The armature is now free to be removed from the engine Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC CLASSIC LINCOLN 5 F 48 F 48 TROUBLESHOOTING amp
11. o 515 0 PEN ale f 5 5 1 Return to Section Return to Master TOC CLASSIC LINCOLN 5 F 35 F 35 TROUBLESHOOTING amp REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 1 800 833 9353 WELD olo 8 DESCRIPTION oz This procedure will aid the technician in the removal and replacement of the main DC 918 generator frame EIE alz c MATERIALS NEEDED Rope sling Wood or steel blocks Pry bars 9 16 Wrench 1 2 Wrench 7 16 Wrench 3 4 Wrench Slot head screw driver Wiring Diagram This procedure takes approximately 8 hours to perform oio O O E E x 2912 0 PEN 2 5 5 1 Return to Section Return to Master TOC CLASSIC
12. LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo O o 515 Oo PEN 2 2 5 5 1 Return to Section Return to Master TOC F 36 F 36 TROUBLESHOOTING amp REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT continued FIGURE F 13 BATTERY PANEL REMOVAL 7 2 CABLE PROCEDURE 1 Turn the engine OFF 3 Using the 1 2 wrench remove the negative battery cable 2 Using the 7 16 wrench remove the two bolts and washers and partially slide out the battery mounting panel See Figure F 13 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo O o 515 Oo PEN 2 2 5 5 1 Return to Section Return to Master TOC F 37 F 37 TROUBLESHOOTING amp REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT continued FIGURE F 14 TOP AND DOORS ASSEMBLY DETAILS lt BOLT NUT 4 L DOOR HOOKS 4 4 Using the 1 2 wrench remove the four nuts and bolts holding the case top and doors assembly to the welder frame Remove the rubber gasket from the top Carefully lift up and remove the top and doors assembly Carefully remove the L shaped door hooks See Figure F 14 CLASSIC LINCOLN 5
13. 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 CURRENT ADJUSTMENT The field rheostat control functions as a fine output cur rent adjustment by controlling the current through the shunt windings thus controlling the amount of magnet ism created in the shunt field windings Open circuit weld voltage can also be controlled by the field rheo stat control ENGINE IDLER CIRCUIT The idler solenoid is mechanically connected to the engine governor linkage When welding current is being drawn the reed switch CR2 is closed This signals the idler PC board to release deactivate the idler solenoid which then lets the machine go to a high speed condition Also when auxiliary power 115VDC is being used the current is passed through a reed switch coil located on the idler PC board which signals the PC board to release the idler solenoid When welding ceases or the auxiliary load is removed a preset time delay of about 15 seconds starts After approximately 15 seconds the idler PC board acti vates the idler solenoid and the machine will return to a low idle speed condition CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio O O e
14. cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Mar 95 Return to Master TOC CLASSIC I LINCOLN 9 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC i WELDING SPARKS can gt 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 Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps h
15. MERE B 9 AUXIIALY POW pa 10 AcCeSSOL GS Section Maintenance Section D Safety Precautions EET D 2 Routine and Periodic Maintenance D 2 Major Component sis D 9 Theory of Operation eee puit dot oe Section E Troubleshooting and Repair 11 Section F Electrical Diagrams ine eiecti ere do e de aie reete Section G Parts Manual Sree LLLI AEA P 292 CLASSIC I LINCOLN 9 Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION o O Installation Technical Specifications ires A 2 E 9 Safety E 3 Location and Ventilation c erred Lond ete eme lens dl geek leave A 3 Sire A 3 SLACKING tess EIL A 4 uu H M A 4 A 4 High Altitude Operation 4 o on Pre Operation Engine Service sienne A 4 4 tute D ee ie 4 3
16. Return to Master TOC D 8 D 8 MAINTENANCE CURRENT RANGE SELECTOR CONTACTS The contacts should not be greased To keep the contacts clean rotate the current control handle through its entire range frequently Good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld Never rotate the han dle while the machine is under load Put a drop of oil on the CURRENT RANGE SELEC TOR shaft at least once every month RECEPTACLE Keep the electrical receptacle in good condition Remove any dirt oil or other debris from surfaces and holes CABLE CONNECTIONS Check the welding cable connections at the weld output terminals often Be sure that the connections are always tight IDLER MAINTENANCE CAUTION Before doing electrical work on the idler printed circuit board disconnect the battery 1 The solenoid plunger must work freely because binding can cause engine surging If surging occurs be sure the plunger is properly lined up with the carburetor lever Dust the plunger about once a year with graphite powder 2 When any service is done reassemble the rubber bellows on the solenoid plunger with the vent hole on the lower side 3 Proper operation of the idler requires good ground ing of the printed circuit board through its mount ing The reed switch and battery must also be grounded properly 4 If desired the welder can be used without automat ic idling
17. ble of CC CV wire feed welding NOTE Gas shielded welding requires a Magnum Gun Gasless welding requires an Innershield Gun CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 2 tc Return to Section TOC Return to Master TOC ACCESSORIES CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS The Lincoln Electric LN 25 wire feeder is recommend ed for wire feed welding with the Classic CONNECTION OF THE LN 25 TO THE CLASSIC ACROSS THE ARC WITH WIRE 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 Connect the work cable to the CV terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application NOTE Figure C 1 shows the electrode connect ed for positive polarity To change polari ty shut the welder off and reverse the electrode and work cables at the Classic output terminals Reverse the LN 25 polarity switch Connect the K444 2 remote control cable to the 14 pin amphenol on the Wire Feed Module Attach the single lead from the LN 25 control box to the work using the spring clip on the end of the lead This is only a control lead it carries no welding current Place the IDLER swi
18. 13 16 PIN 59 moa REEDSWITCH O 0 2 tc o 2 2 5 5 5 05A M16723 2 Return to Section TOC Return to Master TOC 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 not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine CLASSIC I
19. DEGREE MATERIAL TOLERANCE 47 TO AGREE SCALE NONE AUSTRALIA CANADA FRANCE WITH PUBLISHED STANDARDS DR LEB DATE 2 10 93 SUP S D G 520334 SHT No M 16990 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN CLASSIC ELECTRICAL DIAGRAMS Gs PC BOARD ASSEMBLY IDLER PC BOARD Return to Section TOC Return to Master TOC ire mm 1 2 3 8 29 5 516668 5 022 500 M16723 2 1 s13490 35 5 6 7 513290 39 18715 7 IDLER 10 513490 102 LO c D1 02 07 08 Ti2199 1 maoa n 112705334 iN49386 12702 33 1N53478 O 1 12702 17 023 __ 112702 29 N 12704 54 R1 R2 R5 3 19400 1002 R3 R4 19400 2212 22 IK 1 49 1 519400 1333 133 1 4 1 S19400 4752 47 5 1 4w 77 1 518380 1 19400 158 ai 1 112300 80 1 519400 2672 26 7K 1 4 1 519400 1372 13 7K 1 4W 1 519400 51 0 511 174w Ea a 1 R 023 ________ 82 85 RE Reo 89 815 RIO Ri R2 _______ RIS 16 RI7 20 Return to Section Return to Master TOC 19400 332 R12 R13 R17 R20 19400 100 19400 332 15128 11 Ix2 1 s15018
20. MAINTENANCE WELDER GENERATOR MAINTENANCE STORAGE Store the Classic in clean dry protected areas CLEANING Blow out the generator and controls peri odically with low pressure air Do this at least once a week in particularly dirty areas NAMEPLATES Whenever routine maintenance is per formed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those which are no longer clear Refer to the parts list for the replacement item number GENERATOR COMMUTATOR AND BRUSHES The generator brushes are properly adjusted when the welder is shipped They require no particular attention CAUTION DO NOT SHIFT THE BRUSHES or adjust the rocker setting Shifting of the brushes may result in Change in machine output Commutator damage Excessive brush wear Periodically inspect the commutators and brushes by removing the covers DO NOT remove these covers while the machine is running Commutators and brushes require little attention However if they are black or appear uneven have them cleaned by experienced maintenance personnel using a commutator stone Never use emery cloth or paper for this purpose Replace brushes when they wear within 1 4 of the pig tail A complete set of replacement brushes should be kept on hand Lincoln brushes have a curved face to fit the commutator Have experienced maintenance per sonnel seat these brushes by lightly stoning the com mu
21. Wrench 1 2 Wrench 1 5 8 Socket wrench Wiring Diagram This procedure takes approximately 1 5 hours to perform oio O O E E x 2912 0 PEN 2 5 5 1 Return to Section Return to Master TOC CLASSIC LINCOLN 5 F 33 F 33 TROUBLESHOOTING amp REPAIR DC EXCITER ARMATURE AND FIELD COILS REMOVAL AND REPLACEMENT continued FIGURE F 12 EXCITER COVER REMOVAL Return to Section TOC Return to Master TOC POLE PIECE BOLTS 4 EXITER FRAME BRUSH HOLDER ARMATURE ASSEMBLY 2 Q F 2 5 o 2 E Return to Master TOC SLEEVE COLLAR FLAT WASHER ARMATURE LOCKING NUT EXITER COVER 5 5 DC Exciter Armature Removal Procedure Reassembly 8 1 the engine OFF 7 Upon reassembly the armature locking nut should be torqued to 170 ft lbs Install 2 Using the 3 8 nut driver remove the exciter new sleeve collar if necessary Part number 3 3 cover See Figure F 12 T5345 Bend the flat washer against the amp 2 3 Using the 3 8 wrench remove the two brush locking nut holder assemblies Note insulator placement 8 Install the brush holder assemblies Note for reassembly insulator placement 4 Bend the flat washer away from the armature 9 Check the armature air gap Minimum gap locking nut should be 025 5 Using the 1 5 8 socket wrench rem
22. 300 Amps DC 95 PHYSICAL DIMENSIONS Height Weight 40 9 in 1040 mm 1370 Ib 621 kg O10 Fie ci gt 28g 3E 2 cc 1 1 Lincoln rating rating at 60 duty cycle is 200 DC amps 28V Return to Section TOC Return to Master TOC CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo O o 515 Oo PEN 2 2 5 5 1 Return to Section Return to Master TOC Return to Master TOC A 3 INSTALLATION Read this entire installation section before you Start installation SAFETY PRECAUTIONS A WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill not touch electrically live parts electrodes with your skin or wet clothing Insulate yourself from the work and ground Always wear dry gloves insulating ENGINE EXHAUST can kill e Use in open well ventilated areas or vent exhaust to the out side Do not stack anything on or near the engine MOVING PARTS can injure not operate this equipment with any of its doors open or guards off Stop the engine before servi
23. ARMATURE SHAFT ARMATURE CLASSIC LINCOLN 5 6 NOTES CLASSIC LINCOLN 5 E 6 901 191SEN 901 191SEIN 0 901 J91Se N 01 901 J91Se N DOL uonoes oj DOL uonoes oj uumeg DOL uonoes DOL uonoes Section F 1 Section F 1 TABLE OF CONTENTS 3 TROUBLESHOOTING amp REPAIR SECTION 5 2 Troubleshooting amp Repair Section Section F How to Use Troubleshooting Guide ss F 2 S PC Board Troubleshooting Procedures F 3 2 F4 F 12 Test 13 DC Exciter Tests c denied F 13 Idler Solenoid pae reb eae Fee dea F 17 Main Generator Shunt Field Winding Test F 19 Engine Throttle Adjustment Test F 22 Flashing theFi lds 26 Oscilloscope 29 S Normal Open Circuit Voltage Waveform 115VDC F 29 Normal Open Circuit DC Weld Voltage Waveform F 30 5 Typical DC Weld Voltage Waveform Machine F 31 o Removal and Replacement Procedures F 32 o DC Exciter Armature and Coils Removal and Replacement
24. Board Schematic G 4 idler PG B ard Lay t ne eee rte tenter ne ie ner G 5 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio o E a ele lt 5 5 pile ojo G 2 ELECTRICAL DIAGRAMS WIRING DIAGRAM CLASSIC I ALTERNATE IGNITION CIRCUIT WITH RESISTOR SUPPLIED ON EARLIER ENGINES CLASSIC I in L IGNITION 7 TO PLUGS DISTRIBUTOR 0 PRESSURE LIGHT IGNITION SWITCH U O STARTING GROUND MOTOR TO BASE GROUND TO ENGINE TO PLUGS IDLER SWITCH OIL PRESSURE SWITCH Y ALTERNATOR 771 WIRING DIAGRAM ELECTRICAL SYMBOLS PER E1537 LEAD COLOR CODE CONTROL PANEL COMPONENTS SHOWN AS VEIWED FROM REAR B BLACK R RED OR GREY U BLUE G GREEN W WHITE N BROWN Y YELLOW FUSE IN CIRCUIT ON C S A VERSION ONLY AUX POWER RECEPTACLE FOR REMOTE OPTION TO EXCITER OUTPUT CR2 REED lt 5 RHEOSTAT prid gi 600A 41 p 1 22 2 602 ER d SELECTOR SWITCH GENERATOR LEAD BLOCK N K924 1 REMOTE CONTROL OPTIONAL REMOTE CONTROL RECEPTACLE amp SWITCH SWITCH FOR LOCAL OR REMOTE CONTROL SHOWN IN LOCAL POSITION PLUG FOR REMOTE CONTROL POTENTIOMETER RESISTORS G REMOTE CONTROL
25. Cut any necessary cable ties Remove the black lead connecting the idler PC board to the DC exciter See Figure F 19 and the Wiring Diagram Cut any necessary cable ties 20 ojo BB MAIN GENERATOR FRAME REMOVAL 515 AND REPLACEMENT continued amp FIGURE 19 FRONT PANEL WIRING CONNECTIONS 5 5 5 cc 14 BLACK LEAD TO IDLER PC BOARD 18 WHITE LEAD 22 BROWN LEAD TO 21 YELLOW LEAD IDLER SWITCH TO IDLER SWITCH z e S SN ee LS 07 gt SES NI PIN 1 4 2 NO PN 5 CT ER AN 7 TN 15 SHUNT LEADS 13 LEAD QUICK DISCONNECT 2 Q RECEPTACLE 13 Using the slot head screw driver remove the 18 Remove the white lead from the idler PC board See Figure F 19 and the Wiring Diagram Using the 3 8 nut driver remove the blue lead from the ammeter Label for reassem bly See Figure F 19 and the Wiring Diagram Using the 3 8 nut driver remove the black lead from the ammeter Label for reassem bly See Figure F 19 and the Wiring Diagram connect Me end SONT shunt 21 Label and remove the yellow lead from the leads from their quick disconnect splices See the Wiring Diaoram idler switch The yellow lead connects the eR mg idler switch to the oil pressure switch See 16 Disconnect the H lead from the START but Figure F 19 and the Wiring Diagram bom M
26. LINCOLN 5 F 43 F 43 TROUBLESHOOTING amp REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT continued FIGURE F 21 BRUSH BRACKET WRAP AROUND COVER Return to Section TOC Return to Master TOC BRUSH BRACKET REMOVE 2 NUTS WASHERS AND SCREWS WRAP AROUND COVER Return to Section TOC Return to Master TOC 27 Using the slot head screw driver remove the two screws and nuts from the brush bracket wrap around cover Remove the cover See Figure F 21 FIGURE F 22 MAIN GENERATOR BRUSH BRACKET CLAMPING BOLT olo o 515 0 PEN 2 2 5 5 1 28 Lift the eight brushes from the main commu 29 Using the 7 16 wrench loosen do not tator Note their positions for reassembly remove the main generator brush bracket clamping bolt Note the position of the drill spot for reassembly See Figure F 22 Return to Section TOC Return to Master TOC CLASSIC LINCOLN 5 F 44 F 44 TROUBLESHOOTING amp REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT continued FIGURE F 23 MAIN GENERATOR FEET MOUNTING Return to Section TOC Return to Master TOC MAIN GENERATOR FEET 2 REMOVE MOUNTING NUTS WASHERS AND BOLTS Return to Section TOC Return to Master TOC 30 Using the 3 4 wrench remove the frame mounting bolts nuts and washers from the feet of the main generator See Figure F 23 FIGURE F 24 MAIN GENERATOR ENGINE M
27. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o 515 Oo PEN 2 2 5 5 1 Return to Section Return to Master TOC F 38 F 38 TROUBLESHOOTING amp REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT continued FIGURE F 15 FUEL TANK MOUNTING DETAILS BOLTS NUTS WASHERS 4 FUEL LINE FUEL BOWL FUEL TANK 5 Perform the DC Exciter Armature Removal 7 Using the 9 16 wrench remove the four nuts bolts and washers holding the fuel tank 6 Turn off the fuel supply at the fuel bowl and allen ieee ROBES remove the fuel line Plug the line to avoid 8 Carefully remove the fuel tank and set it aside spillage in a safe area CLASSIC LINCOLN 5 39 F 39 TROUBLESHOOTING amp REPAIR glg MAIN GENERATOR FRAME REMOVAL els AND REPLACEMENT continued 8 3 FIGURE F 16 SELECTOR SWITCH LEAD REMOVAL 2 2 SELECTOR SWITCH TERMINAL LEAD 5 ef N Return to Section TOC Return to Master TOC 9 Using the 1 2 wrench remove the five heavy flex leads from the selector switch terminals Label the leads for reassembly See Figure F 16 FIGURE F 17 OUTPUT TERMINAL LEAD REMOVAL COPPER STRAP AND REED SWITCH ASSEMBLY Ojo O o E 515 Oo PEN ale f 5 5 1 POSITIVE OUTPUT TERMINAL AND LEAD
28. __ _ Return to Section TOC Return to Master TOC REMOTE CONNECTOR el ese ase Ge 32 L GROUND GND 1 i CONTACTOR i i REMOTE O 7 iv 2 tc o 2 2 5 LOCAL REMOTE SWITCH 52 SHOWN IN LOCAL MODE i i 300 ANP SHUNT O NEG i BRUSH HOLDER 30000 MFD CONTACTOR 75 VOLT 3 18 94 L9259 NOTE This diagram is for reference only 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 LINCOLN CLASSIC Return to Section TOC Return to Master TOC ot ELECTRICAL DIAGRAMS G4 SCHEMATIC IDLER PC BOARD 06691 N NOT USED OY TO BATTERY B3 Return to Section TOC Return to Master TOC B4 O W TO SOLENOID WHITE xi LM2901 12 TO REED SW GND RED T7 B5 R Return to Section TOC Return to Master TOC
29. amps Work and Electrode welding cable mounting termi nals Separate ground stud for safe connection of case to earth ground 115 volt DC auxiliary power receptacle Electric starting Distributor type electronic ignition Battery Charging Ammeter Engine Hour Meter for determining periodic mainte nance Top of the line 38 HP Continental gasoline engine Top mounted 15 gallon 57 0 litter fuel tank with con venient top fill Automatic engine idler goes to low idle approximate ly 15 seconds after welding for greater fuel economy includes high idle switch WELDING CAPABILITY The Classic is rated 200 amps 40 volts constant cur rent DC at 60 duty cycle based on a ten minute time period Longer duty cycles at lower output currents are possible The current is continuously variable from 40 to 300 amps DC LIMITATIONS The Classic is not recommended for any processes besides those that are normally performed using DC stick welding SMAW and DC TIG welding Specific limitations on using the Classic for these processes are described in the Welding Operation section of this manual Constant voltage welding is available with the optional Wire Feed Module CLASSIC I LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 2 tc Return to Section TOC Return to Master TOC
30. by setting the Idler switch to the High Idle position 5 When installing a new battery or using a jumper bat tery to start the engine be sure the battery polarity is connected properly The correct polarity is nega tive ground Damage to the engine alternator and the printed circuit board can result from incorrect connection CLASSIC I LINCOLN 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 5 Return to Section Return to Master TOC 10 11 12 13 14 15 16 GENERATOR BRUSHES OUTPUT TERMINALS FUEL TANK CASE FRONT WITH CONTROL PANEL MAINTENANCE FIGURE D 5 MAJOR COMPONENT LOCATIONS RIGHT CASE SIDE DOOR BASE WITH BATTERY EXCITER BRUSHES EXCITER GENERATOR LEFT CASE SIDE CASE TOP CASE BACK RADIATOR GASOLINE ENGINE AIR CLEANER IDLER CONTROL CLASSIC I LINCOLN 9 D 9 D 10 NOTES CLASSIC LINCOLN 5 D 10 901 191SEN 901 191SEIN 0 901 J91Se N 01 901 J91Se N DOL uonoes oj DOL uonoes oj uumeg DOL uonoes DOL uonoes Return to Master TOC Return to Master TOC 7 d 3
31. diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Ojo o E 515 Oo PEN g 9 5 5 1 Return to Section Return to Master TOC Return to Master TOC F 3 F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the machine OFF before working on equipment Do not touch electrically hot parts Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static elec trical damage and electrical shock Read the warn ing inside the static resistant bag and perform
32. drain cock Fill the cooling system at the radiator filler with a 50 50 mixture of water and antifreeze Capacity 9 3 quarts 8 8 liters FIGURE D 2A ENGINE COOLANT DRAIN PLUG CLASSIC I LINCOLN 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 2 Return to Section Return to Master TOC O o iv MAINTENANCE FAN BELT Fan belts tend to loosen after the first 50 hours of operation If the fan belt is loose the engine can overheat and the battery can lose its charge Check belt tightness by pressing on the belt midway between the pulleys The belt should deflect no more than 13 mm 0 5 in See Figure D 3 To adjust the fan belt loosen the alternator bolts then push the alternator outward until the correct belt ten sion is achieved Retighten the alternator bolts See Figure D 3 FIGURE D 3 TIGHTENING THE FAN BELT SPARK PLUGS Clean or replace the spark plugs after every 250 hours of operation as follows 1 Before removing the plugs clean the base area to keep dirt from falling into the engine through the plug hole 2 Remove and inspect the plugs Plugs showing signs of fouling or electrode wear should be replaced Do not blast the spark plu
33. five degrees the electrolyte temperature is below 80 degrees F 27 degrees C CHECKING ELECTROLYTE LEVEL If battery cells are low fill them to the neck of the filler hole with distilled water and recharge If one cell is low check for leaks CHARGING THE BATTERY The Classic is equipped with a wet charged battery The charging current is automatically regulated when the battery is low after starting the engine to a trickle current when the battery is fully charged When you charge jump replace or otherwise connect battery cables to the battery be sure the polarity is cor rect Improper polarity can damage the charging cir cuit The Classic charging system is NEGATIVE GROUND The positive battery terminal has a red terminal cover If you need to charge the battery with an external charger disconnect the negative cable first then the positive cable before you attach the charger leads After the battery is charged reconnect the positive bat tery cable first and the negative cable last Failure to do so can result in damage to the internal charger com ponents Follow the instructions of the battery charger manufac turer for proper charger settings and charging time CLASSIC I LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Ojo O o PEN 2 2 1 Return to Section Return to Master TOC Return to Master TOC D 7
34. the following procedures PC Board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm ATTENTION Static Sensitive resistive cord connected to a Devices grounded part of the equipment Handle only at frame Static Safe e you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent stat ic build up Be sure not to touch any electrically live parts at the same time Workstations Reusable Container Do Not Destroy Tools which come in contact with the PC Board must be either conductive anti static or static dissipative Remove the PC Board from the static shielding bag and place it directly into the equipment Don t set the PC Board on or near paper plastic or cloth which could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag e the PC Board uses protective shorting jumpers don t remove them until installation is complete e 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 4 Test the machine to determine if the failure symp tom has been corrected by the replacement PC board NOTE Allow the machine to h
35. the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into four main categories Output Problems Function Problems Engine Problems and Welding Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case top and doors assembly Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub ject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points components terminal strips etc can be found on the referenced elec trical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of to locate the appropriate
36. this machine using lift bail if it is equipped with a heavy accessory such as a trailer 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 PRE OPERATION ENGINE SERVICE Read and understand the information about the gaso line engine in the Operation land Maintenance sec tions of this manual before you operate the Classic A WARNING Keep hands away from the engine muffler or HOT engine parts Stop the engine when fueling Do not smoke when fueling Remove the fuel cap slowly to release pressure Do not overfill the fuel tank Wipe up spilled fuel and allow the fumes to clear before starting the engine Keep sparks and flame away from the fuel tank OIL En The Classic is shipped with the engine filled with SAE 10W 30 oil This should be fine for most ambient operating temperature condi tions See the engine operation manual for specific recommendations CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE This is an added precau tion When full the oil level should be up to but not over the FULL mark on the dipstick If it is not full add enough oil to fill it to the full mark DO NOT overfill For more oil fill and service information see the Maintenance section o
37. to Master TOC CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 5 Return to Section Return to Master TOC F 14 F 14 TROUBLESHOOTING amp REPAIR DC EXCITER TEST continued FIGURE F 1 120VDC RECEPTACLE TEST PROCEDURE 1 Turn off the engine and remove all external loads to the welder terminals and auxiliary receptacle WARNING MOVING PARTS can injure AS Remove guards only when necessary to perform service and replace them when the service requiring their removal is complete Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment If fan guards are missing from a machine obtain replacements from a Lincoln Distributor See Parts List Always use greatest care when working near moving parts CLASSIC LINCOLN 5 SERIES COIL CONNECTION POINT NEGATIVE POSITIVE 2 Start the engine and put the idler switch in the HIGH idle position 3 Using the volt ohmmeter carefully check the DC voltage at the 120 receptacle Observe proper polarity The large slot of the receptacle is negative See Figure F 1 Normal voltage is 125 135VDC no load with the engine at the high
38. voltage is present at the brush holders but not at the 120VDC receptacle the series coil or associated leads may be faulty See the Wiring f fan guards are missing from a machine Diagram Proceed with the shunt coil and obtain replacements from a Lincoln series coil resistance tests Distributor See Parts List Always use greatest care when working near moving parts Return to Section TOC Return to Master TOC CLASSIC LINCOLN 5 F 16 F 16 TROUBLESHOOTING amp REPAIR DC EXCITER TEST continued FIGURE F 3 BRUSH HOLDER LEADS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 2 tc Return to Section TOC Return to Master TOC o d 6 WARRANTY WHITE FLEX LEAD 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 Separate the two leads One will be a larger solid lead series coil The other will be a smaller flex lead shunt coil 9 Using the 3 8 nut driver remove the two flex leads from the right side brush holder Note lead placement for reassembly Using the volt ohmmeter check the shunt coil resistance Check from the left side small flex
39. 3 TO USE THE CLASSIC FOR DC WIRE 4 Set the Idler Switch to AUTO 5 FEED WELDING CONSTANT VOLTAGE 5 Set the CURRENT RANGE SELECTOR to a set 9 WITH WIRE FEED MODULE ting appropriate for your wire size and wire feed o 1 Connect the LN 25 Wire Feeder Follow the instal speed See Table B 1 for recommended settings E lation instructions provided with the wire feeder 6 Set the VOLTAGE ADJUSTMENT to the setting sN 3 Set the wire feeder and Classic for CV operation that gives the best arc characteristics for the range L selected Start the engine See Engine Operation in this 7 section of the manual Pull the gun trigger TABLE B 1 RANGE SETTINGS FOR WIRE SIZE SPEED olo Diameter inches Wire Speed Range Appropriate Current Range 5 5 inches minute 5 035 80 110 75 to 120 Amps 045 70 130 120 to 170 Amps E 068 40 90 125 to 210 Amps dc AUXILIARY POWER A WARNING Be sure that any electrical equipment plugged into the generator DC power receptacle can withstand a 10 voltage variation The DC auxiliary power supplied as a standard has a rating of 1 75 kw of 120V DC power The rating of 1 75 kw permits a maximum continuous current of 15 amps to be drawn from the 120 volt recep tacle An_optional power plug kit is available See the of this manual Fie E 515 0 2 Sa
40. C CLASSIC LINCOLN 5 F 27 F 27 TROUBLESHOOTING amp REPAIR FLASHING THE FIELDS continued FIGURE 10 EXCITER COVER REMOVAL Return to Section TOC Return to Master TOC S al 55 o i P Q L d 2 218 EXITER lt COVER PROCEDURE 1 Turn the engine OFF 2 Using the 3 8 wrench remove the exciter cover See Figure F 10 Ojo O o E 515 Oo PEN ale f 5 5 1 Return to Section Return to Master TOC CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo O o 515 Oo PEN 2 2 5 5 1 Return to Section Return to Master TOC F 28 TROUBLESHOOTING amp REPAIR FLASHING THE FIELDS continued FIGURE F 11 BRUSH HOLDER BATTERY JUMPER CONNECTIONS TO NEGATIVE BATTERY TERMINAL WARRANTY RAISE EXCITER BRUSH OFF COMMUTATOR lt TO POSITIVE BATTERY TERMINAL t 3 Raise one exciter brush off the armature com mutator Using the jumper leads and the 12VDC bat tery first attach the clip of one lead to the POSITIVE terminal of the battery Attach the other end of this same lead to the right side brush holder See Figure 11 Carefully attach one clip of the other lead to the NEGATIVE terminal of the battery Attach
41. C o B 3 OPERATION RECOMMENDED APPLICATIONS WELDER The Classic 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 is also capable of providing 1 75 kw of 115V DC auxiliary power OPERATIONAL FEATURES AND CONTROLS The Classic was designed for simplicity Therefore it has very few operating controls Two switches are used for welding operations five position CURRENT RANGE SELECTOR switch selects current output ranges for constant cur rent stick or TIG applications and constant voltage wire feed applications with optional Wire Feed Module see the Accessories section A FINE CURRENT ADJUSTMENT control for fine adjustment of current from minimum to maximum within each range Controls for the gasoline engine control include a two position IGNITION ON OFF toggle switch a START pushbutton and a two position IDLER switch that selects engine speed for welding or auxiliary power applications Operation in the Operation section of this manual for details about starting run ning stopping and breaking in the gasoline engine DESIGN FEATURES Constant current DC Stick welding SMAW process capability with output range from 40 300 DC
42. CLASSIC TM October 2000 For use with machine code numbers 10068 to 10069 Return to Master TOC View Safety Info 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 Return to Master TOC View Safety Info Flo BI gjo E 8 al tc SERVICE MANUAL n View Safety Info LINCOLN 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 Return to Master TOC SAFETY 8 WARNING 5 A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause 2 cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The For Diesel Engines T
43. E x 2912 PEN 2 1 Return to Section Return to Master TOC E 5 E 5 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 The armature coil sides are placed at opposite points on the rotating shaft with the conductors parallel to the shaft The armature assembly is normally turned at a constant speed by a source of mechanical power con nected to the shaft When the armature rotates through the magnetic field produced by the stationary field winding it induces a coil voltage in the armature winding The voltage induced in an individual armature coil is an alternating AC voltage which must be recti fied In a conventional DC generator machine rectifi cation is provided mechanically by means of a com mutator A commutator is a cylinder formed of copper segments insulated from each other and mounted on but insulated from the rotating shaft Stationary car bon brushes held against the commutator surface con nect the armature windings to external terminals The commutator provides full wave rectification transform ing the voltage waveform between brushes and mak ing available a DC voltage to the external circuit MECHANICAL COUPLING GENERATOR
44. EAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check for loose or missing brushes in the DC exciter 2 The exciter may need flashing See the Fields in this section TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Check for loose or broken wires between the exciter brushes and the DC receptacle and the fine current control field rheostat See the Wiring Diagram 2 Perform the DC Exciter Test CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 2 tc Return to Section TOC Return to Master TOC o O o 9 E 5 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The engine starts and runs at the correct speed but there is no or very low welder output The DC auxiliary output voltage is normal Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check the welding cables for loose or faulty connections Check for loose or missing brushes in the
45. Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS Return to Section TOC Return to Master TOC The welding arc is loud and spat 1 The current setting may be too 1 Check the engine speed High ters excessively high for the electrode and idle speed should be 1600 process RPM If necessary perform the Engine Throttle Adjustment The polarity may be wrong for the electrode and process Check the main DC generator brushes for good commutation and alignment Contact the Lincoln Electric Service Dept at 1 800 833 9353 WELD The welding arc frequently pops The fine current control field Check the engine speed High out rheostat may be set too low for idle speed should be 1600 the process and electrode RPM f necessary perform the Check the welding cables for Teer loose faulty connections The current range selector switch may be faulty Check for proper operation and contact Return to Section TOC Return to Master TOC Check the DC generator brushes for good commutation and align ment Contact the Lincoln Electric Service Dept at 1 800 833 9353 WELD e CiS 2912 PEN 2 2 ala CAUTION If for any reason you do not understand the test procedures or are unable to perform the test r
46. H and AUTO In HIGH the engine runs continuously at high idle In AUTO the idler control works as follows 4 START PUSHBUTTON Press this button to start Welding The engine accelerates to high speed the gasoline engine The IGNITION switch must be when the electrode touches the work and strikes a in the ON position welding arc The engine returns to low idle approx NOTE If you press the START pushbutton when imately 15 seconds after welding stops as long as the engine is running you may damage the engine no auxiliary power is being drawn flywheel gear or starter motor Auxiliary Power The engine accelerates to high 6 ENGINE HOUR METER Records engine running speed when power is drawn at the receptacle for time Use the meter to determine when to lights or tools The engine returns to low idle perform required maintenance 2 approximately 15 seconds after demand for auxiliary power stops 7 AMMETER Shows whether the charging circuit 5 5 is performing its job of charging the battery when 5 2 IGNITION CONTROL TOGGLE SWITCH Has the engine is running The meter will register two positions ON and OFF When the switch is in discharge during starting but then the needle the ON position the engine can be started by should return to a position slightly t
47. INE CAUTION DAMAGE CAN OCCUR TO THE REMOTE CONTROL SWITCH IF IT IS USED WITHOUT THE P11 PLUG INSTALLED OR A WIRE FEED MODULE INSTALLED ON CLASSIC MACHINES CONNECT RED AND BLACK LEADS ON REMOTE TO RED AND BLACK LEADS ON MACHINE 2 HEAVY LEAD 200 AMP THERMOSTAT ASSEMBLY 1 28 2000F Return to Master TOC 9262 NOTE This diagram is for reference only It may not 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 Return to Section TOC LINCOLN CLASSIC I ELECTRICAL DIAGRAMS oo WIRING DIAGRAM WIRE FEED MODULE WIRE FEED MODULE WIRING DIAGRAM ELECTRICAL SYMBOLS PER E1537 FLASHING MOLEX CONNECTORS LEADS J2 J3 J4 1 5 1 4 1 3 90000 000 CONNECTOR CAVITY NUMBERING E SEQUENCE VIEWED FROM 5 8 4 5 COMPONENT SIDE OF BOARD Return to Section TOC Return to Master TOC 5 509 CONNECTS TO 62 610 LEADS 31 32 AND 602 DO NOT GO INSIDE WIRE FEED MODULE BOX ENGINE WELDER COMPONENTS VIEWED FROM REAR BECERTAGLE J5 i 8 CONNECTOR CAVITY NUMBERING SEQUENCE VIEWED FROM LEAD SIDE OF CONNECTOR CC CV SWITCH 51 SHOWN IN CV MODE
48. M D 5 5 D 6 m Ie Iesum D 6 Checking Specific Gravity is D 6 Checking Electrolyte Level D 6 Gharging the Battery rts ordre aan e deities D 6 Welder Generator Maintenance 1100 ennemis D 7 Sire M D 7 o e cuju e E D 7 8 NERO T E TT tales D 7 Generator Commutator and Brushes 1 0040 00 1 0 7 z i o En D 7 5 Current Range Selector Contacts 0 8 m D 8 Cable Connections er ie D 8 laler Maintenance D 8 Major Component Locations sien D 9 o o g E 5 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 3 tc Return to Section TOC Return to Master TOC o 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 mainten
49. ON See ane 22 Label and remove the brown lead from the 17 Diagram Remove the two red leads from the ignition switch Label for reassembly See Figure F 19 and the Wiring Diagram CLASSIC LINCOLN 5 idler switch The brown lead connects the idler switch to the idler solenoid See Figure F 19 and the Wiring Diagram Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 2 tc Return to Section TOC Return to Master TOC o F 42 F 42 TROUBLESHOOTING amp REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT continued FIGURE F 20 FRONT PANEL FASTENER REMOVAL 2 o BOLTS NUTS WASHERS 2 WW MIDDLE SCREW 1 lt MOUNTING BOLTS 4 2 23 Using the 1 2 wrench remove the two bolts 25 Using the 3 8 nut driver remove the screw nuts and washers that hold the front panel from the lower middle of the front panel See assembly to the horizontal rails There is Figure F 20 Onenn gach ROUE red 26 Carefully remove the front panel assembly 24 Using the 9 16 wrench remove the four bolts nuts and washers from the bottom of the front panel assembly These four bolts mount the front to the base There are two on each side See Figure F 20 CLASSIC
50. OUNTING SLING De Do Do SN Ojo O o E 515 Oo PEN ale f 5 5 1 ENGINE GENERATOR MOUNTING HOLES the engine See Figure F 24 ojo EP le 8 31 With the rope sling around the main genera 32 Using the 9 16 wrench remove the bolts 9 tor frame carefully lift the frame a small dis and lock washers mounting the generator tance Slide the wood or steel blocks under frame to the engine See Figure 24 513 e CLASSIC I LINCOLN 9 Return to Section TOC Return to Master TOC Return to Section TOC olo O o 515 Oo PEN 2 2 5 5 1 Return to Master F 45 F 45 TROUBLESHOOTING amp REPAIR MAIN GENERATOR FRAME REMOVAL AND REPLACEMENT continued 33 Using the rope sling and pry bars carefully lift and wiggle the generator frame away from the engine and armature assembly Be careful to support the generator frame as you remove it NOTE The exciter frame is also removed with the main generator frame Reassembly Refer to Figures 13 E24 as needed 1 Using the rope sling carefully lift and wiggle the generator frame onto the engine and armature assembly Be careful to support the generator frame as you position it Using the 9 16 wrench install the bolts and lock washers moun
51. P Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn Wear eye ear and body protection A WARNING ENGINE EXHAUST can kill Use in open well ventilated areas vent exhaust to the outside Do not stack anything on or near the engine A MOVING PARTS can injure Do not operate this equipment with any AN of its doors open or guards off Stop the engine before servicing it Keep away from moving parts Only qualified personnel should install use or ser vice this equipment GENERAL DESCRIPTION The Classic is a heavy duty engine driven DC arc welding power source capable of providing DC con stant current output for stick welding or DC TIG weld ing The Classic 115 wound with all copper coils bet ter arc stability and precise welding control With the addition of the optional Wire Feed Module or CV adapter the Classic will provide constant voltage out put for running the LN 25 wire feeder The Classic has a current range of 40 300 DC amps It provides 1 75 kw of 120V DC auxiliary power This unit uses the four cylinder Continental TM27 industrial water cooled gasoline engine CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 2 tc Return to Section TOC Return to Master TO
52. REPAIR RETEST AFTER REPAIR Retest a machine If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics OR f you repair or replace any electrical components Return to Section TOC Return to Master TOC ENGINE OUTPUT Mode No Load RPM Load RPM Low Idle 1000 1050 NA High Idle 1550 1650 1440 1500 WELDER DC OUTPUT Current Control Current Selector Open Circuit Load Volts Load Amps Rheostat Switch Voltage Maximum Maximum 88 95 33 39 300 Return to Section TOC Return to Master TOC DC AUXILIARY POWER RECEPTACLE OUTPUT Open Circuit Voltage Load Volts Load Amps 123 132 115 125 15 0 FIELD AMPS AND VOLTS Current Rheostat at Maximum Exciter DC Volts Main Shunt Field Amps RPM 123 132 2 35 2 65 1440 1560 O10 Fie E 0 5 2 2 clt Sa cc 1 Return to Section TOC Return to Master TOC CLASSIC LINCOLN 5 Return to Master TOC Return to Master TOC O o 9 2 Return to Master 6 1 ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams Section 000 Section G Wiring Diagram a pce pennies lens G 2 Wiring Diagram Wire Feed Module ss G 3 Idler PC
53. ROBLEMS SYMPTOMS The welding output varies abnor mally The auxiliary output remains constant The engine is operating correctly POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check for loose or faulty weld ing cables 2 This may be a normal condition The machine will normally lose some output as the components are heated Check for loose worn dirty or poorly seated main DC genera tor brushes The main armature commutator may need cleaning TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Check the fine current control field rheostat for resistance and proper operation Normal resis tance is 64 ohms Check asso ciated wires for loose or faulty connections See the Wiring Diagram 2 Perform the Shunt Field Winding Test Check the current range selector switch and contacts for proper operation While the machine is loaded check the interpole and series coils for signs of arcing This condition would indicate short ed turns in the arcing coil The main armature may be faulty Check for grounds CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Retur
54. ROCEDURE 1 2 3 Turn the engine OFF Unlatch and secure the right side door Locate the idler solenoid and the two leads with quick connects See Figure F 4 Disconnect the two solenoid leads at the quick connection splices Using the external power supply apply 12VDC to the idler solenoid leads The solenoid should activate The solenoid should deactivate when the 12VDC is removed CLASSIC LINCOLN 5 If the solenoid does not operate properly check for a mechanical restriction in the link age or for a missing spring If the linkage is intact and the solenoid does not operate correctly when 12VDC is applied the idler solenoid may be faulty Replace the idler solenoid NOTE Normal solenoid coil resistance is approximately 25 ohms 9 After the test and repairs are completed close and latch the right side door F 19 F 19 TROUBLESHOOTING amp REPAIR MAIN GENERATOR SHUNT FIELD WINDING TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are una
55. UIT DC WELD VOLTAGE WAVEFORM HIGH IDLE NO LOAD FINE CURRENT CONTROL RHEOSTAT AND SELECTOR SWITCH AT MAXIMUM Return to Section TOC Return to Master TOC REA 0 volts Return to Section TOC Return to Master TOC 50 volts 5 ms This is the typical DC welding output voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time Note Scope probes connected at machine output terminals O10 Fie E 0 2 2 Sa 1 SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div e e Trigger Internal 55 8 gt 2 2 515 Dlo lt CLASSIC LINCOLN 5 F 31 F 31 TROUBLESHOOTING amp REPAIR TYPICAL DC WELD VOLTAGE WAVEFORM MACHINE LOADED SELECTOR SWITCH AT MAXIMUM Return to Section TOC Return to Master TOC 0 volts Return to Section TOC Return to Master TOC 20 volts 5 ms MACHINE LOADED TO 200 AMPS AT 40VDC This is the typical DC welding output voltage generated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal division represents 5 mi
56. WER PADDLE MARK TEST PROCEDURE Strobe Tach Method 4 Connect the strobe tach according to the manufacturer s instructions 1 hi ith th FF efie 5 Start the engine and direct the strobe tach 2 Unlatch lift and secure the right and left side light on the blower paddle and synchronize it doors to the rotating mark 3 With the white or red marking pencil place a 6 With the machine at HIGH IDLE the tach mark on one of the blower paddles See should read between 1550 and 1650 RPM Figure F 7 With the machine at LOW IDLE the tach should read between 1000 and 1050 RPM CLASSIC LINCOLN 5 F 24 F 24 TROUBLESHOOTING amp REPAIR olo BB ENGINE THROTTLE ADJUSTMENT TEST continued E gt 518 FIGURE 8 HIGH IDLE ADJUSTMENT els 2 2 2 Sree a L olo 4 515 a gt doo 513 LOCKING 9 NUT cb lt ADJUSTMENT SCREW Adjust High Idle a Make sure there is no load on the machine b Set the Idler switch to the HIGH position c Locate the governor on the left side of the engine See Figure F 8 d Using the 3 8 wrench to turn the adjustment screw and locking nut adjust the high idle speed to between 1550 1650 RPM It may not be necessary to remove the seal See Figure F 8 e If further adjustments are necess
57. WIRE FEED MODULE OPTIONAL ON MACHINE REMOVE PLUG P10 FROM CONNECTOR J5 CONNECT PLUG P5 ON W F M TO CONNECTOR J5 ON MACHINE CONNECTORS W F M CONTROL PANEL WIRE CONNECT TO POS amp NEG OUTPUT TERMINALS FEED 5 NEGATIVE CV MODULE OUTPUT TERMINAL NEGATIVE POSITIVE CC CC amp CV WITH WFM OPTION K924 4 REMOTE CONTROL OPTIONAL REMOTE CONTROL RECEPTACLE amp SWITCH SWITCH FOR LOCAL OR REMOTE CONTROL SHOWN IN LOCAL POSITION PLUG FOR REMOTE CONTROL POTENTIOMETER RESISTORS 0 Y CONNECT TO CASE REMOTE CONTROL POTENTIOMETER BOX MACHINE OFF REMOVE PLUG P9 ON MACHINE FROM CONNECTOR J8 THEN CONNECT PLUG P8 POTENTIOMETER BOX CONNECT TO NEG BRUSH HOLDER WITH MACHINE NOT RUNNING REMOVE PLUG P9 ON MACHINE FROM CONNECTOR 8 THEN CONNECT PLUG P8 ON REMOTE CONTROL TO CONNECTOR J8 ON MACHINE CONNECT RED AND BLACK LEADS ON REMOTE TO RED AND BLACK LEADS ON MACHINE ON REMOTE CONTROL KIT TO CONNECTOR J8 ON MACHINE A WIRE FEED MODULE IS INSTALLED WITH THE MACHINE OFF DISPOSE OF THE UNCONNECTED LUG P10 IF ONE IS ON THE MACHINE FASTEN THE NEW PLUG P11 NEARBY LEAVING IT UNCONNECTED MACHINE MUST NOT BE RUNNING IF NO WIRE FEED MODULE IS INSTALLED WITH THE MACHINE OFF DISCONNECT PLUG P10 ON THE MACHINE FROM CONNECTOR J5 CONNECT PLUG P11 FROM THE REMOTE CONTROL KIT TO CONNECTOR WHEN MAKING THESE CONNECTIONS J5 ON THE MACH
58. ance requiring their removal is complete If covers or guards are missing from the machine get replacements from a Lincoln Distributor Read the Safety Precautions in the front of this manu al and in the instruction manual for the engine used with your machine before working on the Classic Keep all equipment safety guards covers and devices in position and in good repair Keep your hands hair clothing and tools away from the fan and all other moving parts when starting operating or repairing this machine ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE CAUTION To prevent the engine from accidentally starting dis connect the negative battery cable before servicing the engine See Table D 1 for a summary of maintenance intervals for the items listed below Follow either the hourly or the calendar intervals whichever come first More fre quent service may be required depending on your spe cific application and operating conditions hours of operation or daily BE SURE TO En MAINTAIN THE OIL LEVEL Change the oil the first time after 50 hours of opera tion Then under normal operating conditions change the oil as specified in Table D 1 If the engine is operat ed under heavy load or in high ambient temperatures change the oil more frequently OIL Check the oil level after every 10 TABLE D 1 CONTINENTAL ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before Sta
59. ary consult the Engine Manual Ojo O o E 515 Oo PEN ale f 5 5 1 Return to Section Return to Master TOC CLASSIC LINCOLN 5 F 25 F 25 TROUBLESHOOTING amp REPAIR olo ENGINE THROTTLE ADJUSTMENT TEST continued 9 5 FIGURE F 9 LOW IDLE ADJUSTMENT SPEED ADJUSTMENT SCREW CJ pale IDLER ae er oso d NUT Return to Section TOC Return to Master TOC Adjust Low Idle a Make sure there is no load on the machine f Tighten the locking nut to the ball joint The b Set the Idler switch to AUTO and wait for the DUEB APY DON ege than the bottom value of the range engine to change to low idle speed g Using the speed adjustment screw on the carburetor set the low RPM to within the range 1000 1050 RPM See Figure F9 c Check the alignment of the idler rod so that the plunger can move freely d Using the 7 16 wrench loosen the idler rod locking nut This is located on the idler rod between the carburetor ball joint and the idler solenoid See Figure F 9 Ojo O o E 515 Oo PEN ale f 5 5 1 Adjust the rod stickout from the ball joint to set the low idle speed to the bottom of the range 1000 RPM The flattened por tion of the idler rod must be vertical This ens
60. ate oil to all the parts See thel Maintenancelsection of this manual for details on changing oil 3 Remove the battery recharge it and adjust the electrolyte level Store the battery in a dry dark place See Battery Maintenance in the Maintenance section of this manual 4 See your engine operation manual for further infor mation on fuel and engine preservation See also short or long term storage in the Engine manual CLASSIC I LINCOLN 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 3 tc Return to Section TOC Return to Master TOC o D 4 INSTALLATION STACKING Classic 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 on other than the ground must be firm non skid and structurally sound The gasoline engine is designed to run in a level posi tion for best performance If you do operate it at a slight angle be sure to check the oil regularly and keep the oil level at the FULL mark as it would be in its normal level condition Also fuel capacity will be a little less at an angle LIFTING The Classic weighs 1370 621 kg A lift bail is provided for lifting with a hoist A WARNING FALLING EQUIPMENT can cause injury Do not lift
61. ave been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c SAFETY CLASSIC LINCOLN 5 CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas a
62. ble to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine whether or not the main shunt field coils are shorted open or grounded Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt ohmmeter Multimeter Wiring Diagram This procedure takes approximately 25 minutes to perform oio O O E E x 2912 0 PEN 9 e 2 cic 5 5 1 Return to Section Return to Master TOC CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo O o 515 Oo PEN 2 2 5 5 1 Return to Section Return to Master TOC F 20 F 20 TROUBLESHOOTING amp REPAIR MAIN GENERATOR SHUNT FIELD WINDING TEST continued FIGURE 5 PLUG P10 LOCATION PLUG P10 IR TEST PROCEDURE 1 Turn the engine OFF 2 Unlatch lift and secure the right side door 3 Locate plug P10 See Figure 5 4 Remove plug P10 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 2 tc Return to Section TOC Return
63. chine 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION If the machine output is low or high this test will determine whether or not the engine is oper ating at the correct speed RPM during both HIGH and LOW idle conditions Directions for adjusting the throttle to the correct RPM are given Return to Section TOC Return to Master TOC MATERIALS NEEDED White or red marking pencil 7 16 Wrench 3 8 Wrench This procedure takes approximately 35 minutes to perform oio O O E E x 2912 0 PEN 2 5 5 1 Return to Section Return to Master TOC CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo O o 515 Oo PEN 2 2 5 5 1 Return to Section Return to Master TOC F 23 F 23 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE F 7 BLOWER PADDLE MARK LOCATION BLO
64. cing it Keep away from moving parts See additional safety information at the front of this manual Only qualified personnel should install use or ser vice this equipment LOCATION AND VENTILATION Always operate the Classic 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 Whenever you use the Classic be sure that clean cooling air can flow through the machine s gasoline engine and the generator Avoid dusty dirty areas Also keep the machine away from heat sources Do not place the back end of the generator anywhere near hot engine exhaust from another machine And of course make sure that engine exhaust is ventilated to an open outside area The Classic may be used outdoors Do not set the machine in puddles or otherwise submerge it in water Such practices pose safety hazards and cause improp er operation and corrosion of parts STORING 1 Store the machine in a cool dry place when it is not in use Protect it from dust and dirt Keep it where it can t be accidentally damaged from construction activities moving vehicles and other hazards 2 Drain the engine oil and refill with fresh SAE 30 or 40 oil Run the engine for two minutes to circul
65. d check the level on the dipstick Figure D 1 the Maintenance section of this manual 3 Add oil if necessary to bring the level up to the full mark Do not overfill 4 Replace the dipstick Check and fill the engine fuel tank 1 Remove the fuel tank cap 2 Fill the tank to allow approximately 1 4 inch 5 mm of tank space for fuel expansion DO NOT FILL THE TANK TO THE POINT OF OVERFLOW 3 Replace the fuel tank cap and tighten securely WARNING Do not add fuel near an open flame welding arc or when the engine is run ning Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been elimi nated NOTE USE GASOLINE ONLY Purchase gasoline in quantities that will be used within 30 days to assure freshness STARTING THE ENGINE NOTE Remove all loads connected to the DC power receptacle before starting the engine Make sure the fuel valve on the sediment bowl is in the open position 1 Place the IDLER switch in the HIGH position and the IGNITION switch in the ON position Pull out the choke cable and then press the START button NOTE If the engine fails to start in 60 seconds wait 30 seconds before repeating Step 1 2 When the engine starts running observe the oil pressure If no pressure
66. de cable to the Negative terminal These connections should be checked periodically and tightened if necessary CAUTION Loose connections will cause the output terminals to overheat The terminals may eventually melt Do not cross the welding cables at the output termi nal connection Keep the cables isolated and sepa rate from one another When welding at a considerable distance from the welder be sure you use ample size welding cables Table A 1 lists recommended cable sizes and lengths for rated current and duty cycle Length refers to the distance from the welder to the work and back to the welder Cable diameters are increased for long cable lengths to reduce voltage drops Lincoln Electric offers a welding accessory kit with the properly specified welding cables See the section of this manual for more information AUXILIARY POWER RECEPTACLE PLUGS AND HAND HELD EQUIPMENT The DC auxiliary power supplied as a standard has a rating of 1 75 kw of 120V DC FIGURE A 2 CLASSIC OUTPUT CONNECTIONS 1 120 VOLT DC RECEPTACLE 2 WELD OUTPUT TERMINALS 2 3 GROUND STUD LOCATION 4 CABLE STRAIN RELIEF BRACKET TABLE RECOMMENDED COPPER WELDING CABLE SIZE AND LENGTH TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable size for combined length of electrode plus work cable Amps Duty Cycle Up to 200 ft 200 to 250 ft 200 60
67. des the connection point for either the electrode holder or the work cable GROUND STUD Provides a connection point for connecting the machine case to earth ground See Machine Grounding in the Installation section of this manual CLASSIC I LINCOLN 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 5 Return to Section Return to Master TOC OPERATION CONTROL OF WELDING CURRENT A 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 See Figure B 2 The CURRENT RANGE SELECTOR provides five overlapping current ranges The FINE CURRENT ADJUSTMENT adjusts the current from minimum to maximum within each range Open circuit voltage is also controlled by the FINE CURRENT ADJUSTMENT permitting control of the arc character istics A high open circuit voltage setting provides the soft buttering arc with best resistance to pop outs pre ferred for most welding To get this characteristic set the CURRENT RANGE SELECTOR to the lowest set ting that still provides the current you need and set the FINE CURRENT ADJUSTMENT near maximum For example to obtain 175 am
68. eat up so that all electri cal components can reach their operating tem perature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and termi nal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROB LEM will help avoid denial of legitimate PC board warranty claims CLASSIC I LINCOLN 9 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 2 Return to Section Return to Master TOC o O o 9 TROUBLESHOOTING REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The engine starts and runs at cor rect speed but there is no or very low welder output voltage There is no DC auxiliary output voltage POSSIBLE AR
69. en the idler PC board and the DC exciter Using the slot head screw driver connect the red lead between the 115VDC receptacle and the DC exciter Replace any cable ties cut during disassembly Using the slot head screw driver install the choke control cable to the engine carburetor assembly noting placement mark Using the 3 4 wrench install the heavy lead to the positive output terminal and the copper strap lead and reed switch assembly to the negative output terminal Using the 1 2 wrench install the five heavy flex leads to the selector switch as labeled during disassembly Carefully position the fuel tank to the mount ing rails Using the 9 16 wrench install the four nuts bolts and washers holding the fuel tank assembly to the rails Remove the plug from the fuel line and attach it to the fuel bowl Perform the DC Exciter Armature Reassembly Procedure Carefully set the top and doors assembly into place Install the L shaped door hooks Using the 1 2 wrench install the four nuts and bolts holding the case top and doors assembly to the welder frame Install the rubber gasket to the top Using the 1 2 wrench install the negative battery cable Slide the battery mounting panel back into place and using the 7 16 wrench install the two bolts and washers that secure the panel Return to Section TOC Return to Master TOC CLASSIC LINCOLN 5 F 46 F 46 TROUBLESHOOTING am
70. epairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 Return to Section TOC Return to Master TOC CLASSIC LINCOLN 5 F 13 F 13 TROUBLESHOOTING amp REPAIR DC EXCITER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will help determine whether or not the DC exciter is operating correctly If oper ation is not correct the test will also determine what component s may be faulty Return to Section TOC Return to Master TOC MATERIALS NEEDED 3 8 Nut driver Volt ohmmeter Multimeter Wiring Diagram This procedure takes approximately 30 minutes to perform oio O O E E x 2912 0 PEN 9 e 2 cic 5 5 1 Return to Section Return
71. f this manual FUEL Fill the fuel tank with clean gasoline only The Classic has a 15 gallon 57 liter fuel tank with a top fill and fuel gauge mounted on the control panel See the Operation sndfiMsinteirancs cie of this manual for more details about fuel BATTERY CONNECTIONS The Classic 115 shipped with the negative battery cable disconnected Before you the machine make sure the IGNITION switch is in the OFF position and attach the disconnected cable securely to the battery terminal If the battery is discharged and won t start the engine see the battery charging instructions in the Maintenance section h CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo O o 515 Oo PEN 2 5 5 1 Return to Section Return to Master TOC Return to Master TOC A 5 A 5 INSTALLATION COOLING SYSTEM The cooling system has been filled at the factory with a 50 50 mixture of ethylene glycol antifreeze and water Check the radiator level and add a 50 50 solution as needed See the engine manual or antifreeze con tainer for alternate antifreeze recommendations 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 Thi
72. gs clean with an abrasive cleaning device Clean the plugs by scraping or by using a wire brush Wash the plugs with a commercial solvent 3 After cleaning or when installing new spark plug set the terminal gap with a feeler gauge or gapping tool See Figure D 4 Gap Specifications 0 032 inch 8 mm 4 Tighten plugs to 30 ft lbs 40 N m FIGURE D 4 SET SPARK PLUG GAP CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 5 Return to Section Return to Master TOC BATTERY MAINTENANCE WARNING P GASES FROM BATTERY can explode 4 Keep sparks flame and cigarettes away from battery 4 BATTERY ACID can burn eyes and skin e Wear gloves and eye protection and be careful when working near a battery Follow the instructions printed on the battery To prevent EXPLOSION when INSTALLING A NEW BATTERY Disconnect the negative cable from the old battery first and connect to the new battery last THE CORRECT POLARITY IS NEGATIVE 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 posi
73. he Above For Gasoline Engines oc ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase of Safety in Welding amp Cutting ANSI Standard 749 1 the American Welding Society Box 351040 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 FOR ENGINE 1 h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment AME hot 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors Return to Master TOC ELECTRIC AND 3 MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld may be dangerous ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric current flowing through any conductor cause
74. hnician 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine whether or not the idler solenoid can function when it is energized with 12VDC MATERIALS NEEDED External 12VDC supply Wiring Diagram Volt ohmmeter Multimeter Return to Section TOC Return to Master TOC This procedure takes approximately 15 minutes to perform oio O O E E x 2912 0 PEN 9 e 2 cic 5 5 1 Return to Section Return to Master TOC CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 2 tc Return to Section TOC Return to Master TOC o F 18 QUICK CONNECT LEADS F 18 TROUBLESHOOTING amp REPAIR IDLER SOLENOID TEST continued FIGURE F 4 IDLER SOLENOID CONNECTIONS TEST P
75. i on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit is
76. idle speed of 1600 RPM If the voltage is normal the DC exciter is functioning correctly If the voltage is low or not present proceed to the next step F 15 F 15 TROUBLESHOOTING amp REPAIR DC EXCITER TEST continued FIGURE F 2 EXCITER COVER REMOVAL Return to Section TOC Return to Master TOC EXITER CHECK VOLTAGE COVER AT BRUSH HOLDERS HERE RIGHT SIDE IS 1 Return to Section TOC Return to Master TOC 4 Turn off the engine Using the 3 8 nut driver 5 Start the engine Using the volt ohmmeter remove the exciter cover See Figure F2 carefully check the DC voltage at the brush holders See Figure F2 The right side brush holder is positive polarity Normal DC voltage is 125 135VDC with the engine at WARNING the high idle speed of 1600 RPM MOVIA FARTS can injure 6 If the DC voltage is normal at the brush hold 4 Remove guards only when ers the DC exciter armature and shunt coils necessary to perform service are OK and replace them when the aS service requiring their removal is complete a If the voltage is low or not present pro ceed with the shunt coil and series coil resistance tests Ojo O o 515 Oo PEN 2 2 5 5 1 Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing b If the correct DC
77. ing current for the battery circuit If the oil pres sure switch does not close due to low oil pressure or inadequate oil supply the oil pressure light will not glow the hour meter will not operate and the engine alternator will not function NOTE Unshaded areas of Block Logic Diagram are the subject of discussion CLASSIC I LINCOLN 5 E 3 E 3 THEORY OF OPERATION FIGURE 3 ENGINE MAIN GENERATOR ARMATURE AND FRAME AND DC EXCITER SELECTOR SWITCH REED ie rapt OR NEGATIVE OUTPUT bend TERMINAL IDLER BOARD Return to Section TOC Return to Master TOC ENGINE OIL PRESSURE LIGHT IDLER SOLENOID GENERATOR SWITCH FRAM SERIES COILS FUEL SHUTDOWN L A ENGINE MECHANICAL COUPLING IGNITION QN T dan SWITCH ALTERNATOR RESIDUAL MAGNETISM GENERATOR ARMATURE EXCITER ARMATURE 77 SHAFT ARMATURE m 115 VDC RECEPTACLE BRUSHES COMMUTATOR INTERPOLE COILS Return to Master TOC TT STARTER MOTOR FIELD Return to Section TOC SHUNT WINDINGS O o Fie ci PEN 2 2 JE 2 cc 1 Return to Section TOC Return to Master TOC BATTERY Hp ENGINE MAIN GENERATOR ARMATURE AND FRAME AND DC EXCITER EXCITATION FLASHING The main generator armature and the exciter arma ture are mechanically coupled to the engine When the engine is started and runn
78. ing the residual mag netism that is stored in the exciter pole pieces is induced upon the exciter armature This causes the exciter to build up and produce a DC output volt age This DC voltage is applied via the field rheostat control to the main generator shunt field coils The exciter output is also connected to the 115VDC recep tacle GENERATOR FIELD CONTROL POSITIVE OUTPUT TERMINAL MAIN SHUNT INTERPOLE AND SERIES COILS The generator armature rotates within the magnetic field created by the shunt field windings A DC voltage is induced in the armature and is transferred through the armature commutator and brushes to the series and interpole coils The interpole coils which are con nected in series with the positive output terminal are located so as to counteract any magnetic influences that could cause mechanical distortion in the rotating armature The series coils are designed to oppose or the DC voltage that is generated in the ture NOTE Unshaded areas of Block Logic Diagram are the subject of discussion CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 2 Return to Section Return to Master TOC O o iv THEORY OF OPERATION ENGINE MAIN GENERATOR ARMATURE AND FRAME AND DC EXCITER CONTINUED
79. itting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 plates to protect your eyes from sparks the rays of the arc when welding or observing open arc welding Headshield and filter lens shou
80. ks usually by retightening the filter but only enough to stop leaks before placing the Classic back in service 6 If there are no leaks stop the engine and recheck the oil level If necessary add oil to bring the level up to the upper dash mark but do not overfill FUEL At the end of each day s use refill the fuel tank to minimize moisture conden sation and dirt contamination in the fuel line Do not overfill leave room for the fuel to expand Refer to your engine operation manual for recommended grade of fuel CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o o 5 tc Return to Section TOC Return to Master TOC o 0 4 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 Inspect the air cleaner daily more often in dusty conditions Never remove the air filter while the engine is running Never apply oil to the air cleaner Clean every 50 hours Every 250 hours more frequently in extreme dust conditions replace the air cleaner as foll
81. l not Start Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS 1 Make sure the ignition switch is in the ON position 2 Check for adequate fuel supply RECOMMENDED COURSE OF ACTION Check the ignition switch for proper operation Check the associated leads for loose or faulty connections See the Wiring Diagram Check the fuel solenoid Make sure it is opening when 12VDC is applied to the red lead See the Wiring Diagram The engine distributor or carbu retor may need servicing The oil pressure light does not light while the engine is running 1 Make sure the correct grade and amount of oil is in the engine crankcase See the Maintenance Section of this manual The oil pressure switch may be faulty Replace If the engine hour meter and alternator function properly the oil pressure switch is closing The oil pressure light may be faulty See the Wiring Diagram The engine may not have ade quate oil pressure and may be in need of repair A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 CLASSIC LINCOLN F 12 F 12 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety
82. ld conform to ANSI Z87 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and
83. le leaving the red lead connected jumper the red lead to frame ground If the engine goes to high speed the fault is in the reed switch or associated leads See the Wiring Diagram If the engine does NOT go to high speed in step 2 the idler PC board may be faulty The engine will NOT go to high speed when a load is applied to the DC auxiliary receptacle The engine does go to high speed when a load is applied to the welding out put terminals 1 Check the auxiliary power plug and associated leads for loose or faulty connections 2 The load may be too small The load must be above 150 watts Check the black B leads con nected to the idler PC board and associated connections See the Wiring Diagram The idler PC board may be faulty A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 2 Return to Section Return to Master TOC o O o 9 11 11 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The engine cranks but wil
84. lead to the right side white flex lead See Figure Normal resistance is 120 130 ohms If the resistance is very high or open the shunt coils are faulty Replace them If the resistance is very low the shunt coils are shorted Replace them Also measure the resistance from either lead to machine ground This resistance should be very high at least 500 000 ohms CLASSIC I LINCOLN 9 10 Using the volt ohmmeter check the series coil resistance a Check from the larger solid lead left side to the 120VDC receptacle Check at the longer slot opening See Normal resistance is less than 1 ohm b Also measure the resistance from the solid lead left side to machine ground See Figure F 3 This resistance should be very high at least 500 000 ohms It may be necessary to disconnect the series coil from the 120VDC receptacle to isolate the series coil from the rest of the circuitry See the Wiring Diagram 11 If the shunt and series coils are good and the exciter is not operating properly the exciter armature may be faulty Replace the exciter armature 12 After the test and repairs are completed install the exciter cover using the 3 8 nut driver F 17 F 17 TROUBLESHOOTING amp REPAIR IDLER SOLENOID TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the tec
85. les If the electrode cable is on your right Do not put your hands near the engine fan Do not attempt to side the work cable should also be on your right side override the governor or idler by pushing on the throttle con trol rods while the engine is running 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance 2 4 5 Do not work next to welding power source work disconnect the spark plug wires distributor cap or magneto wire as appropriate Return to Master TOC CLASSIC I LINCOLN Return to Master TOC Return to Master TOC O O o 9 5 SAFETY ELECTRIC SHOCK can kill 8 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 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as s
86. lliseconds in time The machine was loaded with a resistance grid bank O10 Fie E 515 0 5 2 2 Sa 1 Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div z e DC Trigger Internal 55 8 gt ele 5 5 lt CLASSIC LINCOLN 5 F 32 F 32 TROUBLESHOOTING amp REPAIR DC EXCITER ARMATURE AND FIELD COILS REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 1 800 833 9353 WELD oio E E DESCRIPTION c 2 This procedure will aid the technician in the removal and replacement of the exciter armature 2 S and field coils ele 513 MATERIALS NEEDED 3 8
87. n to Master TOC Return to Master TOC o O o 9 gt 5 Return to Master SAFETY PR CAUTIONS DE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines S
88. n to Master TOC o 2 o 2 2 tc Return to Section TOC Return to Master TOC o O o 7 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The engine starts and runs at the correct speed but there is no DC auxiliary output voltage at the 115VDC receptacle The welding generator is functioning correctly Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check the DC receptacle and plug for loose or faulty connec tions Check the 15 Amp fuse CSA machines only RECOMMENDED COURSE OF ACTION Check for loose or faulty con nections or wires at the 115 VDC receptacle and associated circuitry See the Wiring Diagram The actual welding current is much less than is indicated on the dials Check the welding cables for loose or faulty connections The welding cables may be excessively long or coiled Check the main DC generator brushes for good commutation and alignment Contact the Lincoln Electric Service Dept 1 800 833 9353 WELD The engine RPM may be low If necessary perform the Throttle Adjustment Test 2 Perform the DC Exciter Test 3 Check the fine current control field rheostat for resistance and proper operation Normal resis tance is 64 ohms Check asso cia
89. nals For positive electrode connect the electrode cable to the terminal and the work cable to For negative electrode reverse the electrode and work cables at the welder s output terminals See Figure B 4 Replace and tighten the flange nuts securely Be sure the connections are tight Select the appropriate electrode Attach the work clamp securely to the work you are welding Insert the electrode into the electrode holder Start the engine See Engine Operation in this section of the manual Set the Idler Switch to AUTO T 8 9 Set the CURRENT RANGE SELECTOR to a set ting equal to or slightly higher than the desired welding current Set the FINE CURRENT ADJUSTMENT to the setting that gives the best arc characteristics for the range selected See Control of Welding Current in this section of the manual Strike an arc and begin welding After you finish welding 1 Stop the engine See Engine Operation in this section of the manual Allow the electrode and work to cool completely Remove the work clamp from the work Remove any remaining piece of electrode from the electrode holder FIGURE B 4 WELDING CIRCUIT CONNECTIONS FOR STICK WELDING OUTPUT TERMINALS ELECTRODE CABLE ELECTRODE HOLDER ELECTRODE WORK PIECE WORK CLAMP WORK CABLE CLASSIC LINCOLN 5 B 10 B 10 OPERATION Q 1 o
90. nd pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Retur
91. nmental conditions likely maintenance 5 Conformance with federal state and local laws Consult applicable federal state and local laws about specific requirements for use on public high ways CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 2 tc Return to Section TOC Return to Master TOC o INSTALLATION MACHINE GROUNDING According to the United States National Electrical Code the frame of this portable generator is not required to be grounded and is permitted to serve as the grounding means for cord connected equipment plugged into its receptacle When the Classic is mounted on a truck or a trailer the machine generator ground stud MUST be securely connected to the metal frame of the vehicle See Figure A 1 The ground stud is marked with the ground symbol Some state local or other codes or unusual operating circumstances may require the machine frame to be grounded It is recommended that you determine the extent to which such requirements may apply to your particular situation and follow them explicitly A machine grounding stud marked with the symbol is provided on the welding generator frame foot See Figure A 1 If an older portable welder does not have a grounding stud connect the ground wire to an unpainted frame scre
92. ol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece
93. ove the 10 Install the exciter cover armature locking nut washer and sleeve col lar 6 Carefully remove the armature by sliding it from the shaft NOTE The sleeve collar may have to be removed with a gear puller Be careful not to damage the armature commutator Return to Section TOC Return to Master TOC CLASSIC I LINCOLN 9 F 34 F 34 TROUBLESHOOTING amp REPAIR ojo DC ARMATURE FIELD COILS 5 5 REMOVAL AND REPLACEMENT continued a gt 212 Field Coils Removal Procedure Reassembly E 5 1 Perform the DC Exciter Armature Removal 7 Assemble the new coils to their respective Se pole pieces 2 Using the 3 8 wrench remove the leads from 8 Assemble the coil and pole pieces to the the brush holder Note lead placement for exciter frame with four bolts 9 Make the necessary lead connections to the 8 Using the 1 2 wrench remove the four bolts idler board and 115VDC receptacle Wrap two on each side holding the pole pieces to the slices with tape 10 Assemble the armature and brushes 4 Label and remove the tape and splices from See the DC Exciter Armature Removal the black and red leads that go to the idler board and 115VDC receptacle See the Wiring Diagram 5 Carefully slide the coils and pole pieces from the exciter frame 6 Remove the coils from the pole pieces Return to Section TOC Return to Master TOC Ojo
94. oward positive pressing the START pushbutton When the switch during running The needle will hold position in the is placed in the OFF position the engine stops center when the engine stops 3 OIL PRESSURE LIGHT Lights when the engine oil pressure drops to an unsafe level If the light comes on within 30 seconds after startup the engine should be stopped by placing the IGNITION z 2 switch the OFF position Fle 55 o 8 9 2 gt 2 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 3 tc Return to Section TOC Return to Master TOC o 7 OPERATION ENGINE OPERATION WARNING DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS The maximum allowable high idle speed for the Classic 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 Read and understand all safety instructions included in the Continental engine instruction manual that is shipped with your Classic BEFORE STARTING THE ENGINE Check and fill the engine oil level 1 Be sure the machine is on a level A surface 2 Remove the engine oil dipstick and wipe it with a clean cloth Reinsert the dipstick an
95. ows 1 Loosen the wing nut and remove the cover and the filter element Do not allow dirt to fall into the exposed carburetor Gently tap the element flat on a smooth surface 2 If dust is sticking to the dust collector element blow compressed air through it from the inside out Turn the element as you apply air Air pressure should be under 2 bar 30 psi 3 Check the element for damage before reassem bling the air cleaner Replace the element if it appears damaged The air cleaner element part number is Donaldson 181050 or Nelson 70206N COOLING SYSTEM The Continental engine is water cooled Check the coolant level at the radiator filler daily Add a 50 50 mixture of water and antifreeze as needed To drain and refill the system do the following 1 Ensure that the machine is on level ground A WARNING To avoid personal injury never remove the radiator pressure cap nor the reserve tank cap while the engine is running or immediately after it has stopped Hot water may gush out which can scald people nearby 2 Remove the radiator filler cap 3 Remove the drain plug or cock from the side of the cylinder block in order to drain the engine Ensure that the drain hole is not restricted See Figure D 2A 4 Open the radiator drain cock at the bottom of the radiator in order to drain the radiator See Figure D 2B 5 If necessary flush the system with clean water Replace the engine drain plug and the radiator
96. p REPAIR MAIN GENERATOR ARMATURE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD olo 5 DESCRIPTION 9 8 This procedure will aid the technician the removal and replacement of the main armature 92 Es MATERIALS NEEDED lt Rope sling 5 8 Wrench Wood or steel blocks O10 Fle E 0 2 2 Sa Return to Section Return to Master TOC CLASSIC LINCOLN 5 F 47 F 47 TROUBLESHOOTING amp REPAIR MAIN GENERATOR ARMATURE REMOVAL AND REPLACEMENT continued FIGURE F 25 MAIN GENERATOR ARMATURE MOUNTING o jg 5 o 2 3 Return to Master BLOWER PADDLE gt
97. ps and a soft arc set the CURRENT RANGE SELECTOR to the 190 to 120 position and then adjust the FINE CURRENT ADJUST MENT for 175 amps When a forceful digging arc is required usually for vertical and overhead welding use a higher CURRENT RANGE SELECTOR setting and lower open circuit voltage For example to obtain 175 amps and a force ful arc set the CURRENT RANGE SELECTOR to 240 160 position and the FINE CURRENT ADJUSTMENT setting to get 175 amps Some arc instability may be experienced with EXX10 electrodes when trying to operate with long arc tech niques at settings at the lower end of the open circuit voltage range FIGURE B 2 CURRENT CONTROLS FINE CURRENT ADJUSTMENT CURRENT RANGE SELECTOR CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Q F 2 5 o 2 E Return to Master B 6 OPERATION FIGURE B 3 GASOLINE ENGINE CONTROLS IDLER CONTROL TOGGLE SWITCH IGNITION TOGGLE SWITCH OIL PRESSURE LIGHT START PUSHBUTTON CHOKE CONTROL ENGINE HOUR METER AMMETER NOOR GASOLINE ENGINE CONTROLS See Figure B 3 for the location of the following features 1 IDLER CONTROL TOGGLE SWITCH Adjusts the running speed of the engine The switch has two positions HIG
98. ral state and local laws Various hitches and acces sories are available Power Plug Kit K802 A Provides auxiliary plug for 115VDC receptacle CV Adapter K384 Provides constant voltage out put for semiautomatic welding For K6090 through 4 only Wire Feed Module K623 1 Provides constant volt age output for semiautomatic welding For LN 25 wire feeder For K6090 5 and above Linc Thaw Control Unit L2964 1 Includes meter and fuses to protect the welder when thawing frozen water pipes A WARNING PIPE THAWING IS NOT a CSA approved procedure If not done properly it can result in fire explosion damage to wiring which may make it unsafe dam age to pipes burning up the welder or other haz ards Do not use a welder to thaw pipe before reviewing Lincoln Bulletin E695 1 dated October 1987 or later Accessory Kit K702 Includes the following Electrode cable Work cable Headshield Work clamp Insulated electrode holder Remote Control K888 4 Includes a control box with 100 ft 30 5 meters of cable Allows output to be controlled remotely K888 3 has only 25 ft 7 6 meters of cable For K6090 through 4 only Remote Control Kit K924 1 Includes a control box with 100 ft 30 5 meters of cable Allows output to be controlled remotely For K6090 5 and above SEMIAUTOMATIC WELDING ACCESSORIES LN 25 Wire Feeder This portable wire feeder is capa
99. reed switch CR2 It may be stuck closed Replace if necessary Idler Solenoid Perform the Check for loose or faulty con nections at the idler PC board The idler PC board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 42 o 2 2 tc Return to Section TOC Return to Master TOC o O o 10 10 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The engine will NOT go to high speed when a load is applied to the welding output terminals The engine does go to high speed when a load is applied to the DC auxiliary power receptacle POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS 1 Check welding cables for loose or faulty connections TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Check the reed switch CR2 for proper operation The reed switch should close when there is current flow in the welding cir cuit Locate the red lead connected to the idler PC board Whi
100. rting Engine Visual Inspection Fill fuel tank Check oil level Check radiator level Check air cleaner for dirty loose or damaged parts First 50 Hours Check air filter Change engine oil Change oil filter Change fuel filter Check battery Check fan belt Check fan belt tension Every 50 Hours Change engine and filter Service air cleaner clean element Check battery electrolyte level and connections Every 250 Hours Repeat 50 hour checks Check distributor cap Check ignition wires Replace air cleaner element Clean spark plugs and check gap Refer to your engine Owner s Manual for details and periodic maintenance at 500 hours and beyond CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 2 tc Return to Section TOC Return to Master TOC o 3 FIGURE D 1 OIL DRAIN REFILL 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 0 1 Replace the plug and tighten it securely Remove the oil fill cap and add oil until the level reaches the upper dash full mark on the dip
101. s ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician Keep all equipment safety guards covers and before welding devices in position and in good repair Keep hands hair clothing and tools away from belts gears fans and all other moving parts when starting operating or repairing equip ment Exposure to EMF fields in welding may have other health effects which are now not known 0 9 5 3 All welders should use the following procedures order to minimize exposure to EMF fields from the welding circuit 1 6 In some cases it may be necessary to remove safety 2 d 1 Route the electrode and work cables together Secure guards to perform required maintenance Remove them with tape when possible guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 2 Never coil the electrode lead around your body Always use the greatest care when working near moving parts 2 d 3 Do not place your body between the electrode and work cab
102. s will minimize the amount of water and debris that could enter the muffler during transportation EXHAUST SPARK ARRESTER Some federal state or local laws may require that engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard The stan dard mufflers included with these welders do not qual ify as spark arresters When required by local regula tions a suitable spark arrester must be installed and properly maintained A CAUTION Use of an incorrect arrester may lead to engine dam age or performance loss Contact the engine manu facturer for specific recommendations TRAILERS If you use a non Lincoln trailer you must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment Some of the factors to be consid ered are as follows 1 Design capacity of the trailer vs the weight of the Lincoln equipment and likely additional attach ments 2 Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework 3 Proper placement of the equipment on the trailer to ensure stability side to side and front to back This includes when being moved and when standing by itself for operation or service 4 Typical conditions of use such as travel speed roughness of the surfaces where the trailer will be used enviro
103. shows within 30 seconds stop the engine and consult the engine operating manual 3 As the engine warms slowly return the choke con trol to the in off position 4 Allow the engine to run at high idle speed for sev eral minutes to warm up before welding Cold engines tend to run at a speed too slow to supply the voltage required for proper idler operation CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Ojo O o 515 Oo PEN 2 2 5 5 1 Return to Section Return to Master TOC Return to Master TOC B 8 OPERATION STOPPING THE ENGINE 1 Remove all welding and generator power loads and let the engine cool by running it for several minutes at low 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 received At the end of each day s welding refill the fuel tank to minimize moisture condensation in the tank Also run ning out of fuel tends to draw dirt into the fuel system 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 COLD WEATHER STARTING Follow the instructions on the nameplate and in the engine manual shipped with
104. souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 CLASSIC I LINCOLN 5 MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page rl i iv Installation Section Technical Specifications i RAR REG a eee A 2 Safety 12220825 titu erede Lig tee olei d Lag eade ce rt de Dv aba Loft edad rx A 3 Location and Ventilation sise A 3 Pre operation Engine Service sisi A 4 Electrical Output Connections cce 7 Sri a Section B Sen ce B 2 General faeces B 2 Recommended Applications sise B 3 Operational Features and B 3 DESIGN EPP 3 Welding Capability 2 2 rit B 3 B 3 Controls and B 4 Engine UEM B 7
105. stick Use high quality oil viscosity grade 10W30 Consult the engine manual for oil specifications Always check the level with the dipstick before adding more oil 4 Reinstall the oil fill cap and the dipstick CHANGE THE OIL FILTER Change the oil filter the first time after 50 hours of operation Then under nor mal operating conditions change the oil filter after every 50 hours of operation If the engine is operated under heavy load or in high ambient temperatures change the oil filter more frequently See Table recommended maintenance intervals Order Continental oil filters from your local Continental ser vice center Change the oil filter as follows 1 Drain the oil from the engine and allow the oil filter to drain 2 Remove the old filter spin it off and discard it Wipe off the filter mounting surface and adapter Q max lt MIN OIL DRAIN PLUG LOCATION OIL FILL CAP DIPSTICK OIL FILTER DIPSTICK LEVELS D 3 a thin coat of new oil to the rubber gasket on the new oil filter 4 Spin the new filter onto the mounting adapter finger tight until the gasket is evenly seated Then turn it down another 1 2 turn Do not overtighten the new filter 5 Refill the engine with the proper amount and type of oil as described in the Change the Oil section above Start the engine and check for leaks around the filter element Correct any lea
106. tator as the armature rotates at full speed until con tact is made across the full face of the brushes After stoning blow out the dust with low pressure air A WARNING Uncovered rotating equipment can be dangerous Use care so your hands hair clothing or tools do not catch in the rotating parts Protect yourself from particles that may be thrown out by the rotating armature when ston ing the commutator Arcing or excessive exciter brush wear indicates a pos sible misaligned shaft Have an authorized Lincoln Electric Field Service facility check and realign the shaft BEARINGS The Classic is equipped with double shielded ball bearings having sufficient grease to last indefinitely under normal service Where the welder is used constantly or in excessively dirty locations it may be necessary to add one half ounce of grease per year A pad of grease one inch wide one inch long and one inch high weighs approximately one half ounce Over greasing is far worse than insufficient greasing When greasing the bearings keep all dirt out of the area Wipe the fittings completely clean and use clean equipment More bearing failures are caused by dirt introduced during greasing than from insufficient grease CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Ojo O o 515 Oo PEN 2 2 5 5 1 Return to Section Return to Master TOC
107. tch in the HIGH position 6 Adjust wire feed speed and voltage at the LN 25 FIGURE C 1 CLASSIC I LN 25 ACROSS THE ARC CONNECTION DIAGRAM 14 PIN AMPHENOL LN 25 WIRE FEEDER WITH K444 2 REMOTE VOLTAGE CONTROL OPTION ELECTRODE CABLE TO WORK WORK CLIP LEAD TO WORK CLASSIC LINCOLN 5 C 4 NOTES CLASSIC LINCOLN 5 901 191SEN 901 191SEIN 0 901 J91Se N 01 901 J91Se N DOL uonoes oj DOL uonoes oj uumeg DOL uonoes DOL uonoes Section D 1 Section D 1 TABLE OF CONTENTS o MAINTENANCE 8 ET E Section D Safety Precautions dre mines shane E seen en idee D 2 2 Routine and Periodic se D 2 Engine ee ra tte radin D 2 2 Engine Maintenance Schedule D 2 Change the Oll xc D 3 Change ithe Oil Filter oe t d mn D 3 gi Re aa ae nea nn D 3 FUG oe a D 4 o en rr in el eee reer er eee D 4 8 Cooling tale ie te D 4 X D 5 ferie
108. ted wires for loose or faulty connections See the Wiring Diagram Check the current range selec tor switch and contacts for prop er operation 5 Perform the Shunt Field Winding Test The main armature may be faulty Check for grounds A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 2 Return to Section Return to Master TOC O o iv TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The actual welding current is much greater than is indicated on the dials POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check the main DC generator brushes for good commutation and alignment Contact the Lincoln Electric Service Dept 1 800 833 9353 WELD TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 The engine operating speed may be too high If necessary perform the 2 While the machine is loaded check the series coils for signs of arcing This condition could point to shorted
109. the other end of the same lead to the left side brush holder for approximately five seconds Pull the lead away quickly to minimize arcing See Figure F 11 Remove both leads from the brush holders and the battery Install the brush removed in step 3 Install the exciter cover using the 3 8 nut driver Start the engine The exciter should produce DC output voltage CLASSIC LINCOLN 5 F 29 F 29 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VDC SUPPLY HIGH IDLE NO LOAD FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM Return to Section TOC Return to Master TOC 0 volts Return to Section TOC Return to Master TOC 50 volts 2 ms This is the typical auxiliary output voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal division represents 2 milliseconds in time Note Scope probes connected at machine 115VDC receptacle O10 Fle E 515 0 5 2 2 Sa SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 2 ms Div Coupling DC e e Trigger Internal 55 8 gt ele 5 5 lt CLASSIC LINCOLN 5 F 30 F 30 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRC
110. the welder With a fully charged battery and the proper weight oil the engine should start satisfactorily even when the air tempera ture is down to about 0 F 18 C It is important to follow the engine manufacturer s rec ommendations for oil and fuel to obtain satisfactory cold weather performance Consult the Engine manu al and the Maintenance section of this manual BREAK IN PERIOD Any engine will use a small amount of oil during its break in period Check the oil twice a day during break in Change the oil and oil filter cartridge after the first 50 hours of oper ation Also change the fuel filter cartridge For more details see the Maintenance section of this manual Also see the Engine manual CAUTION During break in subject the Classic to moderate to heavy loads Avoid long periods running at idle Before stopping the engine remove all loads and allow the engine to cool several minutes CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 2 2 tc Return to Section TOC Return to Master TOC OPERATION WELDING OPERATION TO USE THE CLASSIC FOR DC CONSTANT CURRENT STICK OR TIG WELDING 1 Remove the flange nuts from the weld output ter minals and place the work and electrode welding cables over the termi
111. ting the generator frame to the engine Using the 3 4 wrench install the frame mounting bolts nuts and washers to the feet of the main generator Check air gap min 035 for main generator Using the 7 16 wrench tighten the main erator brush bracket clamping bolt Note the position of the drill spot Install the eight brushes against the main commutator Observe the positions you noted during disassembly Using the slot head screw driver install the brush bracket wrap around cover with two nuts and screws Carefully set the front panel assembly into position Using the 3 8 nut driver install the screw for the lower middle of the front panel Using the 9 16 wrench install the four bolts nuts and washers for the bottom of the front panel assembly Then install the two bolts nuts and washers that hold the front panel assembly to the horizontal rails Using the 3 8 nut driver connect the yellow wire from the oil pressure switch and the brown wire from the idler solenoid to the idler switch Connect the blue wire and the black wire to the ammeter See the Wiring Diagram 8 10 11 12 13 14 15 16 Connect the white wire to the idler PC board Connect the two red wires to the ignition switch Connect the H lead to the START button switch Connect the blue and brown main shunt leads at their quick disconnect splices Connect the black lead betwe
112. tive cable and battery clamp When reinstalling connect the negative cable last Keep the area well ventilated USING A BOOSTER Connect the positive lead to the battery first then connect the negative lead to the engine foot To prevent BATTERY BUCKLING tighten the nuts on the battery clamp until snug CLEANING THE BATTERY Keep the battery clean by wiping it with a damp cloth when dirty If the terminals appear corroded discon nect the battery cables and wash the terminals with an ammonia solution or a solution of 1 4 pound 0 113 kg of baking soda and 1 quart 0 946 1 of water Be sure the battery vent plugs if equipped are tight so that none of the solution enters the cells After cleaning flush the outside of the battery the bat tery compartment and surrounding areas with clear water Coat the battery terminals lightly with petroleum jelly or a non conductive grease to retard corrosion Keep the battery clean and dry Moisture accumulation on the battery can lead to more rapid discharge and early battery failure CHECKING SPECIFIC GRAVITY Check each battery cell with a hydrometer A fully charged battery will have a specific gravity of 1 260 Charge the battery if the reading is below 1 215 NOTE Correct the specific gravity reading by adding four gravity points 0 004 for every five degrees the electrolyte temperature is above 80 degrees F 27 degrees C Subtract four gravity points 004 for every
113. to Master TOC O o iv F 21 F 21 TROUBLESHOOTING amp REPAIR MAIN GENERATOR SHUNT FIELD WINDING TEST continued FIGURE F 6 PLUG P10 PIN ASSIGNMENTS PIN 3 PIN 5 10000 CT TAB Locate the blue U pin 3 and the brown pin 5 leads in the harness plug See Figure F 6 Using the volt ohmmeter measure the resis tance between the blue and the brown lead Normal resistance is approximately 40 ohms Also measure the resistance from either lead blue or brown to ground This resis tance should be at least 500 000 ohms If the test does not meet the resistance specifications then check the harness plug for loose connections or shorted leads CLASSIC LINCOLN 5 10 11 12 lf the plug and associated leads are okay the shunt field coils may be faulty Replace the shunt field coils If the test does meet the resistance specifi cations the main shunt coils are okay Replace plug P10 making sure the leads and plug are secure After the test and repairs are completed close and latch the right side door F 22 F 22 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJUSTMENT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or ma
114. turns in the series coils 3 Perform the DC Exciter Test CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 CLASSIC I Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 2 tc Return to Section TOC Return to Master TOC o O o iv 9 9 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The engine will not return to low idle when the welding and auxiliary loads are removed Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Make sure the idler control switch is set to the Auto posi tion Make sure both welding and auxiliary loads are removed Check for mechanical restric tions in the idler and throttle link age While the engine is running if the oil pressure light is NOT lit the oil pressure switch may be faulty See the Wiring Diagram RECOMMENDED COURSE OF ACTION 3 5 Check the idler control switch and associated leads for loose or faulty connections See the Wiring Diagram Check the
115. ures free pivoting of the idler rod in the idler solenoid plunger To achieve this turn the idler rod into the ball joint no more than one half turn Return to Section TOC Return to Master TOC CLASSIC LINCOLN 5 F 26 F 26 TROUBLESHOOTING amp REPAIR FLASHING THE FIELDS WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will magnetize the exciter pole pieces The exciter can then build up when the engine is started MATERIALS NEEDED 12 volt battery Two jumper wires with alligator clips on each end Wiring Diagram 3 8 Wrench Return to Section TOC Return to Master TOC This procedure takes approximately 15 minutes to perform oio O O E E x 2912 0 PEN 9 e 2 cic 5 5 1 Return to Section Return to Master TO
116. urn to Section TOC Ojo O10 Fie ci gt 28g 5 2 cc 1 Return to Section TOC Return to Master TOC Return to Master TOC E 2 E 2 THEORY OF OPERATION FIGURE E 2 BATTERY STARTER ENGINE ALTERNATOR AND OIL SWITCH CIRCUIT IDLER BOARD OIL PRESSURE METER LIGHT IDLER SOLENOID OIL PRESSURE SWITCH FUEL SHUTDOWN a ENGINE IMECHANICAI IGNITION COUPLING IGNITION ENGINE SWITCH ALTERNATOR ii STARTER MOTOR BATTERY H GENERAL DESCRIPTION The Classic is a heavy duty engine driven DC arc welding power source capable of providing constant current output for stick welding or DC TIG welding Also a total of 1750 watts of auxiliary power is available at the 115VDC receptacle The Classic is manufac tured with all copper windings GENERATOR FRAME SERIES COILS GENERATOR ARMATURE INTERPOLE COILS WINDINGS SELECTOR SWITCH Pm NEGATIVE OUTPUT TERMINAL RESIDUAL MAGNETISM SHUNT FIELD DC EXCITER ARMATURE m 115 VDC RECEPTACLE ARMATURE 77 SHAFT COMMUTATOR GENERATOR FIELD CONTROL POSITIVE m OUTPUT TERMINAL BATTERY STARTER ENGINE ALTERNATOR AND OIL SWITCH CIRCUIT The 12VDC battery powers the starter motor and through the ignition switch the engine ignition and fuel shutoff solenoid The engine alternator supplies charg
117. w or bolt In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints or to the metal framework of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A WARNING Do not ground the machine to a pipe that carries explo sive or combustible material FIGURE A 1 GROUND STUD LOCATION 1 Ground Stud CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9 o 5 Return to Section Return to Master TOC 7 INSTALLATION ELECTRICAL OUTPUT CONNECTIONS See Figure A 2 for the location of the 115V DC volt receptacle weld output terminals and ground stud WELDING CABLE CONNECTIONS CABLE INSTALLATION AND CABLE SIZES With the engine off route the electrode and work cables through the strain relief bracket on the base and connect to the terminals located below the fuel tank mounting rail See size recommendations below For positive polarity connect the electrode cable to the ter minal marked Positive For Negative polarity con nect the electro
118. welding genera tor RECOMMENDED COURSE OF ACTION Check the fine current control field rheostat for resistance and proper operation Normal resis tance is 64 ohms Check asso ciated wires for loose or faulty connections See the Wiring Diagram 2 Perform the Shunt Field Winding Test Check the continuity of the inter pole coils They should show continuity from the positive brusholders to the positive out put terminal and should NOT be grounded to the generator frame Check the continuity of the series coils They should show continuity from the negative brusholders through the current selector switch to the negative output terminal and should NOT be grounded to the generator frame The main armature may be faulty Check for grounds and or shorts CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 CLASSIC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 2 tc Return to Section TOC Return to Master TOC o O o 9 F 6 F 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual P

Lincoln Electric SVM134-A User's Manual

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