Lincoln Electric SVM134-A User Manual

CLASSIC I

SVM134-A

October, 2000

For use with machine code numbers 10068 to 10069

TM

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SERVICE MANUAL

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 thought­ful operation on your part. DO

NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS MAN­UAL AND THE SAFETY PRE­CAUTIONS CONTAINED
THROUGHOUT. And, most

importantly, think before you act
and be careful.

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View Safety Info View Safety Info View Safety Info View Safety Info

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Copyright © 2000 Lincoln Global Inc.

i i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

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 saf ety highlights.For additional saf ety inf ormation, it is strongly recommended that you pur­chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. 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.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. 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 eliminated.

____________________________________________________

1.d. K eep all equipment saf ety guards, co v ers and

devices in position and in good repair.Keep
hands, hair, clothing and tools away from V­belts, gears, fans and all other moving parts
when starting, operating or repairing equip­ment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.Do not attempt to
override the governor or idler by pushing on the throttle con­trol rods while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

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2.a. Electric current flowing through any conductor causes

2.b. EMF fields may interfere with some pacemakers, and

2.c. Exposure to EMF fields in welding may have other health

2.d. All welders should use the following procedures in order to

Mar ‘95

CLASSIC I

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

welders having a pacemaker should consult their physician
before welding.

effects which are now not known.

minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

ii ii

SAFETY

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

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 sitting,
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.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition.Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

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.

5.b.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

vapors

to

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5.e. Also see item 1.b.

CLASSIC I

Mar ‘95

iii

SAFETY

iii

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

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.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding.They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

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 and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a.Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

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Mar ‘95

CLASSIC I

iv iv

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c.Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc­tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les par ties sous tension

des porte-électrodes connectés à deux machines à soud­er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soud
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11.Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.

e pas, poser la pince à une endroit isolé de

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b.Porter des vêtements convenab les afin de protéger la peau

de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage.Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

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PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de f aires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar.‘93

CLASSIC I

v v

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

RETURN TO MAIN INDEX

Page

Safety.................................................................................................................................................i-iv

Installation.............................................................................................................................Section A

Technical Specifications..............................................................................................................A-2

Safety Precautions......................................................................................................................A-3

Location and Ventilation ..............................................................................................................A-3

Pre-operation Engine Service.....................................................................................................A-4

Electrical Output Connections.....................................................................................................A-7

Operation...............................................................................................................................Section B

Safety Instructions.......................................................................................................................B-2

General Description ....................................................................................................................B-2

Recommended Applications .......................................................................................................B-3

Operational Features and Controls .............................................................................................B-3

Design Features ..........................................................................................................................B-3

Welding Capability.......................................................................................................................B-3

Limitations .................................................................................................................................B-3

Controls and Settings..................................................................................................................B-4

Engine Operation........................................................................................................................B-7

Welding Operation.......................................................................................................................B-9

Auxiliary Power ..........................................................................................................................B-10

Accessories ..........................................................................................................................Section C

Maintenance..........................................................................................................................Section D

Safety Precautions ......................................................................................................................D-2

Routine and Periodic Maintenance .............................................................................................D-2

Major Component Locations.......................................................................................................D-9

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair ................................................................................................Section F

Electrical Diagrams..............................................................................................................Section G

Parts Manual................................................................................................................................P-292

CLASSIC I

Section A-1 Section A-1

TABLE OF CONTENTS

- INSTALLATION SECTION -

Installation

Technical Specifications..............................................................................................................A-2

Safety Precautions......................................................................................................................A-3

Location and Ventilation ..............................................................................................................A-3

Storing .................................................................................................................................A-3

Stacking................................................................................................................................A-4

Tilting .................................................................................................................................A-4

Lifting .................................................................................................................................A-4

High Altitude Operation ........................................................................................................A-4

Pre-Operation Engine Service ....................................................................................................A-4

Oil ........................................................................................................................................A-4

Fuel .......................................................................................................................................A-4

Battery Connections .............................................................................................................A-4

Cooling System.....................................................................................................................A-5

Muffler .................................................................................................................................A-5

Exhaust Spark Arrester ........................................................................................................A-5

Trailers .................................................................................................................................A-5

Machine Grounding ..............................................................................................................A-6

Electrical Output Connections.....................................................................................................A-7

Welding Cable Connections.................................................................................................A-7

Cable Installation and Cable Sizes..........................................................................A-7

Auxiliary Power Receptacle, Plugs, and Hand-held Equipment...........................................A-7

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CLASSIC I

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - CLASSIC I

INPUT - DIESEL ENGINE

Manufacturer Description Speed Displacement Ignition Capacities

Continental 4 cyl., 4 cycle 1450 RPM 164.7 cu. in. Distributor Fuel: 15 gal.

TM27 Water-cooled Full load (2700 cc) Type (57 liters)

gasoline Electronic
38 HP @ 1600 RPM Oil: 6.0 qt.
1450 RPM High idle (5.7 liters)

1000 RPM Coolant: 9.3 qt.

Low idle (8.8 liters)

RATED OUTPUT - WELDER

Duty Cycle Amps Volts at Rated Amperes

60% Duty Cycle 200 DC Constant Current 40V

OUTPUT - WELDER AND GENERATOR

Welding Ranges Max. Open Circuit Voltage Auxiliary Power

40-300 Amps DC 95 1.75 kw

15 Amps @ 120V DC

PHYSICAL DIMENSIONS

Height Width Depth Weight

40.9 in. 24 in. 67.5 in. 1370 lb.

1040 mm 610 mm 1714 mm 621 kg

1

Lincoln rating. Nema rating at 60% duty cycle is 200 DC amps / 28V.

(1)

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CLASSIC I

A-3 A-3

INSTALLATION

Read this entire installation section before you
start installation.

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live
parts or electrodes with your
skin or wet clothing.

• Insulate yourself from the work
and ground.

• Always wear dry insulating
gloves.

LOCATION AND VENTILATION

Always operate the Classic I with the doors closed.
Leaving the doors open changes the designed air flow
and may cause ov erheating.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 I, be sure that clean
cooling air can flow through the machine’s gasoline
engine and the generator. Avoid dusty, dirty areas.
Also, keep the machine away from heat sources. Do
not place the back end of the generator anywhere near
hot engine exhaust from another machine. And of
course, make sure that engine exhaust is ventilated to
an open, outside area.

The Classic I may be used outdoors. Do not set the
machine in puddles or otherwise submerge it in water.
Such practices pose safety hazards and cause improp­er operation and corrosion of parts.

STORING

ENGINE EXHAUST can kill.

• Use in open, well ventilated
areas or vent exhaust to the out­side.

• Do not stack anything on or near
the engine.

MOVING PARTS can injure.

• Do not operate this equipment
with any of its doors open or
guards off.

• Stop the engine before servicing
it.

• Keep away from moving parts.

See additional safety information at the front of this
manual.

Only qualified personnel should install,use, or ser­vice this equipment.

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 circulate
oil to all the parts. See the
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

Maintenance

4. See your engine operation manual for further infor­mation on fuel and engine preservation. See also
“short” or “long” term storage in the Engine manual.

Battery Maintenance

section of this manual.

Maintenance

section of

in the

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CLASSIC I

A-4 A-4

INSTALLATION

STACKING

Classic I machines CANNOT be stacked.

TILTING

Place the machine on a secure, level surface whenev­er 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 posi­tion 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 I weighs 1370 lb./621 kg. A lift bail is
provided for lifting with a hoist.

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

The Classic I is shipped with the engine

filled with SAE 10W-30 oil. This should be
fine for most ambient operating temperature condi­tions. See the engine operation manual for specific
recommendations. CHECK THE OIL LEVEL BEFORE
YOU START THE ENGINE. This is an added precau­tion. When full, the oil level should be up to b ut not ov er
the FULL mark on the dipstick. If it is not full, add
enough oil to fill it to the full mark. DO NOT overfill.

WARNING

FALLING EQUIPMENT can
cause injury.

Do not lift 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 gaso­line engine in the
tions of this manual before you operate the Classic I.

Operation

and

Maintenance

sec-

For more oil fill and service information, see the

Maintenance

section of this manual.

FUEL

Fill the fuel tank with clean, gasoline only.
The Classic I has a 15 gallon (57 liter) fuel
tank with a top fill and fuel gauge mounted
on the control panel. See the
and

Maintenance

for more details about fuel.

sections of this manual

Operation

BATTERY CONNECTIONS

The Classic I is shipped with the negative battery cable

–+

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

disconnected. Before you operate the
machine, make sure the
IGNITION switch is in the OFF position and

section.

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CLASSIC I

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 con­tainer for alternate antifreeze recommendations.)

MUFFLER

This welder is supplied with an adjustable rain cap for
the muffler. Install the rain cap using the clamp provid­ed with the outlet facing away from the direction in
which this unit will be transported. This will minimize
the amount of water and debris that could enter the
muffler during transportation.

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 stan­dard mufflers included with these welders do not qual­ify as spark arresters. When required by local regula­tions, a suitable spark arrester must be installed and
properly maintained.

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 consid­ered are as follows:

1. Design capacity of the trailer vs. the weight of the
Lincoln equipment and likely additional attach­ments.

2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.

3. Proper placement of the equipment on the trailer to
ensure stability side to side and front to back. This
includes when being moved and when standing by
itself for operation or service.

4. Typical conditions of use, such as travel speed,
roughness of the surfaces where the trailer will be
used, environmental conditions, likely maintenance.

5. Conformance with federal, state, and local laws.
Consult applicable federal, state, and local laws
about specific requirements for use on public high­ways.

CAUTION

Use of an incorrect arrester may lead to engine dam­age or performance loss. Contact the engine manu­facturer for specific recommendations.

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CLASSIC I

A-6 A-6

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 I is mounted on a truck or a trailer,
the machine generator ground stud MUST be securely
connected to the metal frame of the vehicle. See
Figure A.1.The ground stud is marked with the ground
symbol.

Some state, local, or other codes or unusual operating
circumstances may require the machine frame to be
grounded. It is recommended that you determine the
extent to which such requirements may apply to your
particular situation and follow them explicitly. A
machine grounding stud marked with the symbol
is provided on the welding generator frame foot. See
Figure A.1. (If an older portable welder does not have
a grounding stud, connect the ground wire to an
unpainted frame screw or bolt).

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.

FIGURE A.1 - GROUND STUD LOCATION

1

1. Ground Stud

Do not ground the machine to a pipe that carries explo­sive or combustible material.

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WARNING

CLASSIC I

A-7 A-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 brack et 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 ter­minal marked Positive (+). For Negative polarity, con­nect the electrode 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 termi­nal connection. Keep the cables isolated and sepa­rate 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.

Accessories

FIGURE A.2 - CLASSIC I OUTPUT CONNECTIONS

2

4

TABLE A.1 - RECOMMENDED COPPER WELDING CABLE SIZE AND LENGTH

TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES

1

3

1. 120 VOLT DC RECEPTACLE

2. WELD OUTPUT TERMINALS (2)

3. GROUND STUD (LOCATION)

4. CABLE STRAIN RELIEF BRACKET

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Cable size for combined length of

electrode plus work cable

Amps Duty Cycle Up to 200 ft. 200 to 250 ft.

200 60% 1 1/0

CLASSIC I

A-8 A-8

NOTES

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CLASSIC I

Section B-1 Section B-1

TABLE OF CONTENTS

- OPERATION SECTION -

Operation...............................................................................................................................Section B

Safety Instructions.......................................................................................................................B-2

General Description ....................................................................................................................B-2

Recommended Applications .......................................................................................................B-3

Welder .................................................................................................................................B-3

Generator..............................................................................................................................B-3

Operational Features and Controls .............................................................................................B-3

Design Features ..........................................................................................................................B-3

Welding Capability.......................................................................................................................B-3

Limitations .................................................................................................................................B-3

Controls and Settings..................................................................................................................B-4

Welder/Generator Controls...................................................................................................B-4

Control of Welding Current ...................................................................................................B-5

Gasoline Engine Controls .....................................................................................................B-6

Engine Operation........................................................................................................................B-7

Before Starting the Engine ...................................................................................................B-7

Starting the Engine...............................................................................................................B-7

Stopping the Engine.............................................................................................................B-8

Cold Weather Starting ..........................................................................................................B-8

Break-in Period.....................................................................................................................B-8

Welding Operation.......................................................................................................................B-9

Classic I DC Constant Current Stick or TIG Welding ...........................................................B-9

Classic I DC Wire Feed Welding (Constant Voltage)..........................................................B-10

Auxiliary Power ..........................................................................................................................B-10

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CLASSIC I

B-2 B-2

OPERATION

OPERATING INSTRUCTIONS

Read and understand this entire section before operat­ing your Classic I.

SAFETY INSTRUCTIONS

WARNING

Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; 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.

• Insulate yourself from the work and
ground.

• Always wear dry insulating gloves.

WARNING

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust to the outside.

• Do not stack anything on or near the
engine.

MOVING PARTS can injure.

• Do not operate this equipment with any
of its doors open or guards off.

• Stop the engine before servicing it.

• Keep away from moving parts.

Only qualified personnel should install, use, or ser­vice this equipment.

GENERAL DESCRIPTION

FUMES AND GASES can be dan­gerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove
fumes from breathing zone.

WELDING SPARKS can cause
fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have held
combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

The Classic I is a heavy duty engine driven DC arc
welding power source capable of providing DC con­stant current output for stick welding or DC TIG weld­ing. The Classic I is wound with all copper coils for bet­ter arc stability and precise welding control. With the
addition of the optional Wire Feed Module or CV
adapter, the Classic I will provide constant voltage out­put for running the LN-25 wire feeder.

The Classic I 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.

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CLASSIC I

B-3 B-3

OPERATION

RECOMMENDED APPLICATIONS

WELDER

The Classic I provides excellent constant current DC
welding output for stick (SMAW) welding and for DC
TIG welding. For more details on using the machine as
a welder, see
section of this manual.

Welding Operation

in the

Operation

GENERATOR

The Classic I is also capable of providing 1.75 kw of
115V DC auxiliary power.

OPERATIONAL FEATURES AND
CONTROLS

The Classic I was designed for simplicity. Therefore, it
has very few operating controls . T w o s witches are used
for welding operations:

• A five-position CURRENT RANGE SELECTOR
switch selects current output ranges f or constant cur­rent stick or TIG applications and constant voltage
wire feed applications (with optional Wire Feed
Module - see the

• 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 two­position IGNITION ON/OFF toggle switch, a START
pushbutton, and a two-position IDLER switch that
selects engine speed for welding or auxiliary power
applications. See
section of this manual for details about starting, run­ning, stopping, and breaking in the gasoline engine.

Accessories

Engine Operation

section)

in the

Operation

DESIGN FEATURES

• Constant current DC Stick welding (SMAW) process
capability with output range from 40 - 300 DC amps.

• Work and Electrode welding cable mounting termi­nals.

• 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 per iodic mainte­nance.

• Top-of-the-line 38 HP Continental gasoline engine.

• Top-mounted 15 gallon (57.0 litter) fuel tank with con­venient top fill.

• Automatic engine idler goes to low idle approximate­ly 15 seconds after welding for greater fuel economy;
includes high idle switch.

WELDING CAPABILITY

The Classic I is rated 200 amps, 40 volts constant cur­rent 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

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The Classic I is not recommended for any processes
besides those that are normally performed using DC
stick welding (SMAW) and DC TIG welding. Specific
limitations on using the Classic I for these processes
are described in the
manual. Constant voltage welding is available with the
optional Wire Feed Module.

CLASSIC I

Welding Operation

section of this

B-4 B-4

OPERATION

CONTROLS AND SETTINGS

The welder/generator controls are located on the
Output Control Panel of the machine case front.
E

ngine idler control and start/stop controls are also on

FIGURE B.1 – OUTPUT CONTROLS

4

5

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.

1

2

WELDER/GENERATOR CONTROLS

See Figure B.1 for the location of the f ollowing f eatures:

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

tion.

2. FINE CURRENT ADJUSTMENT: Allows fine
adjustment of current within the selected output
range. See

Control of Welding Current

information.

3. 120 VOLT DC RECEPTACLE: Connection point for
supplying 120V DC power to operate DC electrical
devices.

for more informa-

for more

3

6

1. CURRENT RANGE SELECTOR

2. FINE CURRENT ADJUSTMENT

3. 115 VOLT DC RECEPTACLE

4. WELD OUTPUT TERMINAL (–)

5. WELD OUTPUT TERMINAL (+)

6. GROUND STUD

4. WELD OUTPUT TERMINAL (–) WITH FLANGE
NUT: Provides the connection point for either the
electrode holder or the work cable.

5. WELD OUTPUT TERMINAL (+) WITH FLANGE
NUT: Provides the connection point for either the
electrode holder or the work cable.

6. GROUND STUD: Provides a connection point for
connecting the machine case to earth ground. See

Machine Grounding

in the

Installation

this manual.

section of

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CLASSIC I

B-5 B-5

OPERATION

CONTROL OF WELDING CURRENT

CAUTION

• DO NOT turn the CURRENT RANGE SELECTOR
while welding because the current may arc between
the contacts and damage the switch.

• DO NOT attempt to set the CURRENT RANGE
SELECTOR between the five points designated on
the nameplate.

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, per mitting control of the arc character­istics.

A high open circuit voltage setting provides the soft
"buttering" arc with best resistance to pop-outs pre­ferred for most welding. To get this characteristic, set
the CURRENT RANGE SELECTOR to the lowest set­ting that still provides the current you need and set the
FINE CURRENT ADJUSTMENT near maximum. For
example: to obtain 175 amps and a soft arc, set the
CURRENT RANGE SELECTOR to the 190 to 120
position and then adjust the FINE CURRENT ADJUST­MENT 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 force­ful arc, set the CURRENT RANGE SELECTOR to 240­160 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 tech­niques at settings at the lower end of the open circuit
voltage range.

CURRENT
RANGE
SELECTOR

FIGURE B.2 – CURRENT CONTROLS

CURRENT RANGE
SELECTION

190-120

240-160

130-80

220

MAX.

90

MIN.

OIL

IGNITION

IDLER

PRESSURE

FINE CURRENT
ADJUSTMENT

60

70

80

90

START

REMOTE
CONTROL

50

40

30

20

10100

CHOKE

FINE CURRENT
ADJUSTMENT

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CLASSIC I

B-6 B-6

OPERATION

FIGURE B.3 – GASOLINE ENGINE CONTROLS

1. IDLER CONTROL TOGGLE SWITCH

2. IGNITION TOGGLE SWITCH

3. OIL PRESSURE LIGHT

4. START PUSHBUTTON

5. CHOKE CONTROL

6. ENGINE HOUR METER

7. AMMETER

GASOLINE ENGINE CONTROLS

See Figure B.3 for the location of the f ollowing f eatures:

1. IDLER CONTROL TOGGLE SWITCH: Adjusts the
running speed of the engine. The switch has two
positions, "HIGH" and "AUTO." In "HIGH," the
engine runs continuously at high idle. In "AUTO,"
the idler control works as follows:

Welding: The engine accelerates to high speed
when the electrode touches the work and strikes a
welding arc. The engine returns to low idle approx­imately 15 seconds after welding stops, as long as
no auxiliary power is being drawn.

Auxiliary Power: The engine accelerates to high
speed when power is drawn at the receptacle for
lights or tools. The engine returns to low idle
approximately 15 seconds after demand for
auxiliary power stops.

2. IGNITION CONTROL TOGGLE SWITCH: Has
two positions, ON and OFF. When the switch is in
the ON position, the engine can be started by
pressing the START pushbutton. When the switch
is placed in the OFF position, the engine stops.

3. OIL PRESSURE LIGHT: Lights when the engine
oil pressure drops to an unsafe level. If the light
comes on within 30 seconds after startup, the
engine should be stopped by placing the IGNITION
switch in the OFF position.

CURRENT RANGE
SELECTION

190-120

130-80

240-160

220

90

MAX

MIN

1

OIL

IDLER

IGNITION

PRESSURE

2

3

FINE CURRENT
ADJUSTMENT

50

60

70

80

90

100

START CHOKE

REMOTE
CONTROL

40

30

20

10

5

4

6

7

4. START PUSHBUTTON: Press this button to start
the gasoline engine. The IGNITION switch must be
in the ON position.

NOTE: If you press the START pushbutton when
the engine is running, you may damage the engine
flywheel gear or starter motor.

6. ENGINE HOUR METER: Records engine running
time. Use the meter to determine when to
perform required maintenance.

7. AMMETER: Shows whether the charging circuit
is performing its job of charging the battery when
the engine is running. The meter will register
discharge during starting, but then the needle
should return to a position slightly toward positive
during running. The needle will hold position in the
center when the engine stops.

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CLASSIC I

B-7 B-7

OPERATION

ENGINE OPERATION

WARNING

DO NOT RUN THE ENGINE AT EXCESSIVE
SPEEDS. The maximum allowable high idle speed for
the Classic I is 1550 RPM, no load. Do NOT increase
the idle speed on the engine. Severe personal injury
and damage to the machine can result if it is operated
at speeds above the maximum rated speed.

Read and understand all safety instructions included in
the Continental engine instruction manual that is
shipped with your Classic I.

BEFORE STARTING THE ENGINE

Check and fill the engine oil level:

1. Be sure the machine is on a level
surface.

2. Remove the engine oil dipstick and wipe it with a
clean cloth. Reinsert the dipstick and check the
level on the dipstick. See
Maintenance section of this manual.

Figure D.1

in the

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 run­ning. Stop the engine and allow it to
cool before refueling to prev ent 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 elimi­nated.

NOTE: USE GASOLINE ONLY. Purchase gasoline in
quantities that will be used within 30 days, to assure
freshness.

3. Add oil (if necessary) to bring the level up to the full
mark. Do not overfill.

4. Replace the dipstick.

ST ARTING 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 shows within 30 seconds,
stop the engine and consult the engine operating
manual.

3. As the engine warms, slowly return the choke con­trol to the in (off) position.

4. Allow the engine to run at high idle speed for sev­eral minutes to warm up before welding. Cold
engines tend to run at a speed too slow to supply
the voltage required for proper idler operation.

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CLASSIC I

B-8 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, run­ning 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 valv e 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 WEA THER STAR TING

Follow the instructions on the nameplate and in the
engine manual shipped with the welder. With a fully
charged battery and the proper weight oil, the engine
should start satisfactorily even when the air tempera­ture is down to about 0oF (-18oC).

It is important to follow the engine manufacturer’s rec­ommendations for oil and fuel to obtain satisfactory
cold weather performance. Consult the Engine manu­al 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 oper­ation. Also change the fuel filter cartridge. For more
details, see the
Also see the Engine manual.

Maintenance

section of this manual.

CAUTION

During break-in, subject the Classic I to moderate to
heavy loads. Avoid long periods running at idle. Before
stopping the engine, remove all loads and allow the
engine to cool several minutes.

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CLASSIC I

B-9 B-9

OPERATION

WELDING OPERATION

TO USE THE CLASSIC I FOR DC
CONSTANT CURRENT STICK OR TIG
WELDING:

1. Remove the flange nuts from the weld output ter­minals and place the work and electrode welding
cables over the terminals. For positive electrode,
connect the electrode cable to the + terminal and
the work cable to –. For negative electrode,
reverse the electrode and work cables at the
welder’s output terminals. See Figure B.4.
Replace and tighten the flange nuts securely. Be
sure the connections are tight.

2. Select the appropriate electrode.

3. Attach the work clamp securely to the work you are
welding.

4. Insert the electrode into the electrode holder.

5. Start the engine. See
section of the manual.

6. Set the Idler Switch to "AUTO."

Engine Operation

in this

7. Set the CURRENT RANGE SELECTOR to a set­ting equal to or slightly higher than the desired
welding current.

8. Set the FINE CURRENT ADJUSTMENT to the
setting that gives the best arc characteristics for
the range selected. See

Current

in this section of the manual.

Control of Welding

9. Strike an arc and begin welding.

After you finish welding:

1. Stop the engine. See

Engine Operation

in this

section of the manual.

2. Allow the electrode and work to cool completely.

3. Remove the work clamp from the work.

4. Remove any remaining piece of electrode from the
electrode holder.

FIGURE B.4 – WELDING CIRCUIT CONNECTIONS FOR STICK WELDING

1

2

1. OUTPUT TERMINALS

2. ELECTRODE CABLE

3. ELECTRODE HOLDER

4. ELECTRODE

5. WORK PIECE

6. WORK CLAMP

7. WORK CABLE

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3

4

5

76

CLASSIC I

B-10 B-10

OPERATION

TO USE THE CLASSIC I FOR DC WIRE
FEED WELDING (CONST ANT V OL TAGE)
WITH WIRE FEED MODULE:

1. Connect the LN-25 Wire Feeder. Follow the instal­lation instructions provided with the wire feeder.

2. Set the wire feeder and Classic I for CV operation.

3. Start the engine. See
section of the manual.

Diameter (inches) Wire Speed Range Appropriate Current Range

.035 80-110 75 to 120 Amps
.045 70-130 120 to 170 Amps
.068 40-90 125 to 210 Amps

Engine Operation

RANGE SETTINGS FOR WIRE SIZE/SPEED

in this

TABLE B.1

(inches/minute)

4. Set the Idler Switch to "AUTO."

5. Set the CURRENT RANGE SELECTOR to a set­ting appropriate for your wire size and wire feed
speed. See Table B.1 for recommended settings.

6. Set the VOLTAGE ADJUSTMENT to the setting
that gives the best arc characteristics for the range
selected.

7. Pull the gun trigger.

AUXILIARY POWER

WARNING

Be sure that any electrical equipment plugged into the
generator DC power receptacle can withstand a ±10%
voltage variation.

The DC auxiliary power, supplied as a standard, has a
rating of 1.75 kw of 120V DC power.

The rating of 1.75 kw permits a maximum continuous
current of 15 amps to be drawn from the 120 volt recep­tacle.

An optional power plug kit is available. See the

Accessories

section of this manual.

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CLASSIC I

Section C-1 Section C-1

TABLE OF CONTENTS

- ACCESSORIES -

Accessories...........................................................................................................................Section C

Options/Accessories ...................................................................................................................C-2

Semiautomatic Welding Accessories ...................................................................................C-2

Connection of Lincoln Electric Wire Feeders..............................................................................C-3

Connection of the LN-25 “Across the Arc”...........................................................................C-3

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CLASSIC I

C-2 C-2

ACCESSORIES

OPTIONS/ACCESSORIES

The following options/accessories are av ailable f or your
Classic I 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 fed­eral, state and local laws.

Trailer (K913) - Two-wheeled trailer for in-plant and
yard towing. For highway use, consult applicable fed­eral, state, and local laws. Various hitches and acces­sories are available.

Power Plug Kit (K802-A) - Provides auxiliary plug for
115VDC receptacle.

CV Adapter - (K384) - Provides constant voltage out­put for semiautomatic welding. (For K6090 through -4
only.)

Wire Feed Module - (K623-1) - Provides constant volt­age output for semiautomatic welding. For LN-25 wire
feeder. (For K6090-5 and above.)

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.)

SEMIAUT OMATIC WELDING ACCESSORIES

LN-25 Wire Feeder - This portable wire f eeder is capa-

ble of CC/CV wire feed welding.
NOTE: Gas-shielded welding requires a Magnum Gun.

Gasless welding requires an Innershield Gun.

Linc Thaw™ Control Unit (L2964-1) - Includes meter
and fuses to protect the welder when thawing frozen
water pipes.

WARNING

PIPE THAWING IS NOT a CSA approved procedure.
If not done properly, it can result in fire, explosion,
damage to wiring which may make it unsafe, dam­age to pipes, burning up the welder, or other haz­ards.

Do not use a welder to thaw pipe before reviewing
Lincoln Bulletin E695.1 (dated October 1987 or later.)

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CLASSIC I

C-3 C-3

ACCESSORIES

CONNECTION OF LINCOLN
ELECTRIC WIRE FEEDERS

The Lincoln Electric LN-25 wire feeder is recommend­ed for wire feed welding with the Classic I.

CONNECTION OF THE LN-25 TO THE
CLASSIC I “ACROSS THE ARC”WITH
WIRE FEED MODULE (SEE FIGURE C.1.)

1. 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 polari­ty, shut the welder off and reverse the
electrode and work cables at the Classic I
output terminals. Reverse the LN-25
polarity switch.

FIGURE C.1

CLASSIC I/LN-25 ACROSS THE ARC CONNECTION DIAGRAM

3. Connect the K444-2 remote control cable to the 14
pin amphenol on the Wire Feed Module.

4. Attach the single lead from the LN-25 control box
to the work using the spring clip on the end of the
lead. This is only a control lead — it carries no
welding current.

5. Place the IDLER switch in the “HIGH” position.

6. Adjust wire feed speed and voltage at the LN-25.

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+
CV-

TO
WORK

14 PIN
AMPHENOL

ELECTRODE CABLE

CLASSIC I

LN-25 WIRE FEEDER
WITH K444-2 REMOTE
VOLTAGE CONTROL OPTION

WORK CLIP
LEAD TO WORK

C-4 C-4

NOTES

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CLASSIC I

Section D-1 Section D-1

TABLE OF CONTENTS

-MAINTENANCE-

Maintenance .........................................................................................................................Section D

Safety Precautions ......................................................................................................................D-2

Routine and Periodic Maintenance .............................................................................................D-2

Engine Maintenance.......................................................................................................D-2

Oil ............................................................................................................................D-2

Engine Maintenance Schedule................................................................................D-2

Change the Oil ........................................................................................................D-3

Change the Oil Filter ...............................................................................................D-3

Fuel..........................................................................................................................D-3

Fuel Filter.................................................................................................................D-4

Air Cleaner...............................................................................................................D-4

Cooling System .......................................................................................................D-4

Fan Belt...................................................................................................................D-5

Spark Plugs.............................................................................................................D-5

Battery Maintenance ......................................................................................................D-6

Cleaning the Battery................................................................................................D-6

Checking Specific Gravity........................................................................................D-6

Checking Electrolyte Level ......................................................................................D-6

Charging the Battery ...............................................................................................D-6

Welder/Generator Maintenance.....................................................................................D-7

Storage....................................................................................................................D-7

Cleaning ..................................................................................................................D-7

Nameplates .............................................................................................................D-7

Generator Commutator and Brushes......................................................................D-7

Bearings ..................................................................................................................D-7

Current Range Selector Contacts ...........................................................................D-8

Receptacle...............................................................................................................D-8

Cable Connections..................................................................................................D-8

Idler Maintenance ...........................................................................................................D-8

Major Component Locations.......................................................................................................D-9

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CLASSIC I

D-2 D-2

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

• Have qualified personnel do all maintenance and
troubleshooting work.

• Turn the engine off before working inside the
machine.

• Remove covers or guards only when necessary to
perform maintenance and replace them when the
maintenance requiring their removal is complete.

• If covers or guards are missing from the machine, get
replacements from a Lincoln Distributor.

Read the Safety Precautions in the front of this manu­al and in the instruction manual for the engine used
with your machine before working on the Classic I.

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, dis­connect 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 fre­quent service may be required, depending on your spe­cific application and operating conditions.

OIL: Check the oil level after every 10
hours of operation or daily. BE SURE TO
MAINTAIN THE OIL LEVEL.

Change the oil the first time after 50 hours of opera­tion. Then, under normal operating conditions, change
the oil as specified in Table D.1. If the engine is operat­ed under heavy load or in high ambient temperatures,
change the oil more frequently.

TABLE D.1

CONTINENTAL ENGINE MAINTENANCE SCHEDULE

FREQUENCY MAINTENANCE REQUIRED
Daily or Before • Visual Inspection.

Starting Engine • Fill fuel tank.

• Check oil level.

• Check air cleaner for dirty, loose, or damaged parts.

• Check radiator level.

First 50 Hours • Check air filter.

• Change engine oil.

• Change oil filter.

• Change fuel filter.

• Check battery.

• Check fan belt.

Every 50 Hours • Change engine oil and filter.

• Service air cleaner (clean element).

• Check fan belt tension.

• Check battery electrolyte level and connections.

Every 250 Hours • Repeat 50-hour checks.

• Clean spark plugs and check gap.

• Check distributor cap.

• Check ignition wires.

• Replace air cleaner element.

Refer to your engine Owner's Manual for details and periodic maintenance at 500 hours and beyond.

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CLASSIC I