Lincoln Electric CLASSIC IM553-C User's Manual
Contents
1. AT8N3SSV 3NIHOVW SIH L NO Q3103NNOO LON SGV31 HOV18 SNOLLO3NNOO 4S3HL NINNNY 38 LON LSNW 3NIHOV p ava zi NO 87 HOLO3NNOO OL TOHLNO9 SLOWSY NO 9 LO3NNO9 7 87 HOLO3NNOO 3NIHOVIN NO 919 3AOW3H NINNNY LON 3NIHOVA HLIM y mom mem mom mem mom mem mom mum m m mm mom NOILISOd 1V901 NI NMOHS 10H1NOO 3103H H313WOLLN310d 410104 OH1NOO SLOWSY O3N OL L93NNO9 NOLLISOd 1V901 NI IOH1NOO 310 3H NMOHS 10H1NOO 310 38 38v9 OL 1 201 5 JINON WNIWYAL 1901 HOLIMS NO 3NLVO3N DIAGRAMS WIRING DIAGRAM CODE 10219 amp 10219CV F 2 pem 0334 STWNINYSL l 1 SOd 01103 00 1 RNCS 9 moal SHOLO3NNOO I 2 x suoisisau 9 Wd HALINOILN310d ANIHOVW NO HOLO3NNOO OL W 4 M 8 9N1d LO3NNOO 10HLNO9 310W3H 7 9 HOLO3NNOO WOHd DNId 3AOW3H NO SINGOW 0333 SHIM HOLIMS 8 31071430234 1OHINOO SLOWSY 9 SHOLISIS3H H313OLLN3LOd TOHLNOO SLOWSY HOS HOLIMS 319V1d4393H TOHLNO9 SLOWSY CIVNOLLdO 1081 09 SLOWSY 4 726 HLIM A9 00 00 3ALLVO3N IYNOILdO 10HINOO 31038 L 1269 YAWHOASNVYL 0334 euo IN344N9 3unss3ud 110 HOLON SON2. SI FINGOW 0334 SHIM ON Q3103NNOONRn LI 1 JHL 15 3 JHL NO SI 3NO 30 01 9 8 G3193NNOONn 40 3804510 340 SNIHOVW JHL HLIM GATIVLSNI SI FINGOW 0395 SHIM V dl y y ANIHOVW NO 87 HOLO3NNOO OL LIM TOHINOO SLOWSY NO HOLO3NNOO OL 10H 1NOO 31ONN3H JHL 14 9f 1d LO3NNOO JHL NO Olds 9N1d LO3NNOOSIQ 440 3NIHOVIN IHL ITW SNOLLOANNOO SSSHL 9NDIVIN N3HM AI8N3SSV l1VISOWH3HL ONINNNE 38 LON LSNN 3NIHOVIN SAN UT QV31AAV3H 2 H3Q 0H 93N OL LO3NNOO YALSWOLLNALOd OH1NOO 310W3H sjeued eJnsojoue JO euo uo juo 10 S 541 3 LON SIHL NO Q3103NNOO LON SQV3150V 18 ANIHOVW NO HOLO3NNOO OL 10H1NOO 310W3H NO 90719 193NNOO N3HL 7 8 HOLO3NNOO 3NIHOVIN NO 9 SAOWSH LON 3NIHOVIN y LOINNOO 8 HO103NNOO WOW NO 9 SAOWSY 340 3NIHOVIN HLIM H313WOl1N3 0d OH1NOO 31038 3590 OL 103 00 NOILISOd 1 201 NI NMOHS 10H1NOO 310W3H 1 201 HOLIMS DIAGRAMS WIRING DIAGRAM CODE 10220 amp 10220CV F 3 SHOISIS3H HA13NOIIN310d TOHLNOO JLOWJH 9 HOLIMS 8
3. 1 NO 97 HO103NNOO OL NO 9f 1d LO3NNOO 7 57 HOLO3NNOO 014 9 19 3AOW3H 1 SINGOW 0333 SHIM H3MOd x HOIVNH3LTIV HOLIMS 80193135 87 1 1809 hoe 319V143934 060 NOU OL 1S3uV3N dS SONIY dS 80108 1 1 3934 LIOA SHL NV 3040994 JYLNIN OL 1VHINAN uv3u Q3M3lA SV NMOHS SLNANOdWOO TANVd IOHLNOO NMOHS N N3349 9 X9V18 4 3009 80109 Qv31 45913 Yad 5108 5 1 21 102313 1 NO LON 50731 2 18 038 SNIHOVIW NO 0103 00 OL TOHLNOO 31038 NO 193 02 87 HOLO3NNOO 3NIHOVIN NO S d 3AOW3H LON 3NIHOVIN HLIM NOILISOd 7901 NI NMOHS 10H1NOO 310N 34 1V907 HOLIMS H313WOlIN3LOd 310 38 3Sv9 OL LO3NNOO H313AOLLN310d 10 1 02 SLOWSY 9019 HOLIMS 319V143934 10HLNO9 310 3H TOHLNOO SLOWSY 1 726 YOLOW ONILHYIS HOSN3S Er Ed 110 HOLIMS 3NION3 I d NOIL9110Hd 3NION3 H3 QI 3ufriivd 3NION3 19 CLASSIC DEUTZ 2 Jequunu
4. welder be sure you use ample size welding cables PRE OPERATION SERVICE READ the engine operating and maintenance instruc tions supplied with this machine Cil This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W 30 oil This oil should be acceptable for most typical ambient temperatures Consult the engine operation manual for specific engine manufacturers recommendations Upon receipt of the welder check the engine dipstick to be sure the oil is at the full mark DO NOT overfill Note A optional Oil Drain Kit is available for this engine Order K1604 1 NOTE This unit is equipped with an Engine Protection Package an internal kill switch will shut down the engine if the oil pressure drops below a minimum operating specification or if the oil temperature reaches an excessive level Fuel Fill the fuel tank with the grade of fuel recommended in the Engine Operators manual Make sure the fuel valve on the sediment bowl is in the open position CLASSIC DEUTZ LINCOLN 8 4 Battery Charging The Classic Il 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 replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed This system is NEGATIVE GROUND
5. 3 stie A 3 ure A 3 Op ration me EE Section B sra B 1 Gen ral DescripliOn er erc B 1 Starting and Stopping the Engine sse B 1 Cold Weather Starting s ctn territoire Eua B 1 Duty Cycle EE 1 Control of Welding rtr rc En etch B 1 iun E EU B 2 Auxiliary et ere er ole eene B 2 Section D G n ral Instretiols n crane D 1 Cooling A ua D 1 ae re D 1 Comm tator 5 te etn D 2 Sr Maintenance ER D 2 en D 2 Troubleshooting nennnnennnnnnennnennns Section E LE Section F Parts List 219 78 25 1 INSTALLATION TECHNICAL SPECIFICATIONS CLASSIC DEUTZ 1406 Make Model Description 3 cylinder 28 5 HP 1700 RPM INPUT DIESEL ENGINE Speed RPM High Idle 1800 Low Idle 1350 Full Load 1725 Bore x Stroke 3 58 x 4 13 91mm x 105mm Starting System 12VDC battery amp Start
6. Il 2155 19 YILIN 3NION3 gquniva CLASSIC DEUTZ LINCOLN E DIAGRAMS F 5 F 5 99 018 80 92 00 ONILNNOW 99 79 0 9 d d 6119 06 0 2269 7 Uu HSI19 00 g V d3013M 1dVd WO Ole La 310H ONILNNOW AIMS a 99 amp dVONIVH HO MO413 LSnVHX3 TANVd 10 1 09 NOISNANIQ dOl OL NOISN3WIGO O N 8310H ONILNNON 99 791 Q AN 71305 ON 108 NI H31VM ANY 110 ALIAVHO JO H31N3O0 V N SALON CLASSIC DEUTZ LINCOLN E 5 CLASSIC DEUTZ LINCOLN 8 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toq
7. WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes BATTERY ACID can burn eyes and skin be careful when boosting charging or working near battery To prevent EXPLOSION when a Installing a new battery disconnect the negative cable from the old battery first and connect the negative cable to the new battery last b Connecting a battery charger remove the battery from the welder by disconnecting the negative cable first then the positive cable and battery clamp When reinstalling connect the negative cable last Using a booster connect the positive lead to the battery first then connect the negative lead to the ground lead on the base To prevent ELECTRICAL DAMAGE when a Installing a new battery b Using a booster Use correct polarity Negative Ground To prevent BATTERY DISCHARGE if you have an ignition switch turn it off when engine is not running To prevent BATTERY BUCKLING tighten nuts on battery clamp until snug Muffler This welder is supplied with an adjustable rain cap for the muffler Install the rain cap using the clamp pro vided with the outlet facing away from the direction in which this unit will be transported This will minimize the amount of water and debris which could enter the muffler during transportation CLASSIC Il DEUTZ LINCOLN 8 B 1 OPERATION B 1 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment
8. High position Allow it to run at high idle speed for several minutes to warm the engine See SPECIFICATIONS for operating speeds The idler is controlled by the Idler toggle switch on the welder control panel The switch has two posi tions as follows 1 Inthe High position the idler is off and the engine high speed is controlled by the governor 2 Inthe Auto position the idler operates as follows a When welding or drawing power for lights or tools approximately 100 150 watts minimum from the receptacles the engine operates at full speed b When welding ceases or the power load is turned off a preset time delay of about 15 seconds starts This time delay cannot be adjusted c If the welding or power load is not re started before the end of the time delay the idler reduces the engine to low idle speed Auxiliary Power The AC auxiliary power supplied as a standard has a rating of 3 0 kVA of 115 230V AC 60 hertz With the 3 0 kVA 115 230V AC auxiliary power one 115V duplex and one 230V grounding type receptacle are provided The circuit is protected with circuit breakers The rating of 3 0 kVA permits a maximum continuous current of 13 amps to be drawn from the 230 volt duplex receptacle Or a total of 26 amps can be drawn from the 115 volt duplex receptacle The 115 volt duplex receptacle has a configuration which permits 15 amps on the K1406 3 amp 5 and 20 amps on the K1406 4 amp
9. 8 5 9 0 ohms amp leads 3 Check ground connections in idle circuit 4 Replace P C Board Engine Will Not Pick Up Speed When The Arc Is Struck The Auxiliary Power Load 15 Turned On Reed Switch In Weld Circuit Power Load Too Small Defective Will Not Close Try Load Above 150 Watts To Check Short The Red Lead Engine Does Not Pick Up Speed On P C Board To Welder Frame Check Connections And Continuity Of Current Transformer Replace P C Board Engine Picks Up Speed Engine Does Not Pick Up Speed 1 Check for break in Red Replace PC Board lead and repair 2 Replace reed switch in weld circuit CLASSIC Il DEUTZ LINCOLN 8 DIAGRAMS F 1 WIRING DIAGRAM CODE 10628 amp 10629 F 1 Jequunu epoo jueuudinbe 2 104 96 9 si eui j sjeued eunsoj oue y euo uo eui episui pejsed si epoo 10 siy Aq je 10 eq jou Aew Ajuo JO 51 SIUL 310 086 2 01 11215910 SHL 03103 00 34y 50 31 Mov 8 JHL 31 110599 THM ANIHOVN TOHINOO 310 38 1 OL 3NIHOVIA NO 03103 00 LON 5 19ISSV TO NO G3SN SAYI MOVIE ONY JHL Q3TIVISNI FINGOW 033
10. 310 V1d303H 1OHINOO SLOWSY IVNOLLdO 1091 00 310IN3H v r26 HLIM 9 00 99 3ALLISOd AV134 4388 299 HANHOASNVEL IN344N9 8 8 SONIGNIM H3MOd HO1VNH3I TV 8 280 0193135 id 1WLSOZHH 3iovid3o3u 062 OL lS3HVdN dS SONIH dis 1 M NY 30H099V4 38103N 3Nvu3 OL 1VHLNAN 434 SV NMOHS SLNANOdWOO TANVd TOHINOO INVYSVIC ONIHIM JINON 0334 ANIHOWW 97 HOLO3NNOO OL IW4 M NO Sd 9019 LOANNOD 7457 HOLO3NNOO WOH 014 DN1d 3AOW3H 3NIHOVIN NO oan O sod O swa TWNIWHAL 114100 o 3NIVON SIVNINHAL DIN SOd 01 103NNOO 25 3570 OL LOJNNOO NOILISOd 1V9071 NI NMOHS 10H1NOO SLOWSY 1 201 HOLIMS 777 HNvd OHINOO WEM SHOLO3NNOO anon amp X X YALAWOLLNALOd OHLNOO SLOWSY HOLIMS 8 310V1d3O3H 10 1 00 11034 VNOILLdO INGON 333 SHIM VNOILdO TOHLNOD SLOWSY 1 726 Ce OLA Tr 370 1 3034 NMOU amp N N3349 9 H9V19 4 3009 40109 Qv31 16913 Yad STOSWAS 1VOIHLO3 3 WUOIVNB3ITV o d e er HOLO3NNOO 7901 gos eh 69 1 HOSN3S 3unss3ud 10 1 1 YOSNAS a Ed dial 110 HOLIMS EB vos QgvO8 I d NOILO31OHd 3NISN3 E3 10 Il JISSV TO HO1ON ONIL
11. 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 2 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards coversand devices in posi tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety minimize exposure to EMF fields from the welding circuit 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 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 1 f Do not put your hands near the engine fan Do not attem
12. oig guet LINCOLN e World s Leader 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
13. open or guards off Stop engine before servicing Keep away from moving parts See additional warning information at the front of this operator s manual GENERAL INSTRUCTIONS 1 Blow out the welder and controls with an air hose at least once every two months particularly dirty locations this cleaning may be necessary once a week Use low pressure air to avoid driving dirt into the insulation 2 Current Range Selector contacts should not be greased To keep the contacts clean rotate the current control through its entire range frequently Good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld 3 Change the crankcase oil and oil filter after the first 50 hours of operation and thereafter at 750 hour intervals using the proper grade of oil See recom mendations in the engine Operation Manual Order Deutz oil filter 117 4416 or 117 4417 from 4 Inspect the air filter daily more often in dusty condi tions When necessary clean or replace The filter should never be removed while the engine is running The air filter element part number is Donaldson 181050 or Nelson 70206N 5 Drain any accumulated water from the engine fuel fil ter water separator daily Change the filter every 1000 hours of operation Order Deutz fuel filter 117 4482 from your local Deutz Service Center A fuel filter ele ment without the water separator may be used in p
14. position securely chained to an undercarriage or fixed support Oylinders 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 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 Mar 95 CLASSIC Il DEUTZ LINCOLN SAFETY PR CAUTIONS DE 5 5 Pour votre propre protection lire et observer toutes les instruc ti
15. until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill TA not touch electrically live parts electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill e Use in open well ventilated areas or vent exhaust outside MOVING PARTS injure Do not operate with doors open or guards off A Stop engine before servicing Keep away from moving parts See additional warning information at the front of this operator s manual GENERAL DESCRIPTION The Classic Il is a heavy duty engine driven DC arc welding power source capable of providing constant current output for stick welding or DC TIG welding The Classic Il is wound with all copper coils and is configured in a new shorter case with no exciter stick out and setup for one side service With the addition of the optional Wire Feed Module on models K1406 3 and K1406 4 the Classic will provide constant volt age output for running the LN 7 or LN 25 This unit uses the Deutz F3L 1011F industrial air cooled diesel engine Starting the Deutz F3L 1011F Engine To start the engine place the IDLER switch in the HIGH position the IGNITION switch in the pos
16. 4 V HO Q3TIVISNI 9019 JHL 1 0381 SI HOLIMS SLOWSY OL HN990 JNIHOVIN 3HL NO HOLO3NNO9 OL LIY 1OH1NOO SLOWSY JHL 91d 103NNOO 7 97 0103 00 3NIHO NO Olds 918 LO3NNOOSIO 340 3NIHOVW HLIM C3TTV LSNI SI 31000 0334 38IM ON dl Q3193NNOONn ENIAV31 ABHVN 119 OM Id MIN JHL NILSY4 3NIHOVIN IHL SI INO JI 019 9Md G3LO3NNOONN JHL JO 3504510 340 3NIHOVIA IHL O3TTVISNI SI SINGOW 0383 3HIM V 31 y y NO 8f HOLO3NNOO OL 11H TOHLNOO 310N3H NO 9f 1d LO3NNOO 8 HOLO3NNOO WOU 3NIHOVIW NO SAOWSY 340 INHOVWHLIM y U313WOl1N3LOd pm Sms m 1 201 NI 310W34 35v0 OL NMOHS 10 1 SLOWSY 1O3NNOO 1 201 HOLIMS B 54 wk Mu MOR x SHOLSIS34 YALAWOLNALOd 1091 09 SLOWSY HOLIMS 31071430238 10 1 00 SLOWSY IYNOILdO 10H1NOO JLOWSY f t26 CW AM HLIM 9 8 99 00 INLISOd 3ALLVO3N H3 NHOJSNVH L 4334 049 HO 1VH3N39 SONIGNIM SNOLLO3NNOO 3 3H1 9NDIVIA N3HM ONINNNE LON LSNW 3NIHOVIN 0 31 2 2 JINON 0383 JHM 355 1V1SOWH3HI dv 092 H3 10H HSNHE OIN OL 103NNOO WNIWH3LI1ndinO DAN 3 SOd OL 103NNOO wa 1 WIMI
17. 6 to be drawn from either half The total combined load of all receptacles is not to exceed 3 0 kVA An optional power plug kit is available When this kit is specified the customer is supplied with a plug for each receptacle An optional GFCI 115 volt receptacle kit is also avail able Note that the use of this GFCI kit reduces avail able current to 15 Amps from each half of the duplex receptacle and to a total of 20 Amps of available 115 volt power CLASSIC DEUTZ LINCOLN P 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the machine In some cases it may be neces sary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is com plete Always use the greatest care when work ing near moving parts Do not put your hands near the engine cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work ground Always wear dry insulating gloves e ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure Do not operate with doors
18. Above For Gasoline 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 safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 9 om 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 2 m MAGNETIC FIELDS be dangerous 1 Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with
19. CLASSIC II IM553 C DC ARC WELDER WITH DEUTZ F3L 1011F ENGINE For use with machines having Code Numbers 10219 10219CV 10220 10220CV 10628 10629 10872 and 10910 RETURN TO MAIN MENU 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 MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful mE OPERATOR S MANUAL v ANSI RAB IS 7 FE 7 ign der a NCOLN Copyright 2008 Lincoln Global Inc e World s Leader 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 l WARNING 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 cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The
20. HVIS NA 3NION3 ZTN dAV1 34n11v4 3NI9N3 19 CLASSIC DEUTZ Jequunu epoo BAIN 101 2219S si eui j sjeued eunsoj oue eu Jo euo uo y pejsed si epoo sejnomed 0 oyioeds siy Aq 10 eq jou Aew 101 51 SIUL 310 2 SNOLLOSNNOO 3S2HL iganassy ONINNNY LON LSNN ANIHOVN 052 QV31AAV3H A ON OL LOANNOO H313WOILN310d 310W3H 3570 OL L93NNO9 MOTI3A A ALIHM M NMOSHSN 307141 N33H9 5 Qa MOVIS g I1 V8 3d8029VH JYLNIN OL WHLNAN STVNIWYAL LNdLNO SAN 8 SOd OL LOANNOO HV3H SV NMOHS SIN3NOdINOO TANVd 5805 40109 42913 SIOEWAS VOIH LO3 T3 I 540151534 M3 13WOLLN31Od TOHLNOO 04 Sa TENYd 1014 00 AO 8 X SHOLO3NNOO ANIHOVW Su HOLO3NNOO OL we M NO ON Id LOANNOD HOLO3NNOO WO 01 SAOWSY 3NIHOVIN NO IVNOILdO INOW Q334 3HIM TOHINOO S
21. IONIM 3onv9 ONILHVLS HIMOd WO1VNH3LTV YOLVYANAD CLASSIC DEUTZ HOLIMS 193135 805525 3unssaud 10 9 mni 1 1503 87 d dWAL 110 HOLIMS aioNa10s P NOLLINSI 5 uaa P 419V141934 110 062 10 143034 LOA SLL HOLIMS OL 1544 3 4115 O d SONIY ZTN HOLOH HOIVNH3LIV NMGUEEN 68 N33H9 9 3NION3 Ov 18 8 19 3009 40109 Qv31 16913 S108WAS 1VOIH1O3 3 0 3H103N OL GAGNO8 1VH1LNIAN uvdd SV NMOHS SIN3NOdWOO TANVd 1OHLNOO INVH9VIG ONIHIM JISSV TO F 3 Jequunu 1ueuudinbe juowesedai JO juowyedeq 29S 01 M S eu paysed si opoo 5 enueui siy Aq jou 1 l 9188719 SHL NI G3LOSNNOO 38V SQV31 MOVIE ONY 41 L 1038 3NIHOVIN 1 310W3H JHL OL 39VINVO SNIHOVIN SIHL NO Q3193NNOO LON SHV AINO SANIHOWW 1 2155 10 NO 5 5 31 MOVIE JHL 0311 19 INGON 0334 SHIM V HO 0311 15 5079 3HL 1NOHLIM G3SN SI LI 41 HOLIMS TOHINOO SLOWSY JHL OL YNDDO NYO 39VIVO NOILOYVO JNIHOVIN JHL NO Sf HOLOANNOO
22. LOWSY 97267 DIAGRAMS WIRING DIAGRAM CODE 10910 F 4 CW 3 M HLIM A9 8 99 99 3AMISOd o JALLVO3N n 172 WOLVNH3ITV 2018 LT o V LI AVI 5 EN 4 OL HI HOLIINNOI WOLIVH3N39 NOILISOd 1V201 NI NMOHS HOLIMS OHLNOO 310N3H HO19373S Be LVLSO3HY 209 209 ev r ev SONIGNIM ose 14 HOLVNHALTV Y 309 WaldWAWV 3unssaud 9 voog ie We ONILAVLS ves Pr 319V143934 2 lt 5009 L iv 319V143934 SEL Dt MOSN3S E td AWAL HOLIMS 062 v 009 NO3I OL 153 vooz dis 370V 143934 310W3H 8007 c SON dS door Sr 6 OLLL CL Old 8 Y 007 INVHOVICO HOLIMS NOILINOI QHvOS Dd NOILOSLOYd 3NION3 H31Ql Lr QesZ9SvEect 9
23. NG E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION PROBLEMS Welding arc is loud and spatters Current setting may be too high excessively Polarity may be wrong Welding current too great or too Exciter output low causing low small compared to indication on the output compared to dial indica dial tion Operating speed too low or high Engine shuts down and engine Low oil pressure protection light comes on High oil temperature Broken fan belt Battery charging alternator is not operating Fuel solenoid coil shorted Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CLASSIC DEUTZ LINCOLN 8 4 TROUBLESHOOTING E 4 ELECTRONIC IDLER TROUBLESHOOTING GUIDE Engine Will Not Return To Idle In Approximately 15 Seconds Set Idler Control Switch To The Auto Position Remove Weld and Auxiliary Power Loads Check Continuity of Idler Control Switch Continuity Good Open 1 Reed switch in weld circuit may be stuck Replace Switch closed 2 Check continuity of idler solenoid coil
24. OLN 8 2 MAINTENANCE D 2 Commutator and Brushes The generator brushes are properly adjusted when the welder is shipped They require no particular attention DO NOT SHIFT THE BRUSHES or adjust the rocker set ting Shifting of the brushes may result in change in machine output commutator damage excessive brush wear Periodically inspect the commutator slip rings and brushes by removing the covers DO NOT remove or replace these covers while the machine is running Commutators and slip rings require little attention However if they are black or appear uneven have them cleaned by an experienced maintenance man using fine sandpaper or a commutator stone Never use emery cloth or paper for this purpose NOTE If the welder is used in dirty or dusty locations or if the welder is not used for prolonged periods of time it may be necessary to clean the commutator and slip rings more often Replace brushes when they wear within 1 4 of the pigtail A complete set of replacement brushes should be kept on hand Lincoln brushes have a curved face to fit the commutator Have an experienced mainte nance man seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact is made across the full face of the brushes After stoning blow out the dust with low pressure air To seat slip ring brushes position the brushes in place Then slide one end of a piece of fine sandpa per betwe
25. R SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entliiftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventila o exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRcocuc 9 fsUPBHEILTASESUCFEU CARE FR E fE 24758 else e SUAS MAS PARAH Turn power off before servicing Desconectar el cable de ali mentaci n de poder la maquina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine
26. anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico toque as partes el tricas nuas e XL7TTL2A 9 AVCWRUD PRE RET BRAY FE e HE BIS AGS XA Do not operate with panel open guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes com 05 paineis abertos ou guardas removidas NRIVOAN ERUALEEE CRMREBIFELEWTEEU CHRRIARRARS SHAE Ro 20 Sel AE Asal WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG BIR Qai dul Jaial os Qui BALL cal sd ue Aie Ab pha J dust jui e cuts gall l Jai y e ue Ll LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR SRM OBUOX HD OHBRBEE lt K RA CL TRHORERMEI HS TFE Uo 85 ET REL BE SUCR Rr de OE MR EL ES AMENER 0 HYRAS SAAD HHR ele EFSA BEHE ET gl aul y Qui al gll
27. aterial 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 9 5 5 5 5 5 a Welding produce fumes 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 5 6 5 Shielding gases used for arc welding displace air cause injury or death Always use enough ventila
28. ction may be poor Wrong grade of brushes may have been installed on generator Field rheostat may be making paor coment and overheating Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance Welder starts but fails to generate Generator or exciter brushes may current be loose or missing Exciter may not be operating Field circuit of generator or exciter may be open Exciter may have lost excitation Flash Fields 1 Series field and armature circuit be open circuited 1 FLASHING THE FIELDS 1 Stop the engine welder and remove the cover from the exciter 2 Turn the Fine Adjustment Control rheostat to 100 on the dial 3 Using a 12 volt automotive battery connect its negative terminal to the negative brush holder The negative brush holder is the one nearest to the rotor lamination See the wiring diagram With the engine NOT running touch the positive battery ter minal to the positive brush holder Remove the bat tery from the circuit 4 Replace the exciter cover Start the welder and the generator voltage should build up CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CLASSIC DEUTZ LINCOLN 8 3 TROUBLESHOOTI
29. d on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE CONTENTS Page Safety i iv EE OM tect Section A Technical Specifications er err peru 1 sri cl hrs eee 2 rus ue A 2 Location Ventilation sis A 2 eremum A 2 2 ee 2 Polarity Control and Cable Sizes A 3 Pre Operation Engine Service A 3 3 gu
30. d 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 install the optional spark arrester kit Spark arresters must be installed and properly main tained instructions are included in the kit CAUTION Use of an incorrect arrester may lead to engine damage or performance loss Location Ventilation Always operate the welder with the doors closed Leaving the doors open changes the designed air flow and may cause overheating The welder should be located to provide an unrestrict ed flow of clean cool air Also locate the welder so that engine exhaust fumes are properly vented to an outside area INSTALLATION A 2 CAUTION DO MOUNT OVER COMBUSTIBLE SUR FACES Where there is a combustible surface directly under stationary or fixed electrical equipment the surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not more than 5 90 150mm beyond the equipment all sides 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 Some state local or other codes or unusual operating circumstances
31. debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 CLASSIC DEUTZ LINCOLN 2 V V for selecting a QUALITY product by Lincoln Electric We want you Thank You io take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printe
32. ect connection Nameplates Whenever routine maintenance is performed 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 replace ment item number CLASSIC DEUTZ LINCOLN 8 E TROUBLESHOOTING E HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by 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 malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Se
33. ed are as follows 1 Design capacity of undercarriage vs weight of 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 under carriage to ensure stability side to side and front to back when being moved and when standing by itself while being operated or serviced 4 Typical conditions of use i e travel speed rough ness of surface on which the undercarriage will be operated environmental conditions likely mainte nance 5 Conformance with federal state and local laws Consult applicable federal state and local laws regarding specific requirements for use on public highways Polarity Control 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 studs 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 stud These connections should be checked peri odically and tightened if necessary When welding at a considerable distance from the RECOMMENDED COPPER CABLE SIZES Cables Sizes for Combined Length of Electrode Plus Work Cable 200 to 250 ft Duty Cycle Up to 200 ft
34. en slip rings and brushes with the coarse side against the brushes With slight additional finger pressure on top of the brushes pull the sandpaper around the circumference of the rings in direction of rotation only until brushes seat properly In addition stone slip ring with a fine stone Brushes must be A WARNING seated 100 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 rotat ing armature when stoning the commutator Arcing or excessive exciter brush wear indicates a possible misaligned shaft Have an authorized Field Service Shop check and realign the shaft Idler Maintenance 1 The solenoid plunger must work freely and not bind Dust the plunger about once a year with graphite powder 2 Proper operation of the idler requires good ground ing of the printed circuit board reed switch and battery 3 If desired the welder can be used without automat ic idling by setting the Idler switch to the High position CAUTION Before doing electrical work on the idler printed circuit board disconnect the battery When installing a new battery or using a jumper battery 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 incorr
35. epoo jueuudinbe jueujeoe daoi 104 si eui j sjeued eunsoj oue euo uo episui paysed si epoo siy Aq 10 eq jou JO SI SIUL 310 11 OISSY79 JHL 03103 00 SQV31 H9V18 034 JHL 41 1101538 THM 3NIHOVIN HO ONY 1 1 310W3H JHL OL 3NIHOVIN SIHL NO LON 38V AINO S3NIHOVMW 1 2155710 NO 5 38V 50 31 ONY JHL O3 TIVLSNI FINGOW 0334 3HIM V YO GATWLSNI 919 3HL LNOHLIM Q3Sh SI 41 HOLIMS TOHLNOO ALOW3H OL NYI ANIHOVN IHL NO 9 OL 10H1NOO SLOWSY JHL 119 ON Id LOANNOO Sf HOLO3NNOO SNIHOVIN IHL NO Old LOANNOOSIG 140 3NIHOVIA GATIVLSNI SI INGON 333 SHIM ON 31 GaLOANNOONN LI ABHV3N 11 ONId MAN IHL N31SV4 GNIHOVW IHL NO SI 30 019 9 GALOANNOONN 3HL 40 3809510 110 HUM GSTIVLSNI SI FINGOW 0334 SHIM V 31 NO HOLO3NNOO OL LIM TOHLNOO SLOWSY NO L03NNOO 87 0103 00 WOH NO SAOWSY 340 3NIHOVIN HLIM XOS usto GC
36. er A 1 Capacities Fuel 15gal 57L Oil 6 3 5 6 0L RATED OUTPUT WELDER Duty Cycle Constant Current Volts at Rated Amps 32 volts 30 volts 28 volts 300 amps DC 250 amps DC 200 amps DC OUTPUT WELDER AND GENERATOR NEMA Output Rating Auxiliary Power 115 250 VAC 3kVA 6096 Duty Cycle 40 325 Amps 250 amps 30 volts 960 Duty Cycle PHYSICAL DIMENSIONS HEIGHT WEIGHT 42 94 in 1340 Ibs 608 kg 1040 mm 1524 mm CLASSIC DEUTZ LINCOLN 8 2 SAFETY PRECAUTIONS A WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists gt ELECTRIC 5 kill Do not touch electrically live parts or electrode with skin or wet clothing eInsulate yourself from work ground Always wear dry insulating gloves ENGINE EXHAUST can kill 9 Use open well ventilated areas 8 KA vent exhaust outside 4 MOVING PARTS can injure Do not operate with doors open or guards off M Stop engine before servicing Keep away from moving parts See additional warning information at the front of this operator s manual Exhaust Spark Arrester Some federal state or local laws may require that diesel engines be equippe
37. er contre les chutes dans le cas ou on recoit un choc Ne 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 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol 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 lev age 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 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 forte ment toxique ou autres produits irrita
38. idental 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 VE 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 standards 4 b Use suitable clothing made from durable flame resistant 5 b m
39. ipped with a self priming feature Cold Weather Starting 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 down to about 02 If the engine must be frequently started below 10 F it may be desir able to install the optional ether starter kit Installation and operating instructions are included in the kit Use ether starting only when required because excessive use shortens engine life It is important that the Engine Manufacturer s recommendations for oil and fuel are followed to obtain satisfactory cold weather perfor mance Consult the engine manual Duty Cycle The NEMA output rating of the Classic II is 250 amperes at 30 1 arc volts on a 60 duty cycle consult SPECIFICATIONS for alternate ratings Duty cycle is based on a ten minute period thus the welder can be loaded at rated output for six minutes out of every ten minute period 1 The Lincoln plus output rating at 60 duty cycle is 250 amperes at 40 volts 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 The Current Range Selector provides five overlapping current ranges The Fine Current Adjustment adjusts the current from min imum to maximum within each range Open circuit voltage is als
40. ition and then press the START button 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 To stop the engine place the IGNITION switch in the OFF position If the engine protection warning light comes on during cranking or after start up the igni tion switch must be placed in the OFF position to reset the engine protection system When an engine is started for the first time some of the oil will be needed to fill the passages of the lubricating system Therefore on initial starting run the engine for about five minutes and then stop the engine and recheck the oil If the level is down fill to the full mark again The engine controls were properly set at the factory and should require no adjusting when received At the end of each day s welding drain accumulated dirt and water from the sediment bowl under the fuel tank and from the fuel filter per instructions in the engine manufacturer s operating manual 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 In diesel engines if the fuel supply is cut off or runs out while the fuel pump is operating air may be entrapped in the fuel distribution System If this happens bleeding of the fuel system should not be required since the Deutz F3L 1011F engine is equ
41. lace of the standard element Order Deutz 117 4696 6 Fan belts tend to loosen after the first 50 hours of operation Check engine Operation Manual and tighten if necessary DO NOT OVER TIGHTEN 7 Put a drop of oil on the Current Range Selector shaft at least once every month 8 See the engine manufacturer s Operation Manual for detailed engine maintenance and troubleshooting instructions COOLING SYSTEM The Classic is equipped with an air cooled Deutz engine Clean the engine cooling system periodically to prevent clogging the air passages on the cylinder heads and oil cooler and overheating the engine Consult the Engine Operation Manual It is important that the welder is located in a manner which will provide an unre stricted flow of clean cool air BEARINGS This welder is equipped with a double shielded ball bear ing having sufficient grease to last indefinitely under nor mal 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 equip ment More bearing failures are caused by dirt introduced during greasing than from insufficient grease CLASSIC Il DEUTZ LINC
42. 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 777 is provided on the welding generator frame foot 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 alter nate means of grounding electrical equipment Lift Bail A lift bail is provided for lifting with a hoist WARNING FALLING EQUIPMENT can cause injury Do not lift this machine using lift bale if it is equipped with a heavy accesso ry such as a trailer or gas cylinder Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting CLASSIC DEUTZ LINCOLN 8 3 INSTALLATION A 3 Undercarriages If the user adapts non Lincoln undercarriage must assume responsibility that the method of attach ment and usage does not result in a safety hazard nor damage the welding equipment Some of the factors to be consider
43. nts 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 jamais enrouler le c ble lectrode autour de n importe quelle PR CAUTIONS DE S RET POUR partie du corps LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 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 pantalons sans revers et chaussures montantes Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece 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
44. o controlled by the Fine Current Adjustment permitting control of the arc characteristics CLASSIC Il DEUTZ LINCOLN 8 B 2 OPERATION B 2 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 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 190 120 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 volt age For example to obtain 175 amps and a forceful arc set the Current Range Selector to 240 160 posi tion 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 CAUTION DO NOT attempt to set the Current Range Selector between the five points designated on the nameplate These switches have a spring loaded cam which almost eliminates the possibili ty of setting this switch between the designated points Idler Operation Start the engine with the Idler switch in the
45. ons 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 suivantes 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 metallique 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 defonctionnement 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 Si 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 pro t g
46. plosion 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c CYLINDER may explode 22238 Sr 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 Always keep cylinders in an upright
47. pt to override the governor or idler by pushing on the throttle control rods while the engine is running EN 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 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 work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 CLASSIC DEUTZ ILINCOLN ELECTRIC 5 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 acc
48. rvice Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet cloth ing e insulate yourself from work ground Always wear dry insulating gloves 3 ENGINE EXHAUST can kill Use in open well ventilated areas or AR vent exhaust outside MOVING PARTS injure Do not operate with doors open guards off Stop engine before servicing Keep away from moving parts See additional warning information at the front of this operator s manual A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CLASSIC DEUTZ LINCOLN 8 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION PROBLEMS Machine fails to hold the heat con Ja Rough or dirty commutator stantly Brushes may be worn down to limit Field circuit may have variable resistance connection or intermit tent open circuit due to loose con nection or broken wire Electrode lead or work lead con ne
49. tion 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 Also see item 1 b Mar 95 CLASSIC DEUTZ LINCOLN 2 SAFETY 7 WELDING SPARKS 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 have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an ex
50. ue partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra LiH 7 amp nf dchsn zucct MLMPT APSSAPREBS E GUB S Oa E EERTE ecu Xe HIE AMI uil el jad oa Y O aual ay uit slt AL JS dax ule Y Jio Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e naedoe6 0o08 CIE REA e i8 m eis Jo ALD al gll pis e Ac AI uie Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo A HAUSHERMRELTTF EU RRR ez 119 59 de 4 aun y READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZA
Download Pdf Manuals
Related Search