Lincoln Electric CLASSIC IM514-A User's Manual
Contents
1. SH IOH DNILNOOW AATIVAL 99 part ys Tend ON Lag ANIONS NI WHLVM GNW TIO HLIM ALIAVAD dO WHLNHO TANVd TOULNOO oo gt INIYd NOISNANIA a V LS 0S L L9 d I DISSVIO L 99LOTS 97T So ELL CLASSIC CIT q N Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their a2. CLASSIC LINCOLN 4 D 2 MAINTENANCE D 2 Bearings This welder is equipped with a double shielded ball bearing having sufficient grease to last indefinitely under normal service Where the welder is used con stantly or in excessively dirty locations it may be nec essary to add one half ounce of grease per year A pad of grease one inch wide one inch long and one inch high weighs approximately one half ounce Over greasing is far worse than insufficient greasing When greasing the bearings keep all dirt out of the area Wipe the fittings completely clean and use clean equipment More bearing failures are caused by dirt introduced during greasing than from insuffi cient grease Commutator and Brushes WARNING Uncovered rotating equipment can be dangerous Use care so your hands hair clothing or tools do not catch in the rotating parts Protect yourself from particles that may be thrown out by the rotat ing armature when stoning the commutator The generator brushes are properly adjusted when the welder is shipped They require no particular atten tion DO NOT SHIFT THE BRUSHES or adjust the rocker setting Shifting of the brushes may result in Change in machine output Commutator damage Excessive brush wear Periodically inspect the commutator and brushes by removing the covers DO NOT remove or replace these covers while the machine is running Commutators require little attention However if they
3. 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 Also see item 1 c LINCOLN Y CYLINDER may explode SL s 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 position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or a
4. 44 CAUTION READ the engine operating and maintenance instruc tions supplied with this machine 44 WARNING Fuel can cause fire or explosion Stop engine while fueling Do not smoke when fueling Do not overfill tank Keep sparks and flame away from tank e Wipe up spilled fuel and allow fumes to clear before starting engine oil 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 Add oil at the dipstick tube if required DO NOT OVERFILL Fuel m Fill the fuel tank with the grade of fuel recommended din the Engine Operator s Manual make sure fuel valve on the sediment bowl is in the open position Cooling System The radiator 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 engine manual or antifreeze container for alternate antifreeze recommendations Oct96 x A 5 Battery Charging 44 WARNING GASES FROM BATTERY can explode e Keep sparks flame and cigarettes away EC BATTERY ACID can burn eyes and skin Si Wear gloves and eye protection and be careful wh
5. K888 3 100 ft K888 4 K6090 5 6 100 ft K924 1 JULY97 Trailer K768 For in plant and yard towing at speeds under 10 mph 37 94cm wheel track for narrow pathways amp entranceways Trailer K780 Rugged two wheeled trailer with brakes lights and fenders 54 137cm wheel track For highway use consult applicable federal state and local laws regarding possible additional requirements Trailer K913 Two wheeled highway trailer with steel torsion bar axle 54 137cm wheel track Low sway low center of gravity Sturdy tread plate platform Choice of 3 hitches Add on fender amp light package For highway use consult applicable federal state and local laws regarding possible additional requirements K913 1 Base Trailer K913 2 Ball Hitch K913 3 Lunette Eye Hitch K913 4 Clevis Pin Hitch K913 5 Fender amp Light Kit Wire Feed Module K623 1 K6090 5 6 only Provides constant voltage CV output with improved arc stability for Innershield welding Also excellent for MIG welding Easy Installation Recommended wire feeder is the LN 25 CLASSIC LINCOLN Y D 1 MAINTENANCE e 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
6. NOISWSHA vs NO zrnouro sr asna eh F 1 UVAS HOYA GEMIGA SV NMOHS SLNHNOdNWOO2 THNVd TONLNOD NOIL4O ILONAN woa a gt YD 9 ALIEN 9 MOTTEX 3 NMOYE H ALTHM M NMOUE N KC Rana 9 aau a EK 3q09 40100 QAYIT LESTE uqa S TIOGWAS IVOINLOATE NVIDVIA ONIAIM SONN SA HOLIAS sunssawa TIO HOLIMS ua Tal XOS SALEMOTINALOS zeen o Aen BRLEWOTLNGLOA enge SLOWEY 404 DOTA TYNOILAO HOLOW ONTLUVLS HOLIMS NOILINDI IHDIT sunssaud TIO AJUO S32U819J91 10 SI UeIBHeIP SIUL 3LON ANIHOVH NO savat XOWIS qNV qaw OL Suen NO SVT MOVIE ANY gen LOENNOD ANIHDVH NO ssp HOLOANNOD OL TOWLNOD SLOWEY NO E DOTA LOANNOD NAHL 4824 HOLOENNOD WONI BNTHOWW NO de DOTA SANS ONINNOY LON ANIHOVH HLIM NOILISOd non NI NMOHS IOWINOD Some wo non 404 HOLIMS woe aas b Lan ren pn en pp ios HOLIMS ZUDVIAZOZA TOLNOD BLONTY TIOULNOD HIONHY I FZ63 ANIONZ OL annoxs asve OL annoxs AALAN anon aa0 LOHS TINA SNIONG wormunguvo I DISSVIO worngrursrq 109 NOILINOI worngrursrq worsrsss 109 l NOILINOI NOTLINOI sanroxa sarrava so cartaans vousrsay mimm w AIODWIO NoTLINOT aware P O eee ed CLASSIC M N DIAGRAMS F 2 F 2 99L0TS ATOH aIxs 99 ONT LNOOW add lam 2 08 0L AA 9 T HSITONH UD DIALAN ATOH ONILNAON AIAS 99 zer H
7. See the recommendations in the engine operation manual Inspect the air filter daily more often in dusty conditions when necessary clean or replace The filter should never be removed while the engine is running The air filter should never be removed while the engine is running The air filter element part number is Donaldson 181050 or Nelson 70206N When necessary remove the sediment bowl from beneath the gas tank and clean out any accumulat ed dirt and water Replace the fuel filter in the fuel line as needed In an emergency the fuel filter can be back flushed for continued use until a replace ment can be obtained 6 Fan belts tend to loosen after the first 50 hours of operation Check engine operation manual and tighten if necessary DO NOT OVERTIGHTEN 7 Put a drop of oil on the Current Range Selector shaft at least once every month 8 Keep governor and carburetor toggles and butterfly valve shaft clean and lubricated 9 See the engine manufacturers operation manual for detailed engine maintenance and troubleshoot ing instructions Cooling System The Classic is equipped with a pressure radiator Keep the radiator cap tight to prevent loss of coolant Clean and flush the cooling system periodically to pre vent clogging the passage and overheating the engine When antifreeze is needed always use the permanent type ORDERING COOLING SYSTEM INFORMATION CAPACITY K6090 ALL 9 3 Quarts
8. 515 Pipe Welding Charts 5450 eos I A SUE eo Shipping Costs itary l x y LS _ Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 Name Address Telephone Signature as it appears on Charge Card LE A A A U eee l WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese 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 o los electrodos bajo carga con la piel o ropa moja da O Aislese del trabajo y de la tierra O Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e solez vous du travail et de la terre e 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 e N o toque partes el tricas e elec trodos com a pele ou roupa molha da O Isole se da peca e terra o REPOR iHe ELE Chi suc E J T 19697 Z p OS 363 ATUBS ELTFEL e RREAN DEBREREAR SR MERGE TA e small S458 N2 SA Ez s qa Sal HAR e 2x9 HIE Weal HAR A A gone Al el all Qual YO Hull e ag SONT gh la S ell A d
9. Load 164 7 Cu In Distributor Type Fuel TM27 4 Cycle 1450 RPM 1450 RPM 2 7 Ltrs Electronic 15 Gals 57 Ltrs Water Cooled Gasoline Engine High Idle Lubricating Oil 1600 50 RPM 6 0 Qts 5 7 Ltrs Low Idle Coolant 1000 RPM 9 3 Qts 8 8 Ltrs JULY97 CLASSIC LINCOLN A 2 GENERAL DESCRIPTION The Classic is a heavy duty engine driven DC arc welding power source capable of providing DC con stant current output for stick welding and DC TIG welding With the addition of the optional K384 CV Adapter for K6090 thru 4 or the K623 1 Wire Feed Module for K6090 5 6 the Classic will provide con stant voltage output for running the LN 25 wire feeder The Classic has a current range of 40 300 DC amps with output ratings as follows RATED OUTPUT DUTY CYCLE 60 60 200A 28V 200A 40V The units are also capable of providing 1 75 kw of 115V DC auxiliary power This unit uses the Continental TM27 industrial water cooled gasoline engine DESIGN SUMMARY Control Panel Both the engine and the welder controls are located on one recessed panel at the exciter end of the machine The welder controls consist of a five step Current Range Selector switch and a Fine Current Adjustment rheostat The welder is equipped with a Start button Ignition switch Idler control switch hour meter choke cable a battery charging ammeter and an oil pressure light The control p
10. Loosen choke cable screw and slack off choke wire Replace Remove plugs clean and adjust gap to 0 032 Replace Drain refill with proper grade Fill to Full mark on bayonet gauge Do not overfill Replace Run engine under full load for a short time Time ignition 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 JULY97 CLASSIC LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSES COURSE OF ACTION 9 Overheating 10 Knocking 12 Large decrease in speed PROBLEMS No water in radiator or clogged cooling system Late timing Improper valve clearance Fan belt too loose Poor grade of gasoline Spark advanced too far Governor and carburetor toggles and butterfly valve shaft lever are dirty and sticking Dirty air filter Governor spring adjusting screw misadjusted Governor control rod wrong length Misadjusted governor spring adjusting screw Check throughout for dirty or bro ken hoses clogged radiator or defective water pump Time ignition Intake Exhaust 014 018 Adjust valve tappets cold settin
11. 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 Insulate yourself from work and ground e Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing e Keep away from moving parts See additional warning information at 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 In particularly dirty locations this cleaning may be necessary once a week Use low pressure air to avoid driving dirt into the insulation 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 MAINTENANCE Change the crankcase oil and oil filter after the first 50 hours of operation and thereafter at regular intervals using the proper grade of oil
12. tube 3 The FLEXIBLE HOSE is to be positioned per fig ure 2 IMPORTANT 1 2 clearance between the FLEXI BLE HOSE and the fuel tank edge is required Also 2 clearance between FLEXIBLE HOSE and roof 4 Reconnect negative battery cable FIGURE 2 A FLEXIBLE HOSE B HEAT COLLECTOR SHIELD C AIR FILTER NOTE On welders received directly from the factory the Deicing kit is configured for summer Seasons CLASSIC LINCOLN C 1 ACCESSORIES C 1 OPTIONAL FEATURES field Installed Accessory Set K702 Includes 35 ft 10 7m electrode and 30 ft 9 1m work cables headshield work clamp and electrode holder CV Adapter K384 K6090 thru 4 only Provides constant voltage output for semiautomatic welding Select either CV or CC Linc Thaw L2964 1 Includes meter and fuses to protect welder when thawing frozen water pipes 44 WARNING Pipe Thawing IS NOT a CSA approved procedure If not done properly it can result in fire explosion damage to wiring which may make it unsafe dam age to pipes burning up the welder or other haz ards Do not use a welder to thaw pipe before reviewing Lincoln Bulletin E695 1 dated October 1987 or later Power Plug Kit K802A Provides auxiliary plug for a 120V receptacle Remote Control For Stick operation contains switch remote control rheostat and 100 ft 30 5m or 25 ft 7 6m cable Easy Installation K6090 thru 4 25 ft
13. DREN 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 8 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 FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 QA 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 MAGNETIC FIELDS may be dangerous 1 c 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 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 a Electric curr
14. EE IM514 A C LA S 5 I C I September 1999 For use with machines having Code Numbers 10068 amp 10069 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL ISO 9002 one Al inc to ISO 9002 Re ts CERTIFICATE NUMBER 30273 N O LN ELECTRIC e World s Leader in Welding and Cutting Products e 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 SAFETY 44 WARNING An CALIFORNIA PROPOSITION 65WARNINGS 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 Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHIL
15. FORMATEUR ET A 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 LINCOLN Y 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 debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 v v for selecting a QUALITY product by Lincoln Electric We want you J hank You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this pro
16. OYH SHL NO er HOLOINNOD OL LIX TOBINOD ALOWA HHL WOUd d ONTE LOENNOD E YOLOZNNOD WOW ANIHOVH AHI NO OTdu DOTA LOINNODSIA 440 ANTHOVA HHL HLIM GHTTWLSNI SI mTnqOW Gaza FEIM ON aT agzoznNoona LT ONTAVET KEUVEN uTIdu OOTA MEN SEL NELSVA SNIH YW HHL NO SI SNO AI 0Tdu 90TA GgLOENNOONA SHL ao ASOASIA 440 SNINOVA HHL HLIM GNTIVASNI SI H INGON QISA BATA V dI x ENIHOYH NO Er HOLOENNOD OL LIN Oe Suen NO Bd DOTA LDENNOD NAHI 8C4 HOLDENNOD WOU ENIHOWH NO 6da DOTA SACHER 440 ENIHOWW HITA XOS WESLEMOTINALOS IOWINOD FLOWN asvo oL 1DENNOD UBLEMOLINELOS TOXLNOD SLOWEY wos DOTA IWNOILdO NOILdO WAM HLIM A9 3 90 HAILISO4 AR RR RR Re M M EM NOILISOS IWOOT NI NMOHS TONINOD es u o sors ao HOLIMS Y ATDWIABDZA TOMLNOD ZLOMEA TOULNOD HLONIY e ECKE 99 BAILVOEN SNOILOHNNOO ASAHI SNINVW NHHM ONINNOY H4 LON ISAW ANIHOVN oni AAVEH Z ATSNESSY LYLSONEHL any ooz HECTOR Sange DEN OL ADENNOD vue Kawan cH ZINCON qasa IAIM ANIHOWA NO SPa HOLOINNOD OL Wan NO manva IVNIM8ZL 104200 AD sAILVDEN s rvNIWumL LNAINO S04 OL IDENNOD ve sanz L 1 DATA LOINNOD 4504 HOLDZNNOD WONS Old DOTA SAOWTH ENIHOWH NO IYVNOILdO SINGOW CAJA JAIM N xAD0718 AYAT Adam Te HOLVIINED DIAGRAMS HOLIMS HOLDITES qusqa zao 1NaLno WELIOXA OL 3aq vras osu waMod xnv IVISOBHA Q ATNO
17. al Jai P dua e die aa e Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e 24 pd U DORMTORRIER HN U THEN EA ep ES ML 1F32 PF o LS Y Aal He Ad d s s S dall pis Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use protec o para a vista ouvido e corpo e B HRUSBCRBRELTE iD RR HRARGHRBAR ex 19 Sal HSE HSSHAR Adi y due de Lily lan Al o A ag 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 UTILIZAR 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
18. anel also contains a three prong ground ing type receptacle for auxiliary power Welding Generator The Classic uses the old style round all copper FJW Generator frame which provides the customer with the original Classic pipe welding arc JULY97 INSTALLATION A 2 Engine Idler The Classic is equipped with an electronic automatic engine idler It automatically increases and decreases engine speed when using starting and stopping weld ing or using auxiliary power A built in time delay per mits changing electrodes before the engine slows to its low idle speed The Idler control switch on the panel locks the idler in full speed position when desired Auxiliary Power 1 75 kw of nominal 120V DC Output voltage is main tained within 10 at all loads up to rated capacity See Optional Features for power plug kits Welder Enclosure The complete welder is rubber mounted on a rugged steel C channel base The output terminals are placed at the side of the machine so that they are protected by the door The output terminals are labeled and Ignition System A Distributor Type electronic ignition is standard Cranking System A 12V electric starter is standard Air Cleaner Heavy duty two stage dry type Exhaust A muffler and rain cap are standard Engine Hour Meter A meter to record the hours of operation Carburetor Deicing Kit Prevents carburetor icing when outside tempera
19. 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 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 Arcing or excessive exciter brush wear indicates a possible misaligned shaft Have an authorized Field Service Shop check and realign the shaft Idler Maintenance CAUTION Before doing electrical work on the idler printed circuit board disconnect the battery 1 The solenoid plunger must work freely because binding can cause engine surging If surging occurs be sure the plunger is properly lined up with the carburetor lever Dust the plunger about once a year with graphite powder 2 When any service is done reassemble the rubber bellows on the solenoid plunger with the vent hole on the lower side 3 Proper operation of the idler requires good ground ing of the printed circuit board through its mount ing reed switch and battery 4 If desired the welder can be used without automat ic idling by setting the Idler switch to
20. cing Kit in wrong Carburetor Deicing Kit per configuration instructions on pages B2 and B3 15 Engine fails to pick up speed Check the idler when arc is struck x See engine manual Flashing the fields Flashing the exciter field consists of passing current through the fields using an external source of 6 to 125 volts of DC power from a storage battery or DC generator If using a DC generator keep the generator turned off except when actually applying the flashing current To flash the fields 1 Turn the welder off Raise one exciter brush off the commutator 2 On Lincoln welders attach the positive lead from the external DC source to the right hand brushholder 3 Carefully holding an insulated section of the negative lead from the DC source touch its lug or clamp to the left hand brushholder for five seconds Pull it away quickly to minimize arcing Remove the lead from the right hand brushholder replace the brush on the commutator start the welder and the generator voltage should build up 44 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 LINCOLN E 6 TROUBLESHOOTING E 6 ELECTRONIC IDLER TROUBLESHOOTING GUIDE Engine Will Not Return to Idle in Approximately 15 Seconds Set Idler Control Switch to the Au
21. der 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 soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince a 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 cables de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des cables jusqu a ce qu ils se rompent masse 9 Assurer une ventilation suffisante dans la zone de soudage Maintenir le porte lectrode la pince de masse le cable de
22. duct 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 Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above 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 44 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 MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page E UE RE Section A Technical Specifications e uuu u luu ege hee A 1 General DiSCr UO 2522282280 edel EE ashe Ed A 2 D sign SuMMAN VA A aa a A 2 Pre Operation Installat
23. en boosting charging or dE 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 c 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 s To prevent BATTERY BUCKLING tighten nuts on battery clamp until snug The Classic is equipped with a wet charged battery The charging current is automatically regulated when the battery is low after starting the engine to a trickle current when the battery is fully charged When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed The correct polarity is NEGATIVE GROUND CLASSIC LINCOLN Y B 1 OPERATION B 1 ENGINE OPERATION 44 WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includ
24. ent 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 covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving Pn Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 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 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 1 f Do not put your hands near the engine fan e Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side
25. ent 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 when being moved and when standing by itself while being operated or serviced 4 Typical conditions of use e travel speed rough ness of surface on which the trailer will be operat ed environmental conditions likely maintenance 5 Conformance with federal state and local laws 1 1 Consult applicable federal state and local laws regarding specific requirements for use on pub lic highways JULY97 INSTALLATION A 4 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 polari ty connect the electrode cable to the Negative stud These connections should be checked periodi cally and tightened if necessary When welding at a considerable distance from the welder be sure you use ample size welding cables RECOMMENDED COPPER CABLE SIZES Cable Sizes for Combined Length of Electrode Plus Work Cable Up to 200 ft 200 250 ft Duty Cycle 60 1 1 0 CLASSIC LINCOLN Y A 5 INSTALLATION PRE OPERATION SERVICE
26. es important safety precautions detailed engine starting operating and maintenance instructions and parts lists _0 ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground e Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or I GA vent exhaust outside a MOVING PARTS can injure e Do not operate with doors open or guards off gt Stop engine before servicing e Keep away from moving parts See additional warning information at front of this operator s manual Operate the welder with the doors closed Leaving the doors open changes the designed air flow and can cause overheating Starting the Continental TM27 Engine a Turn the Idler control switch to HIGH b Turn the Ignition switch to ON c Pull out the Choke cable d Press the Start button e If the engine fails to start in 60 seconds wait 30 seconds before repeating the above procedure f Allow the engine to run at high idle speed for sever al minutes to warm up Cold engines tend to run at a speed too slow to supply the voltage required for proper idler operation g As the engine warms slowly return the choke control to the in off position Stopping the Engine 1 Turn the Ignition switch to OFF At the end of each day s welding refill the fuel tank to minimi
27. 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 e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca e Use ventilac o e exhaust o para remover fumo da zona respirat ria eEi APSR RT K350C UTC TF amp uv BAPHECTIHIEBLTIA DM ECETIA OCF AAA A ARE e zs SH7IAE YelsHiAle e S XACE E 2743 AAS AH FAAA H4 557E ABSHIAIS gal ys Jung dul me SU ARA bo js oi iail arin Li ods Qui BAL Ge ll zg ct e Turn power off before servicing e Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas O Desligue a corrente antes de fazer servico Nao toque as partes el tricas nuas XVLFFYA Y EAKCRUD PRE EFFERRI YA DBF MTF etna RE m e pel HAS xo ett AIR Aie Gb a NM dust Jl ale Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas e N op rez pas avec les panneaux
28. f grounding electrical equipment ANGLE OF OPERATION To achieve optimum engine performance the Classic should be run in a level position The maximum angle of operation for the TM27 engine is 60 degrees in a direction to cause the air intake manifold to be angled up 45 degrees for the air intake manifold to be angled down and 50 degrees for the welder control panel to be angled up or down If the engine is to be operated at an angle provisions must be made for checking and maintaining the oil level at the normal FULL oil capacity in the crankcase When operating the welder at an angle the effective fuel capacity will be slightly less than the specified 15 gallons CLASSIC LINCOLN Y A 4 Lift Bail A lift bail is provided for lifting with a hoist 44 WARNING BR FALLING EQUIPMENT can cause injury e Do not lift this machine using lift bail if it is equipped with a heavy accessory such as a trailer or gas cylinder Lift only with equipment of adequate lifting capacity e Be sure machine is stable when lifting Trailers See optional features If the user adapts a non Lincoln trailer he 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 trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachm
29. gs Adjust for 3 4 to 1 deflection Use at least 75 octane gasoline Retime ignition Clean and lubricate Replace toggles if worn Remove and clean according to instructions on unit Adjust screw enough to eliminate surge Adjust length of control rod so that there is from 1 32 to 1 16 clearance between the stop pin and the stop when the engine is shutoff and the regulator expand ed Adjust screw until speed does not drop more than 100 RPM 25 RPM when arc is struck If surge occurs eliminate it with the con trol rod If high idle speed changes readjust the high idle speed screw 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 LINCOLN E 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed througout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION PROBLEMS 13 Unable to strike an arc a Idle speed screw is misadjusted lla Idle speed is set too low so idler fails to operate when arc is struck Adjust low idle speed screw for 1000 1050 14 Engine runs irregularly a Carburetor set too lean Adjust carburetor adjusting screw so engine will run smoothly at idle speed b Carburetor Dei
30. ion A 3 Pre Operation Sevi CEs ere ii A 5 OPO atl O a AAT T Section B Safety Precautions sise B 1 Engine Operation rk u u E EA B 1 Welder Operation see B 1 Carburetor DelciIng Kitu esd d isa B 2 Accessories u u m a aaa sn siasa arancel benne D DUR cod Section C AGG6SS0T169 uu sms t a laa C 1 ENEE Section D Safety Pr cautions dns et Pt aE a a At dida D 1 General InstrUctiONS cocaina nad aa RAT SRE D 1 TroubleshootiNg 1 gees es Section E e UNE E 1 How to Use Troubleshooting Guide E 1 Troubleshooting GUS cui is E 2 DIANA EE Section F CLASSIC Wiring Daglat serre ss F 1 CLASSIC T DIMENSION Print n L u una y dee ae tada F 2 Parts Mana lu E u en ee e den Ee ee Suil s P292 Series vi A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS CLASSIC I Machine Product Ordering Description Rated DC Output DC Current Range Auxiliary Dimensions amp Weight Name Information Amps Volts Duty Cycle Fine Adjustment in Each Range Power HxWxL Classic wm 6 EE Amp DC Welder Lincoln Plus Rating 40 300 Amps 1 75 kw 40 9 x 24 0 x 67 5 in 200A 40V 60 K6090 5 All Copper Windings 220 Max 15 Amps 1040 x 610 x 1714mm CSA NEMA Rating 160 240 120V DC Pure DC Power 200A 28V 60 120 190 1370 lbs 621 kg Generator 80 130 Min 90 Based on a 10 min period Engine Product Description Horsepower Operating Displacement Ignition Capacities Name Speeds Continental 4 Cylinder 38 HP Full
31. lding 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 ARC RAYS can burn 4 a Use a shield with the proper filter and cover Lo plates to protect your eyes from sparks and TT 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 material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 3 FUMES AND GASES a can be da
32. ly a Commutator should be turned or cleaned Brushes may be worn down to limit Replace brushes Field circuit may have variable Check field current with ammeter resistance connection or intermit tent open circuit due to loose or broken wire to discover varying current This applies to both the main genera tor and exciter Electrode lead or work lead con nection may be poor Tighten all connections Wrong grade of brushes may Use Lincoln brushes have been installed on generator Field rheostat may be making poor contact and overheating Inspect and clean the rheostat Be sure that all brushes bear on the commutator and have proper spring tension 2 Welder starts but fails to generate current Generator or exciter brushes may be loose or missing Exciter may not be operating Check exciter output voltage with voltmeter or lamp Field circuit of generator or exciter may be open Check for open circuits in rheo stat field leads and field coils Check rectifier bridge Exciter may have lost excitation Id Flash fields Series field and armature circuit may be open circuited Check circuit with ringer or volt meter 3 Welding arc is loud and spatters excessively Current setting may be too high Check setting and current output with ammeter Polarity may be wrong Check polarity Try reversing polarity or try an electrode of
33. m the manufacturer 5 e Also see item 1 b Mar 95 LINCOLN Y SAFETY 3 7 WELDING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas 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 explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or
34. mn labeled POSSIBLE CAUSE lists the obvious external possibili ties that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause If you do not understand or are unable to perform the Recommended Course of Action safely contact you local Lincoln Authorized Field Service Facility 44 WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring ENGINE EXHAUST can kill outside 1 D Use in open well ventilated areas or vent exhaust MOVING PARTS can injure Do not operate with doors open or guards off ee ae Stop engine before servicing va Keep away from moving parts Remove guards only when necessary and replace when work requiring removal is complete Only qualified personnel should install use or service this equipment 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 LINCOLN 4 E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed througout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSES COURSE OF ACTION PROBLEMS 1 Machine fails to hold the heat Rough or dirty commutator constant
35. ngerous 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 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 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 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 fro
36. nland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add I 5 00 For order value up to 49 99 l 10 00 For order value between 50 00 amp 99 99 l 15 00 For order value between 100 00 amp 149 00 l For North America invoiced orders over 50 00 8 credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment IMETHOD OF PAYMENT Sorry No C O D Orders l CHECK ONE _ Please Invoice only if order is over PI Invoi ly if order i 50 00 I Check or Money Order Enclosed U S Funds only I Credit Card een Tasa no III III 11 Ep pes Mal LL Le THIS FORM TO ORDER Books OR FREE INFORMATIVE CATALOGS Lincoln Welding School Titles Price Code Quantity Cost I ED 80 New Lessons in Arc Welding 5 00 L JSerninar Information Procedure Handbook Twelfth Edition 15 00 PH How to Read Shop Drawings 450 H Educational Video Information ____ Tncentve Management 8800 M y Eee A New Approach to Industrial Economics 5 00 NA Lames F Lincoln Arc Welding TPS American Century of John C Lincoln 8500 AC J Foundation Book Information Welding Preheal Calculator 300 wes C T JFLF
37. ny other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 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 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 i SAFETY i PRECAUTIONS DE SURETE 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instruc tions 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 Les circuits a l lectrode et la pi ce sont sous tension quand la machine a sou
38. on Ventilation Always operate the welder with the doors closed Leaving the doors open changes the designed air flow and may cause overheating JULY97 INSTALLATION A 3 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 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 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 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 build ing which has been effectively grounded The U S National Electrical Code lists a number of alternate means o
39. ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e Nao opere com os paineis abertos ou guardas removidas O0NFANMPIN AEDNALEZE CRMRBIEE U t AC F e V CRRRIARRARS SRR Ro exo Yel HAE 13 HA L t Cols 13 la lu Jato Yo Aale Viel Al Aaaa WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese it is BIR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SRM OBHOX HD OHBRBEE lt K MA ETHBRMLT EW CL TRHORERE HS lt F ux HAM SUCR UR fit AS EH BB A RRE ARA RAR sp J A BS EE ECKE IAE SAAD HALO Aix PAS EFSA HEHE Aal veel Gl d Lala aul y Llana J AAL all oig Gail guet italai ag ls Gras L LINCOLN e World s Leader in Welding and Cutting Products e 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
40. overlap ping current ranges The Fine Current Adjustment adjusts the current from minimum to maximum within each range Open circuit voltage is also controlled by the Fine Current Adjustment permitting control of the arc characteristics A high open circuit voltage setting provides the soft buttering arc with the 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 190 120 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 the 240 160 position and the Fine Current Adjustment setting to get 175 amps 44 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 possibility of setting this switch between the designated points Carburetor Deicing Kit A carburetor deicing kit is installed on Classic welders leaving the factory The pu
41. rpose of the Carburetor Deicing Kit is to prevent carburetor icing when the outside temperature is 60 F 15 5 c or lower See Carburetor Deicing Kit Usage Instructions For Seasonal Change Over on page B3 To obtain REPLACEMENT PARTS for the Carburetor Deicing Kit contact WIS CON TOTAL POWER COR PORATION Wis Con Part Complete Carburetor Deicing Kit Angled Heat Collector Shield 2 x18 Flexible Hose Gates 28095 1 56 2 50 Gear Clamp M10X70 Bolt JULY97 Description 3 8 Flat Washer Notice Decal Installation Instructions 10250021 LIT10278 Idler Operation Start the engine with the Idler switch in the HIGH position Allow it to run at high idle speed for several minutes to warm the engine The operating speeds are as follows ORDERING FULL HIGH LOW INFO LOAD IDLE IDLE K6090 Cont 1450 1600450 1000 ALL TM27 The idler is controlled by the Idler toggle switch on the welder control panel The switch has two positions as follows 1 In the High position the idler is off and the engine runs at the high speed controlled by the governor 2 In the Automatic lt lt position the idler operates as follows a When welding or drawing power for lights or tools approximately 100 150 watts minimum from the receptacle the engine operates at full speed b When welding ceases or the power load is turned off a preset time delay of about 15 sec ond
42. s starts This time delay cannot be adjust ed c lf 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 1 75 kw of 120V DC auxiliary power is available at the receptacle located below the nameplate CLASSIC LINCOLN B 3 OPERATION B 3 CARBURETOR DEICING KIT USAGE INSTRUCTIONS FOR SEA SONAL CHANGE OVER A WARNING ELECTRIC SHOCK can kill Do not operate with panels open e e Disconnect NEGATIVE BATTERY LEAD before servicing Do not touch electrically live parts MOVING PARTS can injure e Keep guards in place e Keep away from moving parts 12 Only qualified personnel should install use or service this equipment Qe The engine MUST BE COLD before seasonal change over of the carburetor deicing kit When the AVERAGE AIR INTAKE TEMPERATURE Average Ambient is Below 60 F 15 5 C Winter Season Configuration 1 With the engine OFF remove the negative cable from the battery 2 Push the FLEXIBLE HOSE fully onto the HEAT COLLECTOR SHIELD outlet tube see Figure 1 3 Reconnect negative battery cable FIGURE 1 A FUEL TANK B HEAT COLLECTOR SHIELD C FLEXIBLE HOSE D GEAR CLAMP E AIR FILTER Above 60 F 15 5 C Summer Season Configuration 1 With the engine OFF remove the negative cable from the battery 2 Remove the FLEXIBLE HOSE from the HEAT COLLECTOR SHIELD outlet
43. soudage et la machine a 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 a deux machines a soud er parce que la tension entre les deux pinces peut tre le total de la tension a vide des deux machines Si on utilise la machine a 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 ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le cable lectrode autour de n importe quelle PRECAUTIONS DE SURETE POUR partie du corps 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 irritants 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 LES MACHINES A SOUDER A Un coup d arc peut tre plus s v re qu un coup de soliel TRANS
44. ssembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals A 700 00 lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only l IPrices include shipment by 4th Class Book Rate for U S A Mai
45. the High Idle position 5 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 negative ground Damage to the engine alterna tor and the printed circuit board can result from incorrect 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 LINCOLN 4 E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE 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 SYMPTOMS 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 colu
46. the opposite polarity 44 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 LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed througout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSES COURSE OF ACTION Welding current too great or too small compared to indication on the dial Arc continuously pops out Engine fails to start 7 Low oil pressure Light not lit when engine running 8 Lack of Power PROBLEMS a Exciter output low causing low output compared to dial indica tion Operating speed too low or high Current Range Selector switch may be set at an intermediate position Out of fuel Clogged fuel system Choke not closing tightly Ignition switch shorted or open Moisture or carbon on spark plugs Defective distributor Oil too light Oil too low Defective oil pressure switch or light Carbon deposits causing pre igni tion Incorrect timing a Check exciter field circuit Adjust speed screw on governor for rated RPM operating speed Set the switch at the center of the current range desired Fill with at least 75 octane gaso line Check all lines to carburetor
47. the work cable should also be on your right side SY Connect the work cable to the workpiece as close as possible to the area being welded 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 Do not work next to welding power source Mar 95 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 In semiautomatic or automatic wire welding the electrode electrode reel we
48. to Position Check to See Whether Oil Pressure Light is On and Alternator is Charging Light Off Light On If Oil Light is O K Replace Oil Check Continuity of Idler Pressure Switch Control Switch Continuity Good Open 1 Reed switch in weld circuit Replace Switch may be stuck closed 2 Check continuity of idler solenoid coil 25 ohms 3 Replace P C Board Engine Will Not Pick Up Speed When The Arc is Struck The Auxiliary Power Load is 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 When Arc is Struck Up Speed 1 Replace Reed Switch Replace P C Board in Weld Circuit CLASSIC LINCOLN Y 13qUINU po2o 1u uudinb ay ane lJu uu o5e d 1 e 104 3u gunqued q SIMS ou O1 JUM 3 q163 1 S Weep ay y Sjaued aunso us ayy Jo suo uo SUIYDIELW ayy pisu p 1sed si po Jejn3nued e 104 Weep 2u12eds out jenueuu siy Aq pao s ulu2euli e 107 a3em gt gt e q jou Aew y lt LL 29267 IL6 TE OT ANTHOVA NO SAVE XOVIA ANY gen OL ALOWTE NO SWAT NOWIS INV GFU LOHNNOD SANIHOWM I DISSWIO NO wUlde HHL LNOBIIM geen SI LI AI HOLIMS TOWLNOD SLOWEY HHL OL ND90 NYO een GSTIVESNI BINGON qusa FAIM Y YO ABTIVISNI SOTA NOILDVO ENIH
49. ture is 60 F 15 5 C or lower CLASSIC LINCOLN A 3 PRE OPERATION INSTALLATION Safety Precautions 44 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 ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground e Always wear dry insulating gloves ENGINE EXHAUST can kill e Use in open well ventilated areas or I 6 a vent exhaust outside a MOVING PARTS can injure e Do not operate with doors open or guards off e e Stop engine before servicing e Keep away from moving parts See additional warning information at front of this operator s manual 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 suitable spark arrester must be installed and properly maintained CAUTION Use of an incorrect arrester may lead to engine damage or performance loss Contact the engine manufacturer for specific recommendations Locati
50. ze moisture condensation in the tank Also running out of fuel tends to draw dirt into the fuel system When hauling the welder between job sites close the fuel feed valve beneath the fuel tank Failure to turn the fuel off when traveling can cause carburetor flood ing and difficult starting at the new job site WELDER OPERATION WARNING e ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground FUMES amp GASES can be dangerous Keep your head out of the fumes Use ventilation or exhaust to remove fumes from breathing zone De 2 72 WELDING SPARKS can cause fire or rm TY a explosion A Keep flammable material away ARC RAYS can burn Z e Wear eye ear and body protection me Duty Cycle The NEMA output rating of the Classic is 200 amperes at 28 1 arc volts on a 60 duty cycle 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 200 amperes at 40 Volts CLASSIC LINCOLN B 2 OPERATION B 2 Wis Con Part XM37004 Control of Welding Current 44 CAUTION DO NOT TURN THE CURRENT RANGE SELEC TOR WHILE WELDING because the current may arc between the contacts and damage the switch The Current Range Selector provides five
Download Pdf Manuals
Related Search