Lincoln Electric CLASSIC III 10033 User's Manual
Contents
1. si Jo euo uo SUR pased si e 10 enue sup Aq paano 10 Aew y AO SI SUL ILON 59267 IL6 TE OT XOVIS ANY LINSTY TIIM TOULNOD SIOMXH OL 111 OISSYIO NI GH1OSNNOO SNIHOVM NO G3IOSNNOO LON SHY A INO SSNIHOVH I 0155412 NO GISA TAY MOVIE wUlds SHL geen SI LI HOLINS IONLNOD SLOWEY OL 0200 NYO HOLOSNNOD OL LIM TOWLNOD LOSNNOD NO 014 LOSNNODSIG GETTVLSNI HEIM Y NO GETIVESNI NOILOVO ENIHOVH NO SP NOLOSNNOO SNIHOVH HLIM GXTIVISNI SI TAIM ON DNIAVST seen DOTA MEN SNIHOVH NO SI 0Td 40 HLIM SI FEIM V HNIHOVH NO NOLONNNOD Ol LIX 108 SLOWEY NO IOZNNOO er NOLOZNNOO2. M ILVH OL TIVALNEN GHMISA SV NMOHS SINSNOdWOO IONINOO WVYOVId KINO SLINO NO uvsddv SIIHMS NMOWH H NHOUE N NSHUD D xovig 8 aval LESTA S IOSNAS VOIHLOSTH WOIVNHSITV III DISSVIO NI SHY XOVIS ANY TIIM IOMLNOD BLOWTY OL SIHL NO Q3123NNOD uv SENIHOWA OISSYIO NO SHY ANY o were m dorirsos moor 1 wo WOOT ow fer mie uo Moms eo 35 HOLINS IONLNOD SIOHSH IVNOILdO TONLNOO SLONHUH I VZ6X HNIONS OL annoys asva maton ONTLUVES HOLIMS sunsssua 10 HOLIMS HOLIMS arias NOILINDI wOInHINISIG III OISSV IO LHDIT guassaua TIO ano 44O LOHS SNIONG WOLDHINLSIG xozsisssl NSITNVE NO NOLISISHN HLIM LIDONIO NOILINOI SIVNHZLTV MEER CLASSIC IlI LINCOLN E N DIAGRAMS 13ua
3. 9 fsPBHEICTASESUCFEU e Fe ik ER c EUR Bit SH7IAE S XACE E AAS AH 71 97471 557E Qai oe Jung dul ae SU ARA bacs Aa qi axial os uui ARA ge al ue Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico Nao toque as partes el tricas nuas e X7TTL 2A 9 AVCBRUD PRE EFFERRI vF DBF MTF e HERES BEER e Meg xp ett AIR Aie Gb pha NM ale Do not operate with panel open or guards off No operar con panel abierto o 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 N o opere com os paineis abertos ou guardas removidas EX THRERFELEOTTF V SRR Ro eggo Yel HAE L t lu Qai ye Aale Al ll WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese
4. P 1 348 HOLIMS HOLIMS NOILINDI NOIL2SIONd SNIONS 0155 10 1 asna AALAN SNIONG LJ MOTO CLASSIC III LINCOLN E 991015 F 3 A D 4 a aod IdM H 5 d v S 28 CT 76 L 00 OL 8 99 ioo te WI 05556 este 9 8 8 SOT 9 6t 889 a 9 9rTvI 89I UT HSITONH UO OINLSW 79 07 S8 IOH 00 DNILNOQOW 95 rer 0S 8T ONILNOAOW GINS 9S Sat DIAGRAMS SATOH ONILNNOW NHHIIYHL 99 Ke TIAA ON LNA ANIONA NI MNHLVM TIO HLIM ALIAVAD AO TOULNOO LNI d NOISNHNIG F 3 CLASSIC III AND LINCOLN E NOTES CLASSIC 11 LINCOLN NOTES CLASSIC 11 LINCOLN 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 des
5. IM529 A CLASSIC amp CLASSIC For Machines with Code Numbers 10033 10061 10072 or 10156 Supersedes IM 482 Safety Depends on You Lincoln arc welding equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful This manual covers equipment which is obsolete and no longer in production by The Lincoln Electric Co Specifications and availability of optional features may have changed OPERATOR S MANUAL ISO 9002 nufacture Quality Pragram Certified by uatity Eval ABS Qi ns Inc to ISO 9002 Requirements CERTIFICATE NUMBER 30273 LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY WARNING 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 h
6. place V V for selecting a QUALITY product by Lincoln Electric We want you hank You to take pride in operating this Lincoln Electric Company product 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 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 A 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
7. No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pieces 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 Nao toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra o REPOR ELE het EE LATE OHLMPT APYORAPHRBS NTWSHRELTFSU e E 945 CE EC SUE HIER ecran s a e sis HIE amp Ju Gu gone uil oh ye puni das AI gh la pally All apad Jai DA dua aa e Keep flammable materials away Mantenga el material combustible fuera del area de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos e naedoe6008 CORRE LU THEN EA e i 9 E ML LS AIX uie a d s Jo ALD a pis 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 e
8. NO SNIHOVH TONLNOD asvo OL MHELSHOIINSLOd SLOWEY IVNOILdO CW 4 M HLIM 9 00 SAILISOd cooler m o fe D some eo een HOLIMS TOULNOD v TZ6X 29 BAILVOSN SNOILOSNNOO SSHHL NAHM SNINNQN LON 150 AAVSH CH vuan TUIM SNIHOVH NO SP WOLOZNNOO Ol W d M NO SOTA LOBNNOD SP WOLOSNNOD WOU 014 XT8WSSSV IVISONWSHHL osz WZLXHOILNSLOd genge TOWLNOD zen Ol 103NNOO suoisissu TwNIHSSL 104100 AO SAILVDSR 104200 PEN SO4 OL 128NNOD 1 uud INTINTI HRISHOILNSIOd TONINOO ZAOHZH NO IVNOILdO AYAT f ARTE WHNNOASNVHL LINHSNH O HOLIMS 5 vzos SONIGNIM ANVITIXOV MNOIVNHSITV LIOA Ott NONI OL LSHAVEN ONIY dITS SONIE 4115 HOIVNNSITV S TOVLdHOSH LIOA SII
9. e NOIOZNNOO SNIHOVH NO SNIHOVM HLIM XOS WSISHOIINS1Od TOWLNOO asvo o 108802 MHSLSHOILNZLOd SLOWEY IWNOILdO HLIM 45 00 SAILISOd rrr ee ee eee NOILISOd NI NMOHS IONINOO HO non HOLINS mots aas HOLIMS SIOWLdEOZH IOHLNOD S1OWSH TlOWLNOO vT TZ6MX 99 SAILVOSN SNOILOSNNOO DNINVW DNINNNE LON 15 SNIHOVW GVST AAYAH t avat aavan assa TUIM SNIHOVH NO SP WOIOHNNOO OL W d M NO SOTA LOANNOD NOLOSNNOO aval IG s CHO asna avan NHNWHOASNVL Ir n HE HOLIMS OLOST8S Sijam 50 SONIGNIM ANVITIXOV MNOIVNHSITV 110A oe NONI OL ILSHUVEN DNIY 4115 SONIY 4115 HOIVNUSITV a M SQNOOOVN ALNAN OL aan QSMSIA SV NMOHS SINSNOdWOO 8NVd IOHLNOO STI KINO SLINO NXITHVR NO waaay savat NMONS N NSHHD D SNIHOVH NO HIM 3d09 aval LESTA
10. ke 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 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 1 9 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 LINCOLN 8 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 workpie
11. 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 building which has been effectively grounded The U S National Code lists a number of alternate means of grounding electrical equipment CLASSIC III AND LINCOLN 8 A 4 INSTALLATION A 4 Lift Bail A lift bail is provided for lifting with a hoist A WARNING FALLING EQUIPMENT can cause injury Do not lift this machine using lift bale if it is equipped with a heavy accessory such as a trailer or gas cylinder Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Trailer 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 dam age th
12. ATENCAO Japanese it is BIR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR SRM OBHOX HD OHBRBEE lt K MA ETISRUCESU CL TRHORERE HS ET MEL RE Rr de OE ND RES RAR 7 SAAD HAS Aix PAS EFSA HEHE Saal d illai d AAL Gail guet ag ls L LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
13. 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 Fill with gasoline Check all lines to the carburetor Loosen choke cable screw and slack off choke wire Replace Remove plugs clean and adjust gap See Engine Service Chart Replace Drain refill with proper grade Fill to Full mark on bayonet gage Do not overfill Replace Run engine under full load for a short time Time ignition Check throughout for dirty or broken hoses clogged radiator or defective water pump Time ignition Adjust valve tappets See Engine Service Chart for settings Adjust for 3 4 to 1 deflection Use at least 87 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 shut off and the regulator expanded CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local L
14. U S Funds only 15 Credit Card a VE 111 1 Ep pes Mal LL lise THIS FORM TO ORDER Books OR FREE INFORMATIVE CATALOGS li incon Welding School Titles Price Code Quantity Cost ED 80 New Lessons in Arc Welding 500 L 5 Information Procedure Handbook Twelfth Edition 15 00 PH How to Read Shop Drawings 9450 H Educational Video Information Management 3590 A ee New Approach to Industrial Economics 500 NA Lames F Lincoln Arc Welding American Century of John Lincoln 500 Foundation Book Information WekingPrehealCalcuatr 300 wee FLF 515 Pipe Welding Charis ED eo Shipping TOTAL COST 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 ee ue eee el WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground
15. an incorrect arrester may lead to engine damage or performance loss Contact the engine manufacturer for specific recommendations 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 STACKING Classic and machines cannot be stacked ANGLE OF OPERATION To achieve optimum engine performance the Classic and should be run in a level position The max imum angle of operation for the TM27 and TMD27 engines 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 less than the speci fied 15 gallons 57 Ltrs 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
16. and stainless hinges With the addition of the optional K623 1 Wire Feed Module the Classic III or Classic will provide constant voltage output for running the LN 7 LN 23P or LN 25 wire feeders The Wire Feed Module is factory installed on the K1428 3 and K1433 2 The Classic D has Diesel Engine Protection In the event of sudden low oil pressure or high coolant tem perature the engine immediately shuts down The Classic amp Classic D have a current range of 40 350 DC amps with output ratings as follows RATED OUTPUT DUTY CYCLE 225A 29V 300A Q 32V 350A 34V These units are also capable of providing 3 kVA of 115 230 volts of 60 cycle AC auxiliary power The Classic unit uses the Continental TM27 industrial water cooled Gasoline engine while the Classic uses the Continental TMD27 industrial water cooled Diesel engine DESIGN FEATURES 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 Each welder is equipped with a Start button an Ignition switch and an Idler con trol switch The diesel version comes with a Glow Plug feature for easier cold weather starting The control panels also contain an engine tempera ture gauge diesel only a battery charging ammeter an oil pressure
17. corpo e BH HRUBS ISUCRSREUCT RRR ez 12 Sal amp s ESSA dis 4 lan cl ysl gua e A dang 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 exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n 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 Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria
18. gauge oil pressure light on the gaso line version two three prong grounding type recepta cles and circuit breakers for auxiliary power and a choke control gasoline version only All Copper Windings For long life and dependable operation Engine Idler Both the Classic amp are equipped with an electronic automatic engine idler It automatically increases and decreases engine speed when starting and stopping welding or using aux iliary power A built in time delay permits changing electrodes before the engine slows to its low idle speed The Idler control switch the panel locks the idler in full speed position when desired Auxiliary Power 3 0 kVA of nominal 115 230V 60Hz AC Output voltage is maintained within 10 at all loads up to rated capacity See Optional Features for Power Plug Kits Welder Enclosure The complete welders are rubber mounted on a rugged steel C channel base The output terminals are placed at the side of the machines so that they are protected by the door The output terminals are labeled and Cranking System A 12 volt electric starter is stan dard Air Cleaner Heavy duty two stage dry type Muffler A muffler and rain cap are standard Engine Hour Meter A meter to record hours of oper ation Diesel Engine Protection The system shuts the diesel engine down in the event of sudden low oil pressure or high coolant temperature Carbure
19. lbs 638 kg T 120 190 CSA 300 Amp DC 80 130 13 Amps w Wire Feed A Arc Welder x MORE 225A 29V 100 MED 230V All Copper se cogs 300A 32V 50 Windings Classic 1433 1 40 350 Amps 3000 Watts 40 94 x 24 0 x 66 25 in CSAQ Pure DC Power 350A 34 3096 60 Hz AC w o Wire Feed Generator 1040 x 610 x 1683mm Sep 1445 lbs 657 160 240 115V db K1433 2 csa 120 190 13 Amps w Wire Feed 2 130 Ge Module Min 90 Meets Canadian Standards Based on a 10 min period Engine Product Description Horsepower Operating Displacement Capacities Name Speeds Classic Ill 4 Cylinder 4 Cycle Water Cooled Gasoline Engine 45 HP t5 Cast Iron Cylinder Q 1700 RPM Distributor Type Block Crankcase Electronic Fuel Full Load 15 Gals 57 Ltrs 1725 RPM 164 7 Cu In 2 7 ltrs Lubricating Oil 4 Cylinder High Idle 7 0 Qts 6 7 Ltrs Classic 4 Cycle 1800 RPM Water Cooled Coolant Diesel Engine 38 9 HP Low Idle 9 3 Qts 8 8 Ltrs Cast Iron Cylinder Q 1700 RPM 1350 RPM Diesel Block Crankcase CLASSIC LINCOLN A 2 INSTALLATION A 2 GENERAL DESCRIPTION The Classic Ill and Classic IIl D are heavy duty engine driven DC arc welding power sources capable of providing constant current output for stick welding or DC TIG welding These welders are wound with all copper coils rated at 300 amps 32 Volts and provide other Classic features such as improved door latches
20. may be entrapped in the fuel distribution system If this happens bleeding of the fuel system may be necessary See the Engine Operating Manual CLASSIC LINCOLN B 2 OPERATION B 2 WELDER OPERATION A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground FUMES amp GASES can be dangerous Keep your head out of the fumes 3 Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away 77 ARC RAYS can burn 4 Wear eye ear and body protection lie NM Duty Cycle The NEMA output rating of the Classic amp Classic D are each 300 amperes at 32 arc volts on a 50 duty cycle consult Specifications in this manual for alternate ratings Duty cycle is based on a ten minute period thus the welder can be loaded at rated output for five minutes out of every ten minute period Control of Welding Current A 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 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 Curre
21. ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher 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 souder 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 prot ger contre les chutes dans le ca
22. rung EO cds electrode with skin or wet clothing Have qualified personnel do the troubleshooting e Insulate yourself from work and work Turn the engine off before working inside ground the machine In some cases it may be neces Always wear dry insulating gloves 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 ENGINE EXHAUST can kill Use in open well ventilated areas or GA vent exhaust outside 4 MOVING PARTS can injure Do not put your hands near the engine cooling Do not operate with doors open or blower fan If a problem cannot be corrected by Sion engine EE EG following the instructions take the machine to D the nearest Lincoln Field Service Shop Keep away from moving paris 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 11 AND LINCOLN 8 E 2 TROUBLESHOOTING E 2 WELDER TROUBLESHOOTING TROUBLE CAUSES WHAT TO DO Machine fails to hold the heat consistently Welder starts but fails to generate current
23. should not be greased To keep the contacts clean rotate the cur rent control through its entire range frequently Good practice is to turn the handle from maximum to mini mum setting twice each morning before starting to weld 3 Put a drop of oil on the Current Range Selector shaft at least once every month 4 When necessary remove the sediment bowl if so equipped from beneath the fuel tank and clean out any accumulated dirt and water 5 Follow the engine service schedule in this manual and the detailed maintenance and troubleshooting in the engine manufacturer s manual Cooling System The Classic amp D are each equipped with a pres sure radiator Keep the radiator cap tight to prevent loss of coolant Clean and flush the cooling system periodically to prevent clogging the passage and over heating the engine When antifreeze is needed always use the permanent type Capacity 9 3 qts 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
24. 1433 2 CLASSIC LINCOLN D 1 MAINTENANCE D 1 MAINTENANCE A 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 T e electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill 9 Use in open well ventilated areas or vent exhaust outside 24 MOVING PARTS can injure Do not operate with doors open or lt lt guards off N Stop engine before servicing 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 2 Current Range Selector contacts
25. E OPERATION 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 ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or CA vent exhaust outside 4 MOVING PARTS can injure Do not operate with doors open or guards off engine before servicing Keep away from moving parts See additional warning information at the 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 Classic Continental TM27 Gasoline Engine Turn the Idler control switch to High Turn the Ignition control switch to On Pull out the choke control Press the Start button If the engine fails to start in 60 seconds wait 30 seconds before repeating the above procedure Allow engine to run at high idle speed for several minutes to warm the engine Cold engines tend to run at a speed too slow to supply the voltage required for proper idler operation 7 Asengine warms slowly return the choke con
26. High position 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 D 3 MAINTENANCE D 3 ENGINE SERVICE Hours Between Servicing Maintenance Item Type or Capacity s m E Mie 7 qts Including Filter ek Fram PH 8A Purolator 1 E KS AirCleaner Cartridge Donaldson P 181050 Nelson 70206N _ DENT _ cen Spark Plugs Gap 032 4 Champion RN12YC LS LL Le Fuel Filter 5 Continental 4TM D27F00506 WE EC Fuel Filter 6 Continental TMD20F00400 E Valve Clearance Intake20 14 Exhaust 018 2 Inspect C Clean Replace 2 Consult Engine Operators Manual for oil recommendations Or equivalent First inspection after 50 hours every 500 thereafter Gasoline engine only Diesel engine only Welder Code Numbers 10061 and below Diesel engine only Welder Code Numbers above 10061 Consult Engine Operators Manual for additional maintenance schedule information 969236 520919 1 CLASSIC LINCOLN E 1 TROUBLESHOOTING E 1 TROUBLESHOOTING WARNIN ELECTRIC SHOCK can kill
27. OF CONTENTS Page Installation aa aeaea deaan a Ce eea Eaa daa aaa iaaa eenaa AiE Section A Technical Specifications icenen eee nere Ue ed e ie doe Ea EA reines eee A 1 General Description quce e Eet at Hs nt ne Es fece i A 2 Design Features ERE A 2 Pre Operation Installation see A 3 Safety 8 rer tete i e ge d eee ede edo ee e ee dee oes A 3 Exha st Spark Arrester 2 2rd A 3 1 A 3 SLACKING LITERE A 3 Angle eee repre ce eir ee A 3 Machine Groundimg A 3 Lifts 5 C A 4 nn ie MT 4 Polarity Control and Cable Sizes A 4 Pre Operation Service sienne A 5 Oil M A 5 ne eee nien eu A 5 EE EE A 5 SEN UL Le EE A 5 Op ration eed acini Mae AG een E Section B Engine Operatlon ege Hanh esate Re Ue etes delete B 1 Starting The Continental TM27 Engine nennen nens B 1 Starting The Continental TMD27 Engine B 1 Stopping the engine sise B 1 LER te abu ede B 2 CAN el E E ES ee Seat ees B 2 Control of Welding Current see B 2 Idler Op rations cii tree ee RH ee B 2 Auxiliary POWER Re tton B 3 Carburetor Deicing B 3 cM
28. Rough or dirty commutator Brushes may be worn down to limit Field circuit may have variable resistance connection or intermittent open circuit due to loose connection or broken wire Electrode lead or work lead connection may be poor Wrong grade of brushes may have been installed on generator Field rheostat may be making poor contact and overheating Generator or exciter brushes may be loose or missing Exciter may not be operating Field circuit of generator or exciter may be open Exciter may have lost excitation Series field and armature circuit may be open circuited Commutator should be turned or cleaned Replace brushes Check field current with ammeter to discover varying current This applies to both the main generator and exciter Tighten all connections Use Lincoln brushes Inspect and clean the rheostat Be sure that all brushes bear on the commutator and have proper spring tension Check exciter output voltage with voltmeter or lamp Check for open circuits in rheostat field leads and field coils Check rectifier bridge Flash fields 1 Check flashing diode at 5 o clock brushholder in generator Check circuit with ringer or voltmeter 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 it s negat
29. Section C Optional Features Field Installed eene nnne C 1 Section D Safety Pr cautions EE D 1 General p ge det eee D 1 ele TEE D 1 B aringS P ME D 1 Brushes EE D 1 Idler Maintenance mn e rer e tt i ee Lc e D 2 Nameplates die Mob or te Sa Lot eL eet AR Oe TE eS cel D 2 Engine Service Chart uen dete etat ye ENEE NEEN D 3 Troubleshooting Section E Safety Precautlons ee gece E 1 Welder Troubleshooting siiis 2 Electronic Idler Troubleshooting Guide E 3 Engine Troubleshooting Guide TM27 Only ss E 4 E 5 Diagrams c ea ca c asd ect ete Section F Wiring Diagram Classic 111 nnne F 1 Wiring Diagram Classic D F 2 Dimension Prints Ab dite e eiie iecit F 3 Parts Manual sis P232 Series P302 Series III ma INSTALLATION AA TECHNICAL SPECIFICATIONS CLASSIC AND Machine Product Ordering Description Rated DC Output DC Current Range Auxiliary Dimensions Name Information Amps Volts Duty Cycle Fine Adjustment in Each Range Power amp Weight K1428 2 40 350 Amps 3000 Watts 40 94 x 24 0 x 66 25in 60 Hz w o Wire Feed 1040 x 610 x 1683 mm Module 220 Max 26 Amps 160 240 115V 1406
30. 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 is Loaded 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 Lead and Repair Replace P C Board 2 Replace Reed Switch in Weld Circuit 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 III LINCOLN 8 E 4 TROUBLESHOOTING E 4 ENGINE TROUBLESHOOTING TM27 Gasoline Engine Only WHAT TO DO TROUBLE CAUSES Engine fails to start Low oil pressure Light not lit when engine is running Lack of power Overheating Knocking Surging See engine manual 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 ignition Incorrect timing
31. and cigarettes away BATTERY ACID can burn eyes and skin Wear gloves and eye protection and 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 The Classic amp Classic III D are each equipped with a wet charged battery The charging current is auto matically regulated when the battery is low after start ing 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 CLASSIC LINCOLN B 1 OPERATION B 1 ENGIN
32. arm 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 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 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 SX 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
33. asa STOGWAS TVOINLOSTS WVSOVIG ONIAIM 111 OISSVTO HNINOVM AI TOMNLNOO OL BNIHOYM SIHL NO QXIOZNNOD SUM ANY SENIHOWA 1 OISSYIO NO GESA SHY ANY SHL IVISOWHSEHL osz NELEHOILNSIOd usawa TONLNOO OL wues 104200 AO SAIIVDSM inaino OL Lc ANITINI HSISHOLINSIOd IVNOILdO ssonvo HEN MENOS ox ieee SEN Deen muons mme E PN ie AD some 55 HOLINS SLOWEY TONINOO ALOWHAY I YVZ6X sva o aunoso OL LJ us L L sonvo CON HDLIMS SuDINSdHRL sunssaua 110 OLON DNILHVIS Aert LJ E anna S S ON ON D
34. ated Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY PR CAUTIONS DE S RET zones o l on pique le laitier Pour votre propre protection lire et observer toutes les instructions 6 Eloigner les mat riaux inflammables ou les recouvrir afin de et les pr cautions de s
35. ce 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 ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 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 y
36. 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 K802C A power plug kit for the auxiliary power receptacles is available Provides a plug for each receptacle Remote Control Kit K924 4 Contains switch receptacle remote control rheostat and 100 ft 30 5m cable for adjusting the OCV at the welding site Trailer K768 Two wheeled trailer for in plant and yard towing at speeds under 10 mph only Trailer K780 Two wheeled trailer with brakes lights and fenders For highway use consult applica ble federal state and local laws regarding possible additional requirements Trailer Two wheeled 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 Order K913 1 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 Provides constant voltage CV output with improved arc stability for Innershield welding Excellent for MIG welding Recommended wire feeders are the LN 7 LN 23P and LN 25 Factory installed on the K1428 3 and K
37. e 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 In the High position the idler is off and the engine high speed is controlled by the governor 2 In the Auto y position the idler oper ates 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 CLASSIC Ill LINCOLN B 3 OPERATION B 3 Auxiliary Power The AC auxiliary power supplied as a standard has a rating of 3 0 kVA of 115 230 VAC 60 hertz With the 3 0 kVA 115 230 VAC 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 per mits 15 amps to be drawn from either ha
38. e 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 attachment to the base of the welding equipment so there will be no undue stress to the framework 3 Proper placement of the equipment on the trailer to ensure stability side to side and front to back 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 trailer will be operated 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 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 For Negative polarity con nect the electrode cable to the stud These con nections should be checked periodically 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 Cables Sizes for Combined Length of E
39. ed 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 4 700 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 IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value up to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 For North America invoiced orders over 50 00 amp 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 METHOD OF PAYMENT Sorry No C O D Orders 1 Please Invoice only if order is over 4 Invoi ly if order i 50 00 I Check or Money Order Enclosed
40. he 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 tube 3 The FLEXIBLE HOSE is to be positioned per figure 2 CLASSIC AND LINCOLN B 4 OPERATION IMPORTANT 1 2 clearance between the FLEXIBLE 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 AND LINCOLN e ACCESSORIES OPTIONAL FEATURES Field Installed Accessory Set K703 Includes electrode and work cables headshield work clamp and electrode holder Hi Freq K799 Provides high frequency plus gas valve for DC TIG welding Linc Thaw L2964 1 Includes meter and fuses to protect welder when thawing frozen water pipes A WARNING Pipe Thawing IS NOT a CSA approved procedure If not done properly it can result in fire explosion
41. igners 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 assembled 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 respect
42. incoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CLASSIC 11 LINCOLN 8 E 5 TROUBLESHOOTING E 5 ENGINE TROUBLESHOOTING TM27 Gasoline Engine Only TROUBLE CAUSES WHAT TO DO Large decrease in speed Misadjusted governor spring adjusting screw Adjust screw until speed does not drop more than 100 rpm 25 rpm when arc is struck If surge occurs eliminate it with the control rod If high idle speed changes readjust the high idle speed screw Unable to strike an arc Idle speed screw is misadjusted Idle speed is set too low so idler fails to operate when arc is struck Adjust low idle speed screw for 1350 25 rpm Engine runs irregularly Carburetor set too lean 5 Adjust carburetor adjusting screw so engine will run smoothly at idle speed b Carburetor Deicing Kit in wrong configuration Carburetor Deicing Kit per instructions on page B3 and B4 Engine fails to pick up speed Check the idler when arc is struck n See engine 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 11 LINCOLN 8 1 LL DIAGRAMS F 1 qewidinbs AID Wda e
43. ive terminal to the negative brushholder The negative brushholder is the one nearest to the rotor lamination See the wiring diagram With the engine NOT running touch the positive battery terminal to the positive brushholder Remove the battery from the circuit 4 Replace the exciter cover Start the welder and the generator voltage should build up Welding arc is loud and spatters excessively Welding current too great or too small compared to indication on the dial Arc continuously pops out Current setting may be too high Polarity may be wrong Exciter output low causing low output compared to dial indication Operating speed too low or too high Current Range Selector switch may be set at an intermediate position CLASSIC LINCOLN 8 Check setting and current output with ammeter Check polarity Try reversing polarity or try an electrode of the opposite polarity Check exciter field circuit Adjust speed screw on governor for 1800 rpm operating speed Set the switch at the center of the current range desired E 3 TROUBLESHOOTING E 3 ELECTRONIC IDLER TROUBLESHOOTING GUIDE Engine Will Not Return to Idle in Approximately 15 Seconds Set Idler Control Switch to the Auto Position Check Continuity of Idler Control Switch Continuity Good Open 1 Reed Switch in Weld Circuit May be Replace Switch Closed 2 Check Continuity of Idler Solenoid Coil 8 5 9 0 ohms
44. lectrode Plus Work Cable 200 to 250 ft Duty Cycle Up to 200 ft CLASSIC LINCOLN A 5 INSTALLATION A 5 PRE OPERATION SERVICE A CAUTION READ the engine operating and maintenance instruc tions supplied with this machine A WARNING Fuel can cause fire or explosion f 4 Stop engine while fueling Do not smoke when fueling Do not overfill tank Keep sparks and flame away from tank 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 manufacturer s recommendations Upon receipt of the welder check the engine dipstick to be sure the oil is at the full mark DO NOT overfill Fuel gi Fill the fuel tank with the grade of fuel recommended in 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 we Battery Charging A WARNING GASES FROM BATTERY can explode Keep sparks flame
45. lf 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 Carburetor Deicing Kit A carburetor deicing kit is installed on Classic welders leaving the factory The purpose 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 B4 To obtain REPLACEMENT PARTS for the Carburetor Deicing Kit contact WIS CON TOTAL POWER COR PORATION Complete Carburetor Deicing Kit Angled Heat Collector Shield 2 x18 Flexible Hose Gates 28095 1 56 2 50 Gear Clamp M10X70 Bolt 3 8 Flat Washer Notice Decal Installation Instructions CARBURETOR DEICING USAGE INSTRUCTIONS FOR SEA SONAL CHANGE OVER A WARNING ELECTRIC SHOCK can kill Do not operate with panels open Disconnect NEGATIVE BATTERY LEAD before servicing Do not touch electrically live parts MOVING PARTS can injure ma Keep guards in place Keep away from moving parts Only qualified personnel should AX install use or service this equipment 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 t
46. nt Adjustment permitting control of the arc characteristics A high open circuit voltage setting provides the soft buttering arc with best resistance to pop outs pre ferred for most welding To get this characteristic set the Current Range Selector to the lowest 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 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 A 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 Idler Operation Start the engine with the Idler switch in the High position Allow it to run at high idl
47. otates 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 between 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 seated 100 Arcing or excessive exciter brush wear indicates a possible misaligned shaft Have an authorized Field Service Shop check and realign the shaft Idler Maintenance A CAUTION Before doing electrical work on the idler printed circuit board disconnect the battery When installing a new battery or using a jumper bat tery to start the engine be sure the battery polarity is connected properly The correct polarity is negative ground Damage to the engine alternator and the printed circuit board can result from incorrect connec tion 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 bat tery 3 If desired the welder can be used without automat ic idling by setting the Idler switch to the
48. our helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES 4 can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b Do not weld in locations near chlorinated hydrocarbon 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 unde
49. ples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 donc REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 onnement 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 inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN 8 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur
50. rstand 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 5 e Also see item 1 b Mar 95 LINCOLN 8 SAFETY 7 WELDING SPARKS can lt 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 explosion even though they have been cleaned For information purchase Recommended Safe Practices for
51. s ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie dico LES MACHINES SOUDER TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel pr venir tout risque d incendie d 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 9 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 fortement toxique ou autres produits irritants Pour obtenir de plus am
52. 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 Also see item 1 c LINCOLN 8 CYLINDER may explode 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 loc
53. 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 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 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 p Exposure to 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
54. tor Deicing Kit Classic Welders are equipped with a kit that prevents carburetor icing when outside temperature is 60 F 15 5 C or lower CLASSIC LINCOLN A 3 INSTALLATION A 3 PRE OPERATION INSTALLATION 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 ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or E Q vent exhaust outside 4 MOVING PARTS can injure Do not operate with doors open or guards off AW 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 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 arresters must be installed and properly maintained CAUTION Use of
55. trol to the in off position Fabi o Starting the Classic D Continental TMD27 Diesel Engine Turn the Idler control switch to High Turn the Ignition control switch to On Push the reset button Press the Glow Plug button for 10 to 20 seconds Press the Start button Release both buttons when engine starts If engine fails to start in 60 seconds the reset button will pop out Wait 30 seconds reset and repeat the above procedure 7 Allow engine to run at high idle speed for several minutes to warm the engine Cold engines tend to run at a speed too slow to supply the voltage required for proper idler operation Note Extreme cold weather starting may require longer glow plug operation A WARNING Under NO conditions should ether or other starting fluids be used in conjunction with the glow plugs This may cause an explosion or fire o Stopping the Engine 1 Turn the Ignition control switch At the end of each day s welding refill the fuel tank to minimize moisture condensation in the tank Also running out of fuel tends to draw dirt into the fuel sys tem When hauling the welder between job sites close the fuel feed valve beneath the fuel tank In gasoline engines failure to turn fuel off when traveling can cause carburetor flooding and difficult starting at the new job site In diesel engines if the fuel supply is cut off or runs out while the fuel pump is operating air
56. use clean equipment More bearing failures are caused by dirt introduced during greasing than from insuffi cient grease Commutator and Brushes A WARNING Uncovered rotating equipment can be dangerous Use care so your hands hair clothing or tools do not catch in the rotating parts Protect yourself from particles that may be thrown out by the rotat ing armature when stoning the commutator Shifting of the commutator 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 CLASSIC LINCOLN D 2 MAINTENANCE D 2 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 r
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