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™
IM553-C
CLASSIC II
July, 2003
DC ARC WELDER WITH DEUTZ F3L- 1011F ENGINE
For use with machines having Code Numbers 10219, 10219CV, 10220, 10220CV, 10628, 10629,10872 and 10910
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
PRECAUTIO
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 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
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent 6. Eloigner les matériaux inflammables ou les recouvrir afin de dans ce manuel aussi bien que les précautions de sûreté prévenir tout risque d’incendie dû aux étincelles. générales su
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� 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
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vi vi TABLE OF CONTENTS Page Safety .........................................................................................................................i-iv ______________________________________________________________________________ Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precauti
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - CLASSIC II DEUTZ K1406-( ) INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Bore x Stroke Starting Capacities System Deutz 3 cylinder High Idle 1800 3.58” x 4.13 12VDC battery Fuel: 15gal. F3L 1011F 28.5 HP Low Idle 1350 (91mm x 105mm) & Starter 57 L Diesel Engine @ 1700 RPM Full Load 1725 SA-250 Oil: 6.3 Qts. 6.0 L RATED OUTPUT - WELDER Duty Cycle Constant Current Volts at Rated Amps 40% 300 amps (DC ) 32 volts 60% 250 amps (D
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A-2 A-2 INSTALLATION SAFETY PRECAUTIONS CAUTION WARNING Do not attempt to use this equipment until you DO NOT MOUNT OVER COMBUSTIBLE SUR- have thoroughly read the engine manufacturer’s FACES. manual supplied with your welder. It includes Where there is a combustible surface directly under important safety precautions, detailed engine stationary or fixed electrical equipment, the surface starting, operating and maintenance instructions, shall be covered with a steel plate at least and parts li
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A-3 A-3 INSTALLATION Oil Undercarriages This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W/30 oil. If the user adapts a non-Lincoln undercarriage, he This oil should be acceptable for most typical ambient must assume responsibility that the method of attach- temperatures. Consult the engine operation manual ment and usage does not result in a safety hazard nor for specific engine manufacturer's recommendations. damage the welding equipment. Som
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A-4 A-4 Battery Charging The Classic II is equipped with a wet charged battery. The charging current is automatically regulated when the battery is low (after starting the engine) to a trickle current when the battery is fully charged. When replacing, jumping or otherwise connecting the battery to the battery cables, the proper polarity must be observed. This system is NEGATIVE GROUND. WARNING GASES FROM BATTERY can explode. � Keep sparks, flame and cigarettes away. BATTERY ACID can burn eyes an
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B-1 B-1 OPERATION SAFETY PRECAUTIONS When an engine is started for the first time, some of the oil will be needed to fill the passages of the lubricating system. Therefore, on WARNING initial starting, run the engine for about five minutes and then stop the engine and recheck the oil. If the level is down, fill to the full Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s mark again. The engine controls were properly set at the factory manual supplie
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B-2 B-2 OPERATION A high open circuit voltage setting provides the soft Auxiliary Power “buttering” arc with best resistance to pop-outs pre- The AC auxiliary power, supplied as a standard, has a ferred for most welding. To get this characteristic, set rating of 3.0 kVA of 115/230V AC (60 hertz). the “Current Range Selector” to the lowest setting that still provides the current you need and set the “Fine With the 3.0 kVA, 115/230V AC auxiliary power, one Current Adjustment” near maximum. For e
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D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS 4. Inspect the air filter daily - more often in dusty condi- tions. When necessary, clean or replace. The filter should never be removed while the engine is running. WARNING The air filter element part number is Donaldson Have qualified personnel do the maintenance #181050 or Nelson #70206N. work. Turn the engine off before working inside the machine. In some cases, it may be neces- 5. Drain any accumulated water from the engine fuel fil- ter/water separa
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D-2 D-2 MAINTENANCE Idler Maintenance Commutator and Brushes 1. The solenoid plunger must work freely and not bind. The generator brushes are properly adjusted when the Dust the plunger about once a year with graphite welder is shipped. They require no particular attention. powder. DO NOT SHIFT THE BRUSHES or adjust the rocker set- ting. 2. Proper operation of the idler requires good ground- Shifting of the brushes may result in: ing of the printed circuit board, reed switch, � change in machi
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E-1 E-1 TROUBLESHOOTING 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. _______________________________________________________________
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E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION PROBLEMS Machine fails to hold the “heat” con- a. Rough or dirty commutator. stantly. b. Brushes may be worn down to limit. c. Field circuit may have variable resistance connection or intermit- tent open circuit due to loose con- nection or broken wire. d. Electrode lead or work lead con- nection may be poor. e. Wrong grade of b
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E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION PROBLEMS Welding arc is loud and spatters a. Current setting may be too high. excessively. b. Polarity may be wrong. Welding current too great or too a. Exciter output low causing low small compared to indication on the output compared to dial indica- dial. tion. b. Operating speed too low or high. Engine shuts down and engine a
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E-4 E-4 TROUBLESHOOTING ELECTRONIC IDLER TROUBLESHOOTING GUIDE Engine Will Not Return To Idle In Approximately 15 Seconds Set Idler Control Switch To The Auto Position Remove All Weld and Auxiliary Power Loads Check Continuity of Idler Control Switch Continuity Good Open 1. Reed switch in weld circuit may be stuck Replace Switch closed. 2. Check continuity of idler solenoid coil (8.5 - 9.0 ohms) & leads. 3. Check ground connections in idle circuit. 4. Replace P.C. Board Engine Will Not Pick Up S
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F-1 F-1 DIAGRAMS WIRING DIAGRAM - CODE 10628 & 10629 CLASSIC II DEUTZ ELECTRICAL SYMBOLS CONTROL PANEL COMPONENTS PER E1537 SHOWN AS VIEWED FROM REAR. P10 LEAD COLOR CODE NEUTRAL BONDED TO FRAME ' 11 9 8 6 5 4 2 1 NEUTRE RACCORDE AU BATI 12 10 7 3 61 B-BLACK J5 G-GREEN ENGINE W N-BROWN B +Y FAILURE 1 1 2 3 45 6 7 8 9 10 N -W 2 LAMP J1 IDLER/ENGINE ALTERNATOR ROTOR U 3 53B PROTECTION J2 4 SLIP RINGS P.C. BOARD - R + B 610 SLIP RING 57 + 610 NEAREST ENGINE 62 602B R HOUR TO IRON AC AC 600B 53 ME
