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RETURN TO MAIN INDEX
SVM125-A
October 1996
TM
CLASSIC II
For use with machine code numbers 9805 to 10220
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation .
. . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you ac
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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 ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 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 zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Safety.................................................................................................................................................i-iv Installation.............................................................................................................................Section A Technical Specifications.....................................................................................................
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Section A-1 Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Installation Technical Specifications..............................................................................................................A-2 Input – Diesel Engine ...........................................................................................................A-2 Rated Output – Welder.........................................................................................................A-2 Output – Welder and
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - CLASSIC II INPUT - DIESEL ENGINE Manufacturer Description Speed Displacement Ignition Capacities Deutz 3 cyl., 1725 RPM 125 cu. in. Electric Fuel: 15 gal. F3L-1011F Air-cooled Full load (2049 cc) (57 liters) diesel Oil: 6.3 qt. 28 HP @ 1800 RPM (6.0 liters) 1700 RPM High idle 1350 RPM Low idle RATED OUTPUT - WELDER Duty Cycle Amps Volts at Rated Amperes 100% Duty Cycle 200 DC Constant Current 28V 60% Duty Cycle 250 DC Constant Current 40V 40% Duty
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A-3 A-3 INSTALLATION Read this entire installation section before you LOCATION AND VENTILATION start installation. Always operate the Classic II with the doors closed. Leaving the doors open changes the designed air flow and may cause overheating. Always operate the SAFETY PRECAUTIONS welder with the case roof on and all machine compo- nents completely assembled. This will protect you from WARNING the dangers of moving parts, hot metal surfaces, and live electrical devices. Do not attempt to us
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A-4 A-4 INSTALLATION STACKING WARNING Classic II machines CANNOT be stacked. Keep hands away from the engine muffler or HOT engine parts. • Stop the engine when fueling. TILTING • Do not smoke when fueling. Place the machine on a secure, level surface whenev- er you use it or store it. Any surfaces you place it on • Remove the fuel cap slowly to release pressure. other than the ground must be firm, non-skid, and • Do not overfill the fuel tank. structurally sound. • Wipe up spilled fuel
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A-5 A-5 INSTALLATION UNDERCARRIAGES MUFFLER If you use a non-Lincoln undercarriage, you must This welder is supplied with an adjustable rain cap for assume responsibility that the method of attachment the muffler. Install the rain cap using the clamp provid- and usage does not result in a safety hazard nor dam- ed with the outlet facing away from the direction in age the welding equipment. Some of the factors to be which this unit will be transported. This will minimize considered are as foll
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A-6 A-6 INSTALLATION ELECTRICAL OUTPUT CAUTION CONNECTIONS • Loose connections will cause the output terminals to See Figure A.1 for the location of the 115 and 230 volt overheat. The terminals may eventually melt. receptacles, weld output terminals, and ground stud. • Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another. WELDING CABLE CONNECTIONS CABLE INSTALLATION, POLARITY CONTROL, AND CABLE SIZES When welding at a consi
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A-7 A-7 INSTALLATION MACHINE GROUNDING AUXILIARY POWER RECEPTACLES, PLUGS, AND HAND-HELD EQUIPMENT Because the Classic II creates its own power from its diesel-engine driven gener- The AC auxiliary power, supplied as a standard, has a ator, you do not need to connect the rating of 3.0 kVA of 115/230V AC (60 hertz). machine frame to an earth ground. With the 3.0 kVA, 115/230V AC auxiliary power, one However, for best protection against elec- 115V duplex and one 230V grounding type receptacle tric
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A-8 A-8 NOTES CLASSIC II Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION - Operation...............................................................................................................................Section B Safety Instructions.......................................................................................................................B-2 General Description ....................................................................................................................B-2 Recommen
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B-2 B-2 OPERATION WARNING OPERATING INSTRUCTIONS Read and understand this entire section before operat- ing your Classic II. ENGINE EXHAUST can kill. SAFETY INSTRUCTIONS • Use in open, well ventilated areas or vent exhaust to the outside. WARNING • Do not stack anything on or near the engine. Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include MOVING PARTS can injure. important safety precautions
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B-3 B-3 OPERATION RECOMMENDED APPLICATIONS DESIGN FEATURES • Constant current DC Stick welding (SMAW) process WELDER capability with output range from 40 - 325 DC amps. The Classic II provides excellent constant current DC • Constant current DC TIG Welding with output across welding output for stick (SMAW) welding and for DC the entire range of settings. TIG welding. It also offers constant voltage output for DC semiautomatic wire feed welding. For more details • Work and Electrode welding
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B-4 B-4 OPERATION WELDING CAPABILITY LIMITATIONS The Classic II is rated 250 amps, 30 volts constant cur- • The Classic II is not recommended for any process- rent DC at 60% duty cycle based on a ten minute time es besides those that are normally performed using period. Longer duty cycles at lower output currents are DC stick welding (SMAW) and DC TIG welding. possible. Specific limitations on using the Classic II for these processes are described in the Welding Operation The current is co
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B-5 B-5 OPERATION CONTROLS AND SETTINGS the case front. Welding output terminals and ground The welder/generator controls are located on the stud are located on the machine right side, under the Output Control Panel of the machine case front. Diesel door. See Figure B.1 and the explanations that follow. engine idler control and start/stop controls are also on FIGURE B.1 – OUTPUT CONTROLS 1 2 3 5 7 4 6 1. CURRENT RANGE SELECTOR 2. FINE CURRENT ADJUSTMENT 3. 230 VOLT RECEPTACLE 4. 115 VOL
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B-6 B-6 OPERATION CONTROL OF WELDING CURRENT CAUTION When a forceful "digging" arc is required, usually for vertical and overhead welding, use a higher CURRENT RANGE SELECTOR setting and lower open circuit DO NOT turn the CURRENT RANGE SELECTOR voltage. For example: to obtain 175 amps and a force- while welding because the current may arc between ful arc, set the CURRENT RANGE SELECTOR to 240- the contacts and damage the switch. 160 position and the FINE CURRENT ADJUSTMENT setting to get 175 am
