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IM514-A
™
September, 1999
CLASSIC I
For use with machines having Code Numbers 10068 & 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
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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 MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 General Discription ................................................................................................A-2 Design Summary ........................................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – CLASSIC I Machine Product Ordering Description Rated DC Output * DC Current Range Auxiliary Dimensions & Weight Name Information Amps / Volts / Duty Cycle (Fine Adjustment in Each Range) Power H x W x L 200 Amp DC Welder Classic I K6090-6 Lincoln Plus Rating 40 - 300 Amps 1.75 kw 40.9 x 24.0 x 67.5 in 200A / 40V / 60% All Copper Windings K6090-5 220 - Max 15 Amps @ (1040 x 610 x 1714mm) CSA NEMA Rating 160 - 240 120V DC Pure DC Power 200A / 28V
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A-2 A-2 INSTALLATION Engine Idler GENERAL DESCRIPTION The Classic I is equipped with an electronic automatic The Classic I is a heavy duty engine driven DC arc engine idler. It automatically increases and decreases welding power source capable of providing DC con- engine speed when using starting and stopping weld- stant current output for stick welding and DC TIG ing or using auxiliary power. A built-in time delay per- welding. With the addition of the optional K384 CV mits changing elect
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A-3 A-3 INSTALLATION The welder should be located to provide an unrestrict- PRE-OPERATION INSTALLATION ed flow of clean, cool air. Also, locate the welder so that engine exhaust fumes are properly vented to an Safety Precautions outside area. WARNING Machine Grounding Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s According to the United States National Electrical manual supplied with your welder. It includes Code, the frame of this portable gen
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A-4 A-4 INSTALLATION Lift Bail Polarity Control and Cable Sizes A lift bail is provided for lifting with a hoist. 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 WARNING mounting rail. (see size recommendations below). FALLING EQUIPMENT can cause For Positive polarity, connect the electrode cable to injury. the terminal marked “Positive”. For Negative polari- � Do not lift this machin
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A-5 A-5 INSTALLATION PRE-OPERATION SERVICE Battery Charging WARNING CAUTION GASES FROM BATTERY can explode. � Keep sparks, flame and cigarettes READ the engine operating and maintenance instruc- away. tions supplied with this machine. ------------------------------------------------------------ BATTERY ACID can burn eyes and WARNING skin. � Wear gloves and eye protection and Fuel can cause fire or explosion. be careful when boosting, charging or - working near battery. � Stop engine while
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B-1 B-1 OPERATION ENGINE OPERATION Stopping the Engine WARNING Do not attempt to use this equipment until you 1. Turn the Ignition switch to “OFF”. have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine At the end of each day’s welding, refill the fuel tank to starting, operating and maintenance instructions, minimize moisture condensation in the tank. Also, and parts lists. running out of fuel tends to draw di
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B-2 B-2 OPERATION Wis-Con Part# Description Control of Welding Current XM37004 3/8” Flat Washer 10250021 Notice Decal CAUTION LIT10278 Installation Instructions DO NOT TURN THE “CURRENT RANGE SELEC- Idler Operation TOR” WHILE WELDING because the current may arc between the contacts and damage the switch. Start the engine with the “Idler” switch in the “HIGH” ------------------------------------------------------------------------ position.
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B-3 B-3 OPERATION C. FLEXIBLE HOSE CARBURETOR DEICING KIT D. GEAR CLAMP USAGE INSTRUCTIONS FOR SEA- E. AIR FILTER SONAL CHANGE OVER Above 60°F / 15.5°C (Summer Season Configuration) WARNING 1. With the engine OFF, remove the negative cable ELECTRIC SHOCK can kill. from the battery. � Do not operate with panels open. � Disconnect NEGATIVE(-) BATTERY 2. Remove the FLEXIBLE HOSE from the HEAT LEAD before servicing. COLLECTOR SHIELD outlet tube. � Do not touch electrically live parts. 3. The FLEXIB
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C-1 C-1 ACCESSORIES (field Installed) OPTIONAL FEATURES Trailer (K768) Accessory Set (K702) For in-plant and yard towing at speeds under 10 mph. Includes 35 ft (10.7m) electrode and 30 ft (9.1m) work 37” (94cm) wheel track for narrow pathways & cables, headshield, work clamp, and electrode holder. entranceways. CV Adapter (K384) K6090 thru -4 only Provides constant voltage output for semiautomatic welding. Select either CV or CC. Trailer (K780) Linc-Thaw™ (L2964-1) - Includes meter and fuses to
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D-1 D-1 MAINTENANCE MAINTENANCE 3. Change the crankcase oil and oil filter after the first WARNING 50 hours of operation and thereafter at regular Have qualified personnel do the maintenance intervals using the proper grade of oil. See the work. Turn the engine off before working inside recommendations in the engine operation manual. the machine. In some cases, it may be neces- sary to remove safety guards to perform 4. Inspect the air filter daily - - more often in dusty required maintenance.
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D-2 D-2 MAINTENANCE Bearings Idler Maintenance CAUTION 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- Before doing electrical work on the idler printed stantly or in excessively dirty locations, it may be nec- circuit board, disconnect the battery. essary to add one-half ounce of grease per year. A ------------------------------------------------------------------------ pad of grease
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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 througout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSES COURSE OF ACTION PROBLEMS 1. Machine fails to hold the heat a. Rough or dirty commutator. a. Commutator should be turned or constantly. cleaned. b. Brushes may be worn down to b. Replace brushes. limit. c. Field circuit may have variable c. Check field current with ammeter resistance connection or intermit- to discover varying current. This tent open circuit
