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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.
• 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
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CLASSIC
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
I
™
IM514-A
September, 1999
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric CLASSIC IM514-A
Summary of Contents for Lincoln Electric CLASSIC IM514-A
- Page 1 CLASSIC 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.
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Page 2: California Proposition 65 Warnings
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. -
Page 3: Electric Shock Can Kill
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. - Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...
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Page 7: Table Of Contents
General Discription ...A-2 Design Summary ...A-2 Pre-Operation Installation ...A-3 Pre-Operation Service..A-5 Operation ...Section B Safety Precautions ...B-1 Engine Operation...B-1 Welder Operation...B-1 Carburetor Deicing Kit ...B-2 Accessories ...Section C Accessories ...C-1 Maintenance ...Section D Safety Precautions ...D-1 General Instructions ...D-1 Troubleshooting ...Section E... -
Page 8: Installation
TECHNICAL SPECIFICATIONS – CLASSIC I Machine Product Ordering Description Name Information 200 Amp DC Welder Classic I K6090-6 All Copper Windings K6090-5 Pure DC Power Generator Engine Product Description Name Continental 4 Cylinder TM27 4 Cycle Water-Cooled Gasoline Engine JULY97... -
Page 9: General Discription
DESIGN SUMMARY Control Panel Both the engine and the welder controls are located on one recessed panel at the exciter end of the machine. The welder controls consist of a five step “Current Range Selector” switch and a “Fine Current Adjustment”... -
Page 10: Pre-Operation Installation
JULY97 INSTALLATION The welder should be located to provide an unrestrict- ed flow of clean, cool air. Also, locate the welder so that engine exhaust fumes are properly vented to an outside area. Machine Grounding According to the United States National Electrical... - Page 11 “Negative” stud. These connections should be checked periodi- cally and tightened if necessary. When welding at a considerable distance from the welder, be sure you use ample size welding cables. RECOMMENDED COPPER CABLE SIZES Amps Duty Cycle...
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Page 12: Pre-Operation Service
Consult the engine operation manual for specific engine manufacturers recommendations. Upon receipt of the welder, check the engine dipstick to be sure the oil is at the “full” mark. Add oil at the dipstick tube if required. DO NOT OVERFILL. -
Page 13: Operation
60% duty cycle. Duty cycle is based on a ten minute period; thus, the welder can be loaded at rated output for six minutes out of every ten minute period. The Lincoln “plus output” rating at 60% duty cycle is 200 amperes at 40 Volts. -
Page 14: Carburetor Deicing Kit
INFO. K6090- Cont. TM27 The idler is controlled by the “Idler” toggle switch on the welder control panel. The switch has two positions as follows: 1. In the “High” engine runs at the high speed controlled by the governor. 2. In the “Automatic”... - Page 15 CARBURETOR DEICING USAGE INSTRUCTIONS FOR SEA- SONAL CHANGE OVER 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. •...
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Page 16: Accessories
If not done properly, it can result in fire, explosion, damage to wiring which may make it unsafe, dam- age to pipes, burning up the welder, or other haz- ards. Do not use a welder to thaw pipe before reviewing Lincoln Bulletin E695.1 (dated October 1987 or later.) -
Page 17: Maintenance
----------------------------------------------------------- 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. - Page 18 3. Proper operation of the idler requires good ground- ing of the printed circuit board (through its mount- ing), reed switch, and battery. 4. If desired, the welder can be used without automat- ic idling by setting the “Idler” switch to the “High Idle” position.
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Page 19: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE 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. - Page 20 PROBLEMS (SYMPTOMS) 1. Machine fails to hold the heat constantly. 2. Welder starts but fails to generate current. 3. Welding arc is loud and spatters excessively. 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.
- Page 21 Observe all Safety Guidelines detailed througout this manual PROBLEMS (SYMPTOMS) 4. Welding current too great or too small compared to indication on the dial. 5. Arc continuously pops out. 6. Engine fails to start. 7. Low oil pressure. Light not lit when engine running.
- Page 22 Observe all Safety Guidelines detailed througout this manual PROBLEMS (SYMPTOMS) 9. Overheating. 10. Knocking. 11. Surging. 12. Large decrease in speed. 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.
- Page 23 3. Carefully holding an insulated section of the negative lead from the DC source, touch its lug or clamp to the left hand brushholder for five seconds. Pull it away quickly to minimize arcing. Remove the lead from the right hand brushholder, replace the brush on the commutator, start the welder and the generator voltage should build up.
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Page 24: Electronic Idler Troubleshooting Guide
The Arc is Struck Reed Switch in Weld Circuit Defective -- Will Not Close To Check: Short the Red Lead on P.C. Board to Welder Frame. Engine Picks Up Speed When Arc is Struck 1. Replace Reed Switch in Weld Circuit. -
Page 25: Diagrams
PLUGS PLUGS DIAGRAMS CLASSIC I... - Page 26 DIAGRAMS CLASSIC I...
- Page 27 Address: Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Titles: Price New Lessons in Arc Welding $5.00...
- Page 28 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic 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.
- Page 29 ● ● Keep your head out of fumes. Turn power off before servicing. ● Use ventilation or exhaust to remove fumes from breathing zone. ● Los humos fuera de la zona de res- ● Desconectar el cable de ali- piración. mentación de poder de la máquina ●...
- Page 30 • 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...