Lincoln Electric CLASSIC 11572, Operator'S Manual

Page 1: ... 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 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 ...

Page 2: ...AKER 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 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 ava...

Page 3: ...h 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 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 ii SAFETY ii FuMES AND GASES can be dangerous 5 a Welding may produce fu...

Page 4: ...reas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b 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 6 c When not welding make certain no part of the electrode circuit is touc...

Page 5: ...riés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Elo...

Page 6: ...important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEb SITE at www linc...

Page 7: ...ngine Engine Break In B 1 B 2 Welder Operation B 2 Duty Cycle B 2 Control of Welding Current B 2 Idler Operation B 3 Auxiliary Power Fuel Consumption Data B 3 Accessories Section C Optional Features Field Installed C 1 C 2 Maintenance Section D Safety Precautions D 1 General Instructions D 1 Cooling System D 1 Bearings D 1 Commutator and Brushes D 1 Idler Maintenance D 2 Nameplates D 2 Purging Air...

Page 8: ...Th DEPTh WEIGhT K1643 7 CSA w o Wire Feed Module 1354 lbs Code 11572 11640 45 5 in 24 00 in 65 0 in 616 kg 1156 mm 610 mm 1651 mm K1643 8 CSA w Wire Feed Module 1389lbs Codes 11573 11641 630 kg RATED OuTPuT 104 F 40 C GENERATOR DESCRIPTION RATED DC OuTPuT Duty DC CuRRENT RANGE VOLTS RATED AMPS CYCLE Fine Adjustments in each Range 40 350 Amps 220 Max 300 Amp DC Welder 30V 250A 100 160 240 All Coppe...

Page 9: ...engine speed when starting and stopping welding or using auxiliary power A built in time delay permits changing electrodes before the engine slows to its low idle speed The Idler control switch on the panel locks the idler in high idle 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 Feat...

Page 10: ...oints 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 LIFT bAIL A lift bail is provided for lifting with a hoist 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 ...

Page 11: ... 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...

Page 12: ...king near battery To prevent ExPLOSION when a Installing a new battery disconnect thenega tive cable from the old battery first and connect the negative cable to the new battery last b Connecting a battery charger remove the bat tery from the welder by disconnecting the nega tive cable first then the positive cable and bat tery clamp When reinstalling connect the neg ative cable last c using a boo...

Page 13: ... operator s manual WARNING 7 Allow the engine to run at high idle speed for sev eral minutes to warm the engine Stop the engine and recheck the oil level after allowing sufficient time for the oil to drain into the pan If the level is down fill it to the full mark again The engine con trols were properly set at the factory and should require no adjusting when received COLD WEAThER STARTING With a ...

Page 14: ...be loaded at rated output for six minutes out of every ten minute period CONTROL OF WELDING CuRRENT DO NOT TuRN ThE CuRRENT RANGE SELECTOR WhILE WELDING because the current may arc between the contacts and damage the switch The Current Range Selector provides five overlapping cur rent ranges The Fine Current Adjustment adjusts the cur rent from minimum to maximum within each range Open circuit vol...

Page 15: ...ngine 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 solenoid deactivates and the engine goes to high idle speed The speed is controlled by the governor 2 In the Auto position the idler oper ates as follows a When welding or drawing power for lights or t...

Page 16: ...SET K704 Includes 35 feet 10 m of electrode cable and 30 feet 9 m of work cable headshield work clamp and elec trode holder Cable is rated at 500 amps 60 duty cycle Remote Control Kit K924 5 Contains remote control rheostat and 100 ft 30 5 m cable for adjusting the OCV at the welding site TIG OPTIONS TIG Module K930 2 Provides high frequency and shielding gas control for AC and DC GTAW TIG welding...

Page 17: ...able operates contactor inside Wire Feed Module for cold electrode Requires LN 23P Adapter Kit K350 1 and Gun and Cable Assembly LN 23P Adapter Kit K350 1 Required to adapt LN 23P to any Lincoln power source Makes 14 pin connection at power source Magnum 250 Innershield Gun for LN 23P K355 10 For lighter weight and easier handling Rated 250 amps 60 duty cycle For 068 through 5 64 1 7 through 2 0 m...

Page 18: ...duced during greasing than from insufficient grease COMMuTATOR AND bRuShES 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 dama...

Page 19: ...onnected properly The correct polarity is negative ground Damage to the engine alternator and the printed circuit board can result from incorrect connec tion 1 Proper operation of the idler requires good ground ing of the printed circuit board reed switch and battery 2 Idler solenoid is activated for low idle 3 If desired the welder can be used without automat ic idling by setting the Idler switch...

Page 20: ...D 3 MAINTENANCE D 3 CLASSIC 300D PERKINS ...

Page 21: ...cle must not be tripped Reset if necessary Push the Reset button located on the GFCI mod ule This will assure normal GFCI operation Plug a night light with an ON OFF switch or other product such as a lamp into the Duplex receptacle and turn the product ON Push the Test button located on the GFCI module The night light or other product should go OFF Push the Reset button again The light or other pr...

Page 22: ... Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE...

Page 23: ...d circuit may have variable resistance connection or inter mittent open circuit due to loose connection or broken wire 4 Electrode lead or work lead connection may be poor 5 Wrong grade of brushes may have been installed on gener ator 6 Field rheostat may be making poor contact and overheating 1 Generator or exciter brushes may be loose or missing 2 Exciter may not be operating 3 Field circuit of ...

Page 24: ...ch Open Closed Measure DC Voltage on Replace Idler Idler Solenoid Coil Control Switch 0 VDC 12 VDC Check Continuity of Check for Jamming Reed Switch in Weld Circuit of the Idler Solenoid Mechanism Open Closed 1 Check Wiring in Replace Reed Idler Solenoid Switch Circuit 2 Replace Idler P C Board If for any reason you do not understand the test procedures or are unable to perform the tests repairs s...

Page 25: ...pring 2 Check for Continuity of Current Transformer Toroid Replace as Required 3 Check Idler Circuit Wiring and Repair as Required 4 Replace Idler P C Board Engine Picks up Speed 1 Check for Break in Red Lead and Repair 2 Replace Reed Switch in Weld Circuit Engine Does Not Pick up Speed 1 Check for Jamming of the Idler Solenoid Mechanism or broken return spring 2 Check Idler Circuit Wiring and Rep...

Page 26: ...Air mixed in the fuel system 3 Clogged fuel filter 4 Irregular and faulty fuel supply Injector pump trouble 5 Glow plug not heated 6 Clogged air cleaner 7 No compression 8 Engine protection light is ON 1 Faulty Ignition switch and or Injector pump solenoid 2 Insufficient charging or com plete discharge of the battery 3 Improper viscosity of the lubri cating oil 1 Air mixed in the fuel system 2 Une...

Page 27: ...e and correct Loose or slipping fan belt Remove oil dust etc and tighten Damaged fan belt Replace Clogged radiator Flush the radia tor Clogged radiator fin Clean Dust or scale clogged in the cooling water passage Flush the system Faulty function of the thermostat Inspect or replace thermostat Lack of lubricating oil Add oil Overloading Decrease the load Faulty Idler Engine Protection Printed Circu...

Page 28: ...ity of the engine oil 3 Faulty injection timing 1 Unsuitable fuel 2 Excess injection 3 Faulty function of the engine 4 Overloading 5 Clogged air cleaner 1 Loose fan belt 2 Faulty wiring 3 Faulty battery 4 Worn out alternator brush 1 Loose or damaged wiring 2 Drained voltage from battery 3 Damaged starter motor including solenoid 1 Broken Light Bulb 2 Faulty light wiring 3 Faulty Engine Control Uni...

Page 29: ...ly It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 30: ...ly It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 31: ... N S L 4 5 5 C O N T R O L P A N E L N C D I M E N S I O N T O T O P O F E X H A U S T E L B O W O R R A I N C A P 1 8 5 0 2 0 6 2 4 0 9 4 2 4 0 0 3 7 1 2 F F G B H D 2 3 0 0 C 4 0 0 4 0 0 N A N B J K A A L N C C 56 SKID O MOUNTING HOLE O 56 SKID MOUNTING HOLE NOTES OIL AND WATER IN ENGINE BUT NO FUEL N A CENTER OF GRAVITY WITH O N B 56 TRAILER MOUNTING HOLES S10766 C PART NO WELDER A B C D F G H ...

Page 32: ...NOTES CLASSIC 300D PERKINS ...

Page 33: ...NOTES CLASSIC 300D PERKINS ...

Page 34: ...parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa moja da l Aislese del trabajo y de la tierra l Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension l Isolez vous du travail et de la terre l Berühren Sie keine stromführenden Teile oder Elektroden mit ...

Page 35: ... und Entlüftung des Arbeitsplatzes l Mantenha seu rosto da fumaça l Use ventilação e exhaustão para remover fumo da zona respiratória l Turn power off before servicing l Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio l Débranchez le courant avant l entre tien l Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten l Não o...

Page 36: ...s 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 World s Leader in Welding and Cutting Products ...