Lincoln Electric IM10171 User Manual

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WIRE FEED MODULE

For use with machines having Code Numbers:

12207

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Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10171 | Issue D ate Oct- 13

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THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIA L SI TUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

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 is received.

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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you

act and be careful.

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Material Safety

Data Sheet (MSDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your

face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

DO NOT WELD OR CUT containers or materials which previously had

been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release highly toxic fumes or gases.

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit. REMOVE all potential fire hazards from welding area. ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

SECTION A:

Diesel Engines

Gasoline Engines

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER 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 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.

SAFETY

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is

hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

FOR ENGINE POWERED EQUIPMENT.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

SAFETY

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.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage

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.

between the

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes

and gases away from the breathing zone. When welding

with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

3.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

cause

SAFETY

WELDING AND CUTTING 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

parks and hot materials from welding can easily go through

s small cracks and openings to adjacent areas. 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 touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER MAY EXPLODE IF DAMAGED.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety Interactive Web Guide for mobile devices

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour

votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode sʼapplicuent aussi au pistolet de soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soud la masse. Un court-circuit accidental peut provoquer un échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible de la zone de travail quʼil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dʼautres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques dʼincendie ou dʼechauffement des chaines et des câbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

e pas, poser la pince à une endroit isolé de

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de nʼimporte quelle partie du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de soudage. Se protéger avec des vêtements de protection libres de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons 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 lʼon pique le laitier.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de lʼélectricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

TABLE OF CONTENTS

Page

PRODUCT DESCRIPTION ..................................................................................................................................8

INSTALLATION.................................................................................................................................................................Section A

Specifications................................................................................................................................................A-1

Safety Precautions......................................................................................................................

Machine Grounding ............................................................................................

Assembly into Engine Driven Welders.........................................

Assemble WFM into

CLASSIC

300HE and SAE-300

Welders ................................

................................................................A-2

.........................................A-1

...................................A-3 thru A-7

Connection of Lincoln Electric Wire Feeders................................................................................................A-8

................A-1

OPERATION

...................................................................................................................................................................Section B

Design Features ...........................................................................................................................................B-1

Recommended Wire Feeders and Accessories ...........................................................................................B-1

Additional Safety Precautions.......................................................................................................................B-1

Wire Feed Module Operation...

MAINTENANCE............................................................................................................................................Sectio

.....................................................................................................................B-1

n D

Engine Speed Adjustments ..........................................................................................................................D-1

TROUBLESHOOTING...............................................................................................

...................................Section E

How to use Troubleshooting Guide ..............................................................................................................E-1

Troubleshooting ........................................................................................................................................E-2, E-3

PC Board Troubleshooting.....................................................................................................................E-4 thru E-6

DIAGRAMS

Wiring

Diagram .............................................................................................................................................F-1

Connection Diagram .....................................................................................................................................F-2

PARTS LIST .................................................................................................................................. .............P-751 Series

WIRE FEED MODULE™

GENERAL DESCRIPTION

The Wire Feed Module (WFM) is an additional output control device designed to be easily installed into the Classic the dynamic output characteristics of the welder to provide excellent voltage control for semiautomatic wire electrode welding and other open arc processes. With the module installed, the welder can be easily set to operate in either the constant voltage or the standard constant current modes. The constant voltage mode is adjusted with the controls conveniently mounted on the control panel or with an optional remote control. The main module contains a capacitor bank, electronic control circuit and a “COLD TIP” contactor. This module easily attaches to the welders fuel tank support. Field installation takes approximately 60 minutes.

300HE and SAE 300HE. The WFM modifies

PRODUCT DESCRIPTION

TECHNICAL SPECIFICATIONS

Model

K3964-1 Wire Feed Module

to be Field Installed

RATED OUTPUT

Factory-Installed Wire

Feed Module & Welder Per:

Rating @ 60%

Duty Cycle

Max. Output @

35% Duty Cycle

INSTALLATIONWIRE FEED MODULE™

Auxiliary Power

Classic®300HE

SAE-300®HE

K3198-1 K3201-1 K3202-1

Not Available

K3201-2

Not Available

SAFETY PRECAUTIONS

Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists.

Have a qualified technician do the maintenance and troubleshooting work. Turn engine off before working inside the machine. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring removal is complete. Always use the greatest care when working near moving parts.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust outside.

300 Amps

@ 35V

325 Amps

@ 34V

Auxiliary Power

is Reduced 25%

in the CV Mode

MACHINE GROUNDING

Because a portable engine driven welder or generator creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (your home, shop, etc.)

To prevent dangerous electric shock, other equipment to which an engine driven welder supplies power must:

1. Be grounded to the frame of the welder using a grounded type plug,

2. Be double insulated.

When a welder is mounted on a truck or trailer, its frame must be securely connected to the metal frame of the vehicle.

Where an engine driven welder is connected to premises wiring such as that in your home or shop, its frame must be connected for the system earth ground. See further connection instructions in the section entitled “Standby Power Connections” as well as the article on grounding in the latest U.S. National Electrical Code and the local code.

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

Only qualified personnel should install, use, or service this equipment.

------------------------------------------------------------------

In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least 10 feet and having no insulated joints or to the metal framework of a building which has been effectively grounded. The U.S. National Electrical Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the Generator Mount of the welder.

A-1

ASSEMBLE INTO ENGINE DRIVEN WELDERS:

INSTALLATIONWIRE FEED MODULE™

CLASSIC®300HE SAE-300®HE

K3198-1 K3201-1, K3202-1

Pre Installation

Unpack WFM and check the contents against the listed items.

ITEM DESCRIPTION QTY.

1 Control Module Assembly 1 2 Panel Components and Harness Assembly 1 3 Mounting Hardware Packet 1 4 Instruction Manual and Literature 1

5 Classic 6 SAE-300

300HE Nameplate 1

HE Nameplate 1

Tools Required

• Large and Small Flat Head Screwdriver

• Pliers

• 3/32” Allen Wrench

• 3/8” Drive Ratchet with Small Extension

• 1/2” Socket

• 9/16” Deep Well Socket

• 3/4” Socket

• 5/16” Nut Driver and Socket

• 1/2” Open End Wrench

• 9/16” Open End Wrench

• Voltmeter

A-2

INSTALLATIONWIRE FEED MODULE™

ASSEMBLE WFM INTO THE

300

WELDERS:

CLASSIC® 300HE AND SAE-

INSTALLATION SEQUENCE: CLASSIC® 300HE (See Exploded View the following Page)

1. Remove the bottom 5 fastener buttons from the upper control nameplate. Keep the fastener buttons for later use to fasten the WFM nameplate. Once, the fastener buttons have been removed snap / break off the lower section of the nameplate (the section with the welder name on it).

2. SNAP / BREAK OFF

1. REMOVE 5 FASTENER BUTTONS

IN THIS AREA

INSTALLATION SEQUENCE: SAE-300®HE (See Exploded View the following Page)

1. Remove the bottom 3 mounting screws from the upper control nameplate. Keep the screws for later use to fasten the WFM nameplate. Once, the screws have been removed snap / break off the lower section of the nameplate (the section with the welder name on it).

2. SNAP / BREAK OFF IN THIS AREA

1. REMOVE 3 MOUNTING SCREWS

2. Attach the WFM nameplate to the upper control panel on the welder below the original nameplate with 5 mounting screws.

2. Attach the WFM nameplate to the upper control panel on the

welder below the original nameplate with 5 fastener buttons.

REPLACE 5 FASTENER BUTTONS

3. Install the following Items into the welder control panel:

• Item 1 Amphenol receptacle and cap.

• Item 2 Potentiometer, Seal, Spacer and secure the knob.

• Item 3 Local/remote toggle switch (keep all wires connected to it mounting tab down).

• Item 4 CV/CC toggle switch (keep all wires connected to it mounting tab down).

Item 1

Item 2

Item 3

Item 4

REPLACE WITH 5 MOUNTING SCREWS

3. Install the following Items into the welder control panel:

• Item 1 Amphenol receptacle and cap.

• Item 2 Potentiometer, Seal, Spacer and secure the knob.

• Item 3 Local/remote toggle switch (keep all wires connected to it mounting tab down).

• Item 4 CV/CC toggle switch (keep all wires connected to it mounting tab down).

Item 1

Item 2

Item 3

Item 4

A-3

EXPLODED VIEW FOR: CLASSIC® 300HE AND SAE-300®HE

POTENTIOMETER

& SPACER

SWITCH S2

LOCAL / REMOTE

(10 LEADS CONNECTED)

INSTALLATIONWIRE FEED MODULE™

BOTTOM POSITION.

AMPHENOL RECEPTACLE

MOUNT WITH KEY LOCATED IN THE

SWITCH S1

WIRE (CV) / STICK (CC)

(6 LEADS CONNECTED)

USE THIS SCREW TO FASTEN CAP

TO CONTROL PANEL.

AMPHENOL CAP

* CONTROL PANEL NOT SHOWN

PLACE SWITCHES IN CONTROL PANEL WITH

LOCKING KEY WASHER.

NAMEPLATE

A-4

POTENTIOMETER,

SHAFT SEAL & CONTROL KNOB.

CENTER SHAFT SEAL AND SPACER

UNDER KNOB AND W ITH PRESSURE

ON THE KNOB AGAINST THE FELT

WASHER, TIGHTEN THE KNOB

SET SCREW.

INSTALLATIONWIRE FEED MODULE™

4. Remove 2 screws from brush wraparound cover. Loosen and rotate the wraparound cover until negative brushholder is exposed. (Large flat head screwdriver and pliers).

5. The negative brushholder is in the 11:00 O’clock position looking at the control panel end of the generator. Remove negative brushholder 5/16” bolt. (1/2” Socket, ratchet, and small extension.)

7. Feed power cable assembly through the rectangular window on the bottom of the generator.

8. Connect power cable/thermostat assembly and the existing cables to the negative brushholder using the .75” long 5/16” hex head cap screw, (provided in the mounting hardware packet). Make certain the thermostat assembly does not touch the brushholder spring and the cable is clear of any moving parts. Make certain the thermostat is assembled under the cable connections. (1/2” socket, ratchet, small extension).

6. Position Wire Feed Module control box next to the right side of the machine (as shown).

9. Reposition the brush wraparound cover and tighten with the hardware removed in step 5. Keep the tightening flanges below the 3:00 O’clock position. (Large flat head screwdriver and pliers.)

A-5

INSTALLATIONWIRE FEED MODULE™

10. Locate and remove 12-pin jumper plug and install 12-pin connector from control box to 12-pin connector. Connect control box 6-pin connector to control panel 6-pin connector. Connect control box 9-pin connector to control panel 9-pin connector.

11. Remove two (2) fuel tank hold down bolts on the right side of

the machine and save hardware.

13. Mount the control box using .62 spacers, flat washers, lock washers and hex nuts provided in the mounting hardware packet. Tighten all fuel tank bolts to rail.

14. Shows the control box bolted in with the fuel tank.,

12. Position control box into place. Four plastic fuel tank mounting bolts require loosening to slide the tank towards the engine. The control box must be maneuvered out, up and back to clear the door latch catch.

15. Remove the positive output terminal bolt. (3/4” Socket wrench).

A-6

INSTALLATIONWIRE FEED MODULE™

16.a. Using the bolt from step 15, connect WFM control box's positive power cable and machine's positive output cable to machine's positive output terminal.

16.b.1. For

CLASSIC® 300HE

negative cable to the selector switch at the top center tap using the cable extension, 1/2-13X.75 bolt and 1/213 nut. Wrap the bolted connection with electrical tape to insulate (minimum 3 layers of tape).

, connect the WFM control box's

17. Remove the guard from the left side of the welder. Using two screws from the mounting hardware package, fasten the output terminal (also from the mounting hardware package) to the guard. Connect the WFM control box's remaining cable (2 AWG Cable) to machine's new CV output terminal. Reinstall the guard.

18. With the CC/CV switch set to CC, start the engine and check the open circuit voltage on the output terminals. The voltage should be 80 to 100 volts with the fine current control set at maximum. NOTE: OCV may be slightly higher when the unit is cold. (Voltmeter)

16.b.2 For tive cable to reactor at the lower tab. Do not use the cable extension.

SAE-300®HE

, connect the WFM control box's nega-

19. Switch the CC/CV switch to CV and check the voltage between the Positive output terminal and the CV output terminal. The voltage should be 45 to 55 volts at maximum output position and 7 to 12 volts at minimum output position. (Voltmeter)

A-7

INSTALLATIONWIRE FEED MODULE™

(

)

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

WARNING

Shut off welder before making any electrical connections.

------------------------------------------------------------------

CONNECTION OF LN-25 TO THE WIRE FEED MODULE

The LN-25 with internal “COLD TIP” contactor requires the K2614-6 Control Cable for voltage control at the feeder.

The LN-25 with internal “Cold Tip” Contactor can be operated without a control cable (Volt sensing mode) if voltage control at the wire feeder is not desired.

See the appropriated connection diagrams in the Diagrams section.

a) Shut off the welder.

b) Connect the electrode cable from the LN-25 to the positive stud of

the welder. Connect the work cable to the CV negative stud of the welder. (NOTE polarity.)

: reverse the connections for negative electrode

CONNECTION OF THE LN-7, LN-7 GMA TO THE WIRE FEED MODULE

Requires K584-(L) input cable, K864 adapter and optionally the K857 for remote control. See the connection diagram in the Diagrams section.

a) Shut the welder off.

b) Connect the electrode cable from the LN-7 to the positive stud

of the welder. Connect the work cable to the CV negative stud of the welder. electrode polarity.

c) Connect the LN-7 per the instructions on the appropriate con-

nection diagram.

d) Set the “Current Range” switch to the “190-120” position for

most common processes, this may be changed if a different arc characteristic is desired.

e) Set the “LOCAL/REMOTE” control toggle switch to “REMOTE”.

f) Set the “IDLER” switch to the “AUTO” position. The “HIGH”

position may be required when used with some low current processes.

NOTE: Reverse the connections for negative

c) For LN-25’s with internal contactor, connect the K2614-6 remote

voltage control cable from the LN-25 to the14-pin receptacle on the control panel.

d) Attach the single lead from the front of the LN-25 to the work

using the spring clip on the end of the lead. This is a control lead to supply current to the wire feeder motor; it does not carry welding current. Set the polarity switch on the LN-25 to the proper polarity.

e) Set the “Current Range Selector” switch to the “190-120” position

for most common processes, this may be changed if a different arc characteristic is preferred.

f) Set the “LOCAL/REMOTE” Control switch to the “REMOTE” posi-

tion. If operating an LN-25 with internal “Cold Tip” Contactor but without the K2614-6 Remote Voltage Control Cable set the “Local/Remote” Control Switch to the “Local” position.

g) Set the “IDLER” switch to the “HIGH” position. The “AUTO” posi-

tion may be used with some high current processes.

CONNECTION OF THE LN-23P TO THE WIRE FEED MODULE

Requires the K350-1 adapter kit. Adapter kit provides an isolated trigger voltage and allows connection of two wire feeders. See connection diagram in the Diagrams section.

a) Shut the welder off.

b) Connect the electrode cable from the LN-23P to the CV nega-

tive output stud of the engine welder. Connect the work cable to the positive output stud.

c) Mount K350-1 adapter per instructions included with adapter.

d) Connect LN-23P per instructions on appropriate connection

diagram.

e) Connect control lead marked “21” to work connection. Refer

to connection diagram in Diagrams section for routing instructions and wire size.

f) Set the “Current Range Selector” switch to the “190-120”

(middle position) for most common processes, this may be changed if a different arc characteristic is preferred.

g) Set the “LOCAL/REMOTE” control toggle switch to “REMOTE”.

h) Set the idler switch to the “AUTO” position. The “HIGH” posi-

tion may be required when welding with low current processes.

A-8

WIRE FEED MODULE™

OPERATION

DESIGN FEATURES

• Easy access to the controls located on the welder control panel.

• Greatly enhanced welding arc performance. Now a wider range of wire electrodes and processes are supported by this device.

• Improved arc starting characteristics.

• Low spatter MIG welding with CO

Gas.

• Built into the WFM is a power contactor that provides a “COLD” electrode when the gun trigger is released.

• Simplified field installation process. All control wiring connections between the welder, the control panel, and the WFM are easily made with in-line plug type connections.

• Includes thermostatic protection to protect the welder from over current and over temperature.

RECOMMENDED WIRE FEEDERS AND ACCESSORIES

The WFM is designed to work with the complete family of LN-7, LN-25, and LN-23P wire feeders.

When the WFM is in the “CV” mode, the maximum auxiliary power will be reduced by 25%. To obtain maximum auxiliary output, place the CC/CV switch in the CC position.

If the current rating of the welder is exceeded, a thermostat will reduce the output voltage to approximately 5 volts. The thermostat will reset automatically as the machine cools. If the thermo-

stat trips, lower the wire feed speed and output voltage or reduce Duty Cycle.

CONTROLS

The output voltage is set with the voltage control dial mounted on the control panel. Set the “Current Range Selector" to the “190120” position for optimum welding characteristics. Changing the "Current Range Selector” affects arc characteristics. Setting the “Current Range Selector” one position to the right of the "190120” position will give a softer arc. If this switch is placed one position to the left from the "190-120” set point, the machine will produce a crisp arc characteristic. The setting of the “Fine Current Adjustment" has no effect on the operation in “CV” mode.

For Coarse Current Control on the SAE-300 see operator manual.

RECOMMENDED PROCESSES

Please refer to the connection diagram in the back of this manual for details.

ADDITIONAL SAFETY PRECAUTIONS

WARNING

The output terminals are energized when the engine is running. The CV output will be de-energized only if WFM mode switch is in remote position.

-------------------------------------------------------------------------

WIRE FEED MODULE OPERATION

OUTPUT

For constant voltage welding, place the CC/CV mode switch in the CV position. Connect the wire feeder to the CV negative output terminal and connect the work to the positive standard output terminal. For electrode positive, reverse the output leads. The negative standard output terminal is not used for CV welding of either polarity. Refer to diagrams section to determine the correct connection to the remote control receptacle.

Refer to latest Lincoln Bulletins on (Gas Metal Arc Welding) and (Innershield Welding) with the following electrodes:

.030” Super Arc L-50, 56 with C-25 or CO .035” Super Arc L-50, 56 with C-25 or CO .045” Super Arc L-50, 56 with C-25 or CO

Gas

.068” NR-203MP 5/64” NR-203MP 5/64” NR-207 5/64” NR-203Nil%

B-1

WIRE FEED MODULE™

ENGINE SPEED ADJUSTMENTS

CAUTION

Any increase in the engine RPM by changing the governor setting or overriding the throttle linkage will cause an increase in the A.C. auxiliary voltage. If this voltage goes above 140 volts, the control circuits of the WFM and wire feeders will be damaged. The engine governor setting is preset at the factory -- do not adjust above RPM specifications listed in the engine welder operating manual.

------------------------------------------------------------------

MAINTENANCE

D-1

WIRE FEED MODULE™

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by 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.

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. 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 OF

ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Authorized Field Service Facility.

TROUBLESHOOTING CHART

WARNING

Have qualified personnel do the maintenance and troubleshooting work. Turn the engine off before beginning to troubleshoot.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

E-1

WIRE FEED MODULE™

PROBLEMS

(SYMPTOMS)

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

TROUBLESHOOTING

Machine has no output with machine switch in CV mode.

Machine has minimum output and no control.

1. Electrode or work lead loose or broken.

2. No generator output.

3. CR4 is not working, or no input to CR4.

4. Protective circuits operating due to output short circuit.

5. Broken or loose wiring connections.

6. Defective P.C. Board

1. No shunt field voltage.

1. Repair Connection.

2. Refer to quick check procedure for generator only.

3. Refer to procedure for Checking the Cold Tip Contactor (CR4).

4. Turn engine off. Remove short circuit.

5. Broken or loose connections from WFM to control panel and engine welder. Refer to wiring diagram to check.

6. Refer to P.C. Board Troubleshooting Procedure.

1. In CV mode, check for 10-60 VDC across pin 8 of J3 and pin 1 of J4 on WFM P.C. Board.

-- Check for loose or broken con-

nections in wiring harness.

-- Refer to P.C. Board Troubleshooting

Procedure.

2. Excessive current, thermal shutdown.

3. Open in feedback circuitry.

4. Voltage adjust potentiometer circuit open or misconnected.

5. Defective P.C. Board.

2. Remove load and allow machine to cool down. If output returns after cool down, reduce output or duty cycle.

-- Check for continuity at quick con-

nects between leads 609 and 608 inside the WFM.

-- Check wiring harness with these

connections.

-- Check continuity of the thermostat

located on the generator negative brushholder.

3. Check in-line connector, P.C. Board, and wiring harness plugs, especially leads 667 and 621.

4. Refer to procedure for checking Voltage Control Potentiometer on Machine. Check wiring of lead numbers 75, 76, and 77.

5. Refer to P.C. Board Troubleshooting Procedure.

CAUTION

E-2

WARNI NG:

WIRE FEED MODULE™

PROBLEMS

(SYMPTOMS)

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

TROUBLESHOOTING

Machine does not have maximum output.

Poor welding characteristics. Poor arc striking with sticking or “blast-offs”,weld porosity, narrow and ropey looking bead, or electrode stubbing into the plate.

1. Voltage adjust potentiometer leads open.

2. Voltage adjust potentiometer defective.

3. Faulty P.C. Board.

1. Poor work or electrode connection.

2. Improper settings for wire feed speed and volts.

3. Capacitor Bank Contactor not working.

4. Capacitors in power source output circuit failed. A failure is indicated if the small vent plug on the top of a capacitor is raised or blown out.

1. Check and repair broken leads.

2. Refer to procedure for checking Voltage Control Potentiometer on Machine.

3. Refer to Procedure for Replacing P.C. Boards.

1. Check and clean all connections.

2. Refer to a welding procedures guide for proper settings.

3. Refer to the procedure for Checking the Capacitor Bank Contactor CR3.

4. Replace entire bank of capacitors, observe correct polarity. Do not replace individual capacitors.

these capacitors is toxic. Avoid contact with any portion of your body. Clean up vented electrolyte using rubber gloves and a water dampened cloth. Any electrolyte which gets on skin, clean with soap and water.

The liquid electrolyte in

5. Opening in feedback circuit.

6. Faulty P.C. Board.

5. Check wiring and P.C. Board wiring harness plugs. Pay special attention to leads 667 and 621.

6. Refer to procedure for replacing P.C. Board.

CAUTION

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.

E-3

WIRE FEED MODULE™

PC BOARD TROUBLESHOOTING GUIDE CONTROL P.C. BOARD

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

1. P.C. Board Troubleshooting Procedures

Perform the following checks before replacing the P.C. Board.

1. Remove the cover to the Wire Feed Module box located on the right side of the machine. With the engine running the green and red LED on the P.C. Board must be glowing. If not, check the following:

a) Check for loose connections in the P.C. Board plugs,

pay close attention to J3.

b) With machine running at high idle, check the follow-

ing voltages accessible at P.C. Board plug J3:

Lead Number

610 - 600 120 + 13/-10 Volts DC

If these voltages are not present, check the wiring connections between the engine welder and the Wire Feed Module. If wiring is good, then refer to the “Quick Check Procedure for Generator Only”. If generator is operating properly, refer to “Procedure for Replacing P.C. Boards”.

2. Procedures for Replacing P.C. Boards

Before replacing a P.C. Board which is suspected of being defective, visually inspect the P.C. Board in question for any electrical or mechanical damage to any of its components and conductors on the back of the board.

1. If there is no new one and see if this remedies the problem. If the problem is remedied, reinstall the old if the problem still exists. If it does no longer exist the old P.C. Board:

a) Check the P.C. Board harness connector pins for

corrosion, contamination, or looseness.

b) Check leads in the plug harness for loose or inter-

mittent connection.

2. If P.C. Board is visibly damaged electrically possibly subjecting the new P.C. Board to the same cause of failure, check for possible shorts, opens, or grounds caused by:

visible damage to the P.C. Board, install a

Voltage

P.C. Board to see

with

, before

a) Frayed or pinched lead insulation.

b) Poor lead termination, such as a poor contact or a

short to adjacent connection or surface.

c) Shorted or open leads, or other external leads.

d) Foreign matter or interference behind the P.C.

Boards.

3. If P.C. Board is visibly damaged mechanically, inspect for cause then remedy before installing a replacement P.C. Board.

If there is damage to the P.C. Board or if replacing P.C. Board corrects problem, return it to the local Lincoln Electric Field Service Shop.

3. Output Voltage

Constant Voltage Mode -- The open circuit voltage in CV mode is 7-55 volts DC. If any other conditions exist, refer to the Troubleshooting Chart.

4. Procedure for Checking the Cold Tip Contactor (CR4)

1. If there is no output during the initial start up of the

machine, check to see if the “Local/Remote” switch is in “LOCAL”, if so, switch to “REMOTE” and then back to “LOCAL” and check for output voltage. If switch is in “Remote” switch to the “LOCAL” position and check for output voltage.

2. Open side panel of wire feed module. With

machine running, verify the P.C. Board is working by checking to see if the green and red LED’s are on. If LED’s are not on, see P.C. Board Troubleshooting Procedures. If the LED’s are on, check the voltage between the top left stud of the cold tip contactor (CR4) and the positive output stud. The voltage should measure between 7 and 55 volts DC depending on the position of the CV voltage control setting. Try adjusting the voltage control to see if this voltage changes. If voltage is present, go to step 3. If no voltage is present, check for loose cable or wiring connections. If voltage is still not present, refer to Troubleshooting Chart.

CAUTION

E-4

WIRE FEED MODULE™

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

3. Check to see that leads 2 and 4 are connected. Put a voltmeter across these leads and the meter should read close to zero volts. If voltage reads approximately 15 volts, then the trigger circuit (leads 2-4) is open. Check the wiring from the WFM control box to the WFM control panel for loose or broken connections. Turn machine off and check the operation of the “LOCAL/REMOTE” switch by connecting an ohmmeter across leads 2 and 4 at the switch with switch positioned in “LOCAL” mode, if resistance is high or open replace the switch.

4. Check for coil voltage across leads 633 and 634 at P2 plug to the P.C. Board. If voltage is present, check for loose or broken leads from the plug to the contactor coil. If connections are good and voltage correct, replace contactor CR4.

5. If no voltage is present at CR4 contactor coil, see Procedure for Replacing P.C. Boards.

5. Procedure for Checking the Capacitor Bank Contactor (CR3)

1. Verify machine is in CV (wire) mode. Measure voltage across leads 630 and 631 at the contactor. The voltage should be approximately 120 +/- 15V DC with engine set on high idle. If voltage is not present, go to step 3 of this procedure.

4. With an ohmmeter on X1K, connect it to lead 76A and 77A on S2. Rotate the voltage control potentiometer. The resistance reading should be from approximately zero to 10K ohms. Check the resistance reading between lead 75 on potentiometer and 77A on switch S2. The reading must be 10K ohms. No reading will indicate an open potentiometer and a low reading will indicate a shorted or partially shorted potentiometer; in either case, replace. Reconnect P.C. Board plug P2.

7. Remote Control Check

1. The remote control connector pin assignments are: pin G-75A, pin F-76B, pin E-77B. Make sure remote control connections are tight and check for any physical damage to the control cable. Connect an ohmmeter across lead 75 and 76B on switch S2. With S2 in remote mode, rotate the potentiometer in the remote control. The resistance reading should vary from zero to 10K ohms. Repeat with ohmmeter across 77B and 76B with the same results. Connect an ohmmeter across 75 and 77B. The reading should be 10K ohms. If an open or short is measured replace the potentiometer.

2. If the proper voltage is present at leads 630 - 631, measure the voltage between L2 terminal and terminal opposite L2. If the voltage is equal to the output voltage across the positive and negative output terminals, replace the contactor CR3.

3. If the proper voltage is not present at leads 630 631, check the wiring to CR3 coil for loose or broken connections. If connections are good, see Procedure for Replacing P.C. Boards.

6. Checking Voltage Control Potentiometer on Machine

1. Turn machine off.

2. Remove the control panel screws and open the front cover. Turn the “LOCAL/REMOTE” switch (S2) to “REMOTE”.

3. Disconnect P.C. Board harness plug P2 from the P.C. Board.

CAUTION

E-5

WIRE FEED MODULE™

Observe all Safety Guidelines detailed throughout this manual

8. Quick Check Procedure for Generator Only

1. Try running the machine with the mode switch on STICK (CC mode), and check output at CC+ and CC- studs. If a voltage of 45 to 100 volts DC is measured, the generator is working properly. If the generator is working properly, the problem exists in the Wire Feed Module. Refer to Troubleshooting chart.

2. If there is no generator output in step 1, proceed with the following:

a) If jumper plug P10 is available, a quick check

can be performed to see if the generator is operating properly. Disconnect P5 and connect P10. When P10 is connected, the machine will only run in Stick (CC mode). If generator voltage is present between CC+ and CC- studs, then the generator is operating properly.

b) The measured voltage should be between 43-

100 volts DC. This level may be higher when the machine is cold. If the generator is operating properly, disconnect P10 and reconnect P5. Refer to Wire Feed Module Troubleshooting chart.

TROUBLESHOOTING

3. If the generator is not working with the jumper plug P10, then refer to the engine welder Troubleshooting chart.

CAUTION

E-6

WIRE FEED MODULE™

DIAGRAMS

F-1

NOTE: This diagram is for reference only. 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 pan-

els. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

WIRE FEED MODULE™

WIRE FEED

DIAGRAMS

A.02

M17220-1

MODULE

WIRE FEED MODULE / ENGINE WELDER CONNECTION DIAGRAM

ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".

INLINE CONNECTORS

#8 LEAD

PLUG P5

#2 HEAVY LEAD

609

CONNECT "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.

CONNECT AS PER NOTE N.A.

608

NEGATIVE CV

OUTPUT TERMINAL

PANEL

CONNECT TO NEG.

250 AMP THERMOSTAT ASSEMBLY

BRUSH HOLDER

POS.

NEG.

W.F.M.

CONTROL

PANEL

F-2

CONNECT TO POS. OUTPUT TERMINAL

FOR CLASSIC 300 HE, CONNECT (ADD) TO UPPER SELECTOR

N.A. FOR SAE-300 HE, CONNECT (ADD) TO LOWER REACTOR LEAD.

SWITCH STUD (USING 8" EXTENSION LEAD).

PARTS LIST FOR

WIRE FEED MODULE

P-751P-751

This parts list is provided as an informative guide only.

It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electricʼs ofﬁcial Parts Book (BK-34).

When ordering parts, always refer to Lincoln Electricʼs ofﬁcial Parts Book (BK-34) for the latest pages.

WIRE FEED MODULE

P-751-AP-751-A

Wire Feed Module

For Code: 12207

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed.

se the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and

U column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

SUB ASSEMBL Y

PAGE NAME

Miscellaneous Items

PAGE NO.

CODE NO.

12207 1 1 1

P-751-B.1

Control Box Assembly

P-751-C

Control Panel Assembly

P-751-D

WIRE FEED MODULE

Jan-2014

P-751-B.1

MISCELLANEOUS ITEMS

(THESE ITEMS ARE NOT ILLUSTRATED)

P-751-B.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

DESCRIPTION PART NO. QTY. 123456789

Output Cable Assembly S20927 1 X Main Harness, Includes: L9261 1 X

Box Connector T9639-3 1 X Housing Plug

(P5)

S14157-11 1 X Housing Plug (P6) S14157-12 1 X Housing Plug (J7) S14156-10 1 X Plug Housing S18249-10 1 X Plug Housing S18249-8 1 X Plug Housing S18249-6 1 X

Spacer S10731-28 2 X Output Stud Kit T14166-9 1 X Self Tapping Screw S8025-65 2 X Output Stud Nut T3960 1 X 1/2 - 13 x .75 HHC5 CF000020 1 X

WIRE FEED MODULE

Jan-2014

Control Box Assembly

{

11A

11B

P-751-CP-751-C

11B

11A

{

WIRE FEED MODULE

Jan-2014

P-751-C.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Welded Frame Assembly NSS 1X 2A P.C. Board Assembly G2563-[ ] 1 X 2B Plastic Expansion Nut (Not Shown) S14020-3 4 X 2C Thread Forming Screw S8025-97 4 X 3A Front Cover S20879 1 X 3B Thread Forming Screw S9225-51 7 X 3C Door Bumper T14882-1 6 X 4A Contactor (CR3) M12161-33 1 X 4B #10-24 x 50 RHS CF000047 3 X 4C Lock Washer T9695-1 3 X 4D #10-24 HN CF000010 3 X 5A Contactor Assembly (CR4) M17198 1 X 5B Contactor Mounting Bracket S20650 1 X 5C #10-32 x .25 RHS CF000325 4 X 5D Lock Washer T9695-1 4 X 5E Self Tapping Screw S8025-91 4 X

Shunt & Lead Assembly, Includes: S19588-1 1 X 6A Uncalibrated Shunt NSS 1X 6B Plug & Lead Assembly, (Not Shown) NSS 1X 6C Sems Screw T10082-4 2 X 6D #10-24 HN CF000010 2 X 6E 3/8-16 x .75 HHCS CF000034 1 X 6F Plain Washer S9262-4 1 X 6G Lock Washer E106A-16 1 X 6H 3/8-16 HJN CF000121 1 X 7A Resistor S10404-129 1 X 7B Resistor Mounting Bracket Set T15137-2 1 X 7C #8-32 x .50 RHS CF000033 2 X 7D Plain Washer (Not Shown) S9262-3 2 X 7E Lock Washer T4291-A 2 X 7F #8-32 HN CF000042 2 X

Capacitor Bank Assembly, Includes: M17233 1 X 8A Capacitor S13409-105 3 X 8B Capacitor Buss S18292-2 2 X 8C Plain Washer S9262-23 6 X 8D Lock Washer E106A-2 6 X 8E 1/4-28 x .50 HHCS (Part of 8A) NSS 1X

Capacitor Strap Assembly, Includes: S20930 1 X 8F Capacitor Strap NSS 1X 8H Capacitor Insulation S20947 1 X 8J Self Tapping Screw S8025-91 2 X 9A Protection Insulation S21199 1 X 9B Self Tapping Screw S8025-70 6 X 9C Plain Washer S9262-27 1 X 10 Power Cable Assembly S20878 1 X 1 1A Thermostat Assembly T14829-3 1 X 11B 5/16-18 x .75 HHCS CF000040 1 X 11C Plain Washer (Not Shown) S9262-121 1 X 11D Lock Washer (Not Shown) E106A-14 1 X 11E 5/16-18 HN (Not Shown) CF000029 1 X 12 Insulation S24067 1 X

NSS - Not Sold Separately

WIRE FEED MODULE

Jan-2014

P-751-C.2P-751-C.2

# Indicates a change this printing.

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters. The dash number brackets [ ] have purposely been left blank so as to eliminate errors, confusion and updates.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

WIRE FEED MODULE

Jan-2014

NOTES

WIRE FEED MODULE

Control Panel Assembly

10A

P-751-DP-751-D

10A

WIRE FEED MODULE

Jan-2014

P-751-D.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Nameplate (Classic 300 HE) M24602 1 X 1B Nameplate (SAE 300 HE) M24693 1 X 2 Control Panel Wiring Harness, Includes: L9246-1 1 X 2A Potentiometer T10812-119 1 X 2B Connector S12021-70 1 X 2C Switch (S1 & S2) T10800-14 2 X 3A Rheostat Control Knob T10491 1 X 3C Potentiometer Spacer S18280 1 X 4 Self Tapping Screw S8025-96 4 X 6 Cap-Cable Connector S17062-11 1 X 8 Shaft Seal T14034 1 X 9 Spacer T7028-241 1 X 10A Fastener Button T14659-2 5 X 10B Self Tapping Screw S8025-92 5 X

WIRE FEED MODULE

Jan-2014

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

Lincoln Electric IM10171 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual