Lincoln Electric IM513 User Manual

Page 1

WIRE FEED MODULE

RETURN TO MAIN MENU

For Wire Feed Module Code Number: 10066, 10914, 11806

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.

™

IM 513-B

February, 2011

OPERATORʼS MANUAL

• 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

Page 2

SAFETY

WARNING

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 Above For Diesel Engines

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.

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

The Above For Gasoline Engines

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.

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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.

____________________________________________________

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.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

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.

___________________________________________________

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.

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.

Mar ʻ95

Page 3

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 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.

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 coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating products.

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

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

vapors

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.

Jan ‘09

Page 4

iii

SAFETY

iii

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

Remember that welding sparks and hot materials from welding can easily go through 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 been “cleaned”. For information, purchase “Recommended Safe Practices for the 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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. 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.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

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.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code 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.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Jan ‘09

Page 5

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 soude pas, poser la pince à une endroit isolé de 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.

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.

Mar. ʻ93

Page 6

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

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.

CUSTOMER ASSISTANCE POLICY

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.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially 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

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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.

Page 7

TABLE OF CONTENTS

PAGE

SPECIFICATIONS .........................................................................................................................................8

GENERAL DESCRIPTION ............................................................................................................................8

DESIGN FEATURES .....................................................................................................................................8

RECOMMENDED WIRE FEEDERS AND ACCESSORIES ..........................................................................8

INSTALLATION INSTRUCTIONS

Safety Precautions...............................................................................................................................9

Machine Grounding..............................................................................................................................9

Assembly into Engine Driven Welders

Classic Series (K6090-5, K1406-3 and -4, K1428-2, K1433-1, K1643-1, K1754-1), K1643-3, K1643-5, K1643-7, K1643-9 Pipeliner Series (K6090-7 and -9), K6090-10, K6090-11 SA-250 (K1283-4 & -8) or 350SA (K1314-4), SAE-300 (K3003-1)

Pre-Installation ........................................................................................................................9

Tools Required........................................................................................................................9

Assemble into Classic Series Pipeliner, SA-250 and 350SA Installation Sequence (Codes 10066, 10914) ...........10 thru 15

Assemble into SAE-300 Installation Sequence (Code11806) ..................................................................................16 thru 18

Connection of Lincoln Electric Wire Feeders ......................................................................................19

Connection of the LN-25 to the Wire Feed Module................................................................19

Connection of the LN-7, LN-7 GMA to the Wire Feed Module...............................................19

Connection of the LN-23P to the Wire Feed Module .............................................................19

..........................................................9

OPERATING INSTRUCTIONS

Additional Safety Precautions .............................................................................................................20

Wire Feed Module Operation..............................................................................................................20

Output ........................................................................................................................................20

Controls ........................................................................................................................................20

Recommended Processes............................................................................................................20

MAINTENANCE

Engine Speed Adjustments.................................................................................................................20

TROUBLESHOOTING

Troubleshooting Chart ..................................................................................................................20 thru 22

Troubleshooting Procedures.........................................................................................................23 thru 25

DIAGRAMS

Wire Feed Module Wiring Diagram.....................................................................................................26

Wire Feed Module / Engine Welder - Connection Diagram ................................................................27

Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250, 350SA & SAE-300 w/WFM to LN-23P w/ Adapter kit Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250, 350SA & SAE-300 w/WFM to K867 Plug to LN-7 Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250, 350SA & SAE-300 w/WFM to K864 Adapter to LN-7 & Remote Control Connection Diagram-All Classic, All Pipeliner, SA-250, 350SA & SAE-300 w/WFM to K867 Universal Adapter Connection Diagram-All Classic, All Pipeliner, SA-250, 350SA & SAE-300 w/WFM to LN-25 w/ K444-2 Option Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250 Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250, 350SA & SAE-300 w/WFM to K867 Plug to K487 / K488 / K492 Spool Gun

350SA & SAE-300 w/WFM to LN-25 w/ K431, K433 & K432-”L” Option .............................

...........28

...............29

..........................

.................31

.................32

....................

33 34

OUTPUT CURVES

Classic I, Pipeliner 200D and 200G with Wire Feed Module Output Curves ......................................35

Classic II with Wire Feed Module Output Curves ...............................................................................36

Classic III and 300G with Wire Feed Module Output Curves..............................................................37

Classic IIID, Classic 300D, SA250 & SAE-300 (Codes 10890 & above) with Wire Feed Module Output Curves

350SA and SA-250 (Codes 10889 and below ) Perkins with Wire Feed Module Output Curves ......39

PARTS LIST..................................................................................................................................P-231 Series

..................38

Page 8

Classic I

Pipeliner 200G Pipeliner 200D

Classic II

SA250

350SA

(International)

Classic III

Classic IIID

Classic 300D

SAE-300

Classic 300G

SPECIFICATIONS

K623-1 Wire Feed

Module to be Field-

Installed

On: (1)

K6090-6

K6090-5 (CSA)

K6090-7

K6090-9,-10,11(CSA)

K1406-4

K1406-3 (CSA)

K1283-4 (CSA) K1283-8 (CSA)

K1314-4 (CSA)

K1428-2 (CSA)

K1433-1 (CSA) K1643-1 (CSA)

K1643-3 (CSA) K1643-5 (CSA) K1643-7 (CSA) K1643-9 (CSA)

K3003-1 (CSA)

K1754-1

Factory-Installed

Wire Feed Module

& Welder Per:

Not Available

K1406-6

K1406-5 (CSA)

K1283-5 (CSA)

Not Available

K1314-5 (CSA)

K1428-3 (CSA)

K1433-2 (CSA) K1643-2 (CSA) K1643-4 (CSA) K1643-6 (CSA) K1643-8 (CSA)

K1643-10 (CSA)

Not Available Not Available

Rating @ 60%

Duty Cycle

200 Amps

@ 35V

250 Amps

@ 35V

300 Amps

@ 35V

250 Amps

@ 35V

300 Amps

@ 35V

Max. Output

@ 35% Duty

Cycle

250 Amps

@ 30V

310 Amps

@ 32V

325 Amps

@ 34V

310 Amps

@ 32V

325 Amps

@ 34V

Auxiliary

Power

Auxiliary Power

is Reduced 25%

in the CV Mode

(1) K623-1 Wire Feed Module can only be installed on welders with code 10061 and above.

GENERAL DESCRIPTION

The Wire Feed Module (WFM) is an additional output control device designed to be easily installed into the Classic the SA-250 Perkins or 350SA Perkins engine driven welders (with code 10061 and above). The WFM modifies 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.

and Pipeliner Series of Engine Welders or

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 CO2Gas.

• 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.

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

– 8 –

Page 9

INSTALLATION INSTRUCTIONS

Safety Precautions

WARNING

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.

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.

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

Machine Grounding

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.

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.

ASSEMBLY INTO ENGINE DRIVEN WELDERS: CLASSIC SERIES

(K6090-5, K1406-3, -4, K1428-2, K1433-1, K1643-1, -3, -5, -7, -9, K1754-1) Pipeliner (K6090-7, -9, -10, -11) and SA-250 (K1283-4, -8) or 350SA (K1314-4). SAE-300 (K3003-1

Pre Installation

Unpack WFM and check the contents against the listed items.

ITEM DESCRIPTION QTY.

1 Control Module Assembly 1 2 Control Panel Assembly 1 3 CV Negative Output Panel Assembly 1 4 Mounting Hardware Packet 1 5 Instruction Manual and Literature 1 6 WFM Nameplate SAE-300

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:

a) Be grounded to the frame of the welder using a

grounded type plug,

b) 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.

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

– 9 –

Page 10

ASSEMBLE INTO PIPELINER, SA-250 and 350SA

CLASSIC SERIES

INSTALLA-

TION SEQUENCE:

(For codes 10066, 10914)

1) Remove current range selector and fine current adjustment control knobs from front of machine. (small flat screwdriver and 3/32” Allen wrench.)

2) Remove 5 upper nameplate screws, or fastener buttons.

3) Break-off upper half of machine nameplate. Nameplate is scored for easy bending and breakoff.

4) Install control panel assembly. (Wiring connections will be made later).

5) Secure control panel assembly with (7) screws from the mounting hardware packet.(5/16” Nut Driver)

6) Reinstall current range selector and fine current adjustment control knobs to front of machine. (Small flat screwdriver and 3/32” Allen wrench).

7) (For Classic II models ONLY panel. (3/8” Socket wrench).

) Remove the side

– 10 –

Page 11

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

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

10) (NOTE

Classic I, you must change the “250H” thermostat to the thermostat marked “200”, (provided in the mounting hardware packet). Make certain the nut and bolt is tightened and the 608 and 609 leads are connected to the thermostat. (1/2” Socket, ratchet, and 1/2” open end.)

11) Position Wire Feed Module control box next to

the right side of the machine (as shown). Place one plain washer (provided in the mounting hardware packet) over each mounting stud.

:) If you are installing the WFM on the

– 11 –

Page 12

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

13) 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).

14) Reposition the brush wraparound cover and tighten with the hardware removed in step 8. Keep the tightening flanges below the 3:00 position. (Large flat head screwdriver and pliers.)

– 12 –

Page 13

15) 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.

For Classic 300D with Codes (11547, 11548, 11572, 11573) and Pipeliner 200D Code 11591. Remove U (BLUE) and 602C wires from flyback bridge. See machine wiring diagram. Keep U and 602C lead terminals connected and insulate with electrical tape.

16) For Classic I, III, IIID, 300D, 300G and SA250 (Codes 10889 and Below), 350 SA, Pipeliner 200D and 200G remove two (2) fuel tank hold down bolts on the right side of the machine and save hardware. (9/16” deep well socket, ratchet, and 9/16” open end wrench.) For the Classic II and SA250 (Codes 10890 and Above), do not remove the fuel tank hold down bolts. On these machines, the WFM mounts to the adjacent holes with two (2) 1” spacers, flat washer, lock washer and hex nuts, (provided in the mounting hardware packet).

17) For the Classic I & III, the carburetor choke cable must be unclamped at the frame. Reclamp at the flange provided on the WFM.

– 13 –

Page 14

18) Position control box into place. On some models, the control box must be maneuvered out, up and back to clear the door latch catch. On Classic II machines, make sure the battery cable is not caught between the wire feed module and generator.

19) Install flat washer, lockwasher, and hex nut to control box mounting studs and tighten. (9/16” Socket, ratchet, and 9/16” open end wrench).

20) Remove both the positive and negative output terminal bolts. (3/4” Socket wrench).

NOTE: On the Classic II machines, the weld output terminals are located on the right side (facing the control panel) of the machine under the side access door. On all other machines the weld output terminals are located on the left side (facing the control panel) of the machine under the left access door.

21) Using bolts from step 20, connect control boxʼs positive and negative power cables and machineʼs positive and negative output cables to the respective output terminals. Tighten bolts. (3/4” Socket wrench).

NOTE: Use caution when routing the CV power cables; ensure that there is adequate clearance from any sharp surfaces.

22) Connect the remaining lead from the control box

to CV output terminal, using bolt supplied with the output terminal assembly. Output panel leg attaches to the front of the machine (3/4” Socket wrench).

– 14 –

Page 15

23) Drive three (3) self-tapping screws into output panel. (5/16” Nut driver or socket wrench). NOTE: The CV outout terminal assembly mounts under the weld output terminals on all machines.

24) 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 thermostat and range switch set at maximum. NOTE: OCV may be slightly higher when the unit is cold. (Voltmeter)

25) 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)

26) (For Classic IIʼs only) Reassemble the side panel. (3/8” Socket wrench)

– 15 –

Page 16

ASSEMBLY INTO SAE-300 WELDER: INSTALLATION SEQUENCE:

(For Code 11806 )

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).

on this dotted line.

2. Snap or Break off lower section

1. Remove 3 mounting screws.

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

1. Remove 3 mounting screws.

2. Snap or Break off lower section on this dotted line.

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

5 mounting screws.

3. Remove the 2 toggle switches, amphenol & cap and the potentiometer with knob from the original control panel assembly. DO NOT disconnect the wiring from the switches.

4. Insert the local / remote toggle switch (most wires connected to it) first into the upper control panel on the welder with the mounting tab down. Next mount the potentiometer and secure the knob. Next mount the cv / cc toggle switch with the mounting tab down. Mount the amphenol and cap.

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

7. Position Wire Feed Module control box next to the right side of the machine (as shown). Place one plain washer (provided in the mounting hardware packet) over each mounting stud.

– 16 –

Page 17

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

9. 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).

11 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.

12. Remove two (2) fuel tank hold down bolts on the right side of the machine and save hardware.

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

13. Position control box into place. On some models, the control box must be maneuvered out, up and back to clear the door latch catch. On SAE-300 4 plastic fuel tank mounting bolts require loosening to slide the tank towards the engine.

– 17 –

Page 18

14. Mount the WFM using .62 spacers, flat washer, lock washer and hex nuts provided in the mounting hardware packet. Tighten all fuel tank bolts to rail.

15. Remove both the positive and negative output ter-

minal bolts. (3/4” Socket wrench).

18. Drive three (3) self-tapping screws into output panel. (5/16” Nut driver or socket wrench). NOTE: The CV outout terminal assembly mounts under the weld output terminals on all machines.

19. 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 thermostat and range switch set at maximum. NOTE the unit is cold. (Voltmeter)

: OCV may be slightly higher when

16. Using bolts from step 15, connect control boxʼs positive and negative power cables and machineʼs positive and negative output cables to the respective output terminals. Tighten bolts. (3/4” Socket wrench). NOTE: Use caution when routing the CV power cables; ensure that there is adequate clearance from any sharp surfaces.

17. Connect the remaining lead from the control box

to CV output terminal, using bolt supplied with the output terminal assembly. Output panel leg attaches to the front of the machine (3/4” Socket wrench).

20. 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)

– 18 –

Page 19

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

Connection of the LN-7, LN-7 GMA to the Wire Feed Module

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 K444-2 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: reverse the connections for negative electrode polarity.)

c) For LN-25ʼs with internal contactor, connect the K444-

2 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” position. If operating an LN-25 with internal “Cold Tip” Contactor but without the K444-2 Remote Voltage Control Cable set the “Local/Remote” Control Switch to the “Local” position.

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.

(NOTE

electrode polarity.)

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

appropriate connection 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.

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 negative 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 connec-

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

: Reverse the connections for negative

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

“AUTO” position may be used with some high current processes.

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” position may be required when welding with low current processes.

– 19 –

Page 20

OPERATING INSTRUCTIONS

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.

Recommended Processes

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 Gas Gas

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.

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

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

MAINTENANCE

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 pre-set at the factory -- do not adjust above RPM specifications listed in the engine welder operating man-

ual.

Controls

The output voltage is set with the voltage control dial mounted on the control panel. Set the “Current Range Selector" to the “190-120” 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 "190-120” position will give a softer arc. If this switch is placed one position to the left from the "190120” 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.

TROUBLESHOOTING CHART

WARNING

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

– 20 –

Page 21

TROUBLESHOOTING

TROUBLE CAUSES WHAT TO DO

1. Machine has no output with machine switch in CV mode.

2. Machine has minimum output and no control.

a. Electrode or work lead loose or

broken.

b. No generator output.

c. CR4 is not working, or no input to

CR4.

d. Protective circuits operating due to

output short circuit.

e. Broken or loose wiring connec-

tions.

f. Defective P.C. Board

a. No shunt field voltage.

a. Repair Connection.

b. Refer to quick check procedure for

generator only.

c. Refer to procedure for Checking the

Cold Tip Contactor (CR4).

d. Turn engine off. Remove short

circuit.

e. Broken or loose connections from

WFM to control panel and engine welder. Refer to wiring diagram to check.

f. Refer to P.C. Board Troubleshooting

Procedure.

a. 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 connections in wiring harness.

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

b. Excessive current, thermal shut-

down.

c. Open in feedback circuitry.

d. Voltage adjust potentiometer circuit

open or misconnected.

e. Defective P.C. Board.

b. Remove load and allow machine to

cool down. If output returns after cool down, reduce output or duty cycle.

-- Check for continuity at quick connects 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.

c. Check in-line connector, P.C. Board,

and wiring harness plugs, especially leads 667 and 621.

d. Refer to procedure for checking

Voltage Control Potentiometer on Machine. Check wiring of lead numbers 75, 76, and 77.

e. Refer to P.C. Board Troubleshooting

Procedure.

– 21 –

Page 22

TROUBLESHOOTING

TROUBLE CAUSES WHAT TO DO

3. Machine does not have maximum output.

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

a. Voltage adjust potentiometer leads

open.

b. Voltage adjust potentiometer

defective.

c. Faulty P.C. Board.

a. Poor work or electrode connection.

b. Improper settings for wire feed

speed and volts.

c. Capacitor Bank Contactor not

working.

d. 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.

a. Check and repair broken leads.

b. Refer to procedure for checking

Voltage Control Potentiometer on Machine.

c. Refer to Procedure for Replacing

P.C. Boards.

a. Check and clean all connections.

b. Refer to a welding procedures guide

for proper settings.

c. Refer to the procedure for Checking

the Capacitor Bank Contactor CR3.

d. Replace entire bank of capacitors,

observe correct polarity. Do not replace individual capacitors.

WARNING

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

e. Opening in feedback circuit.

f. Faulty P.C. Board.

e. Check wiring and P.C. Board wiring

harness plugs. Pay special attention to leads 667 and 621.

f. Refer to procedure for replacing P.C.

Board.

– 22 –

Page 23

TROUBLESHOOTING PROCEDURES

A. 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:

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.

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 following 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”.

B. 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 visible damage to the P.C. Board, install a new one and see if this remedies the problem. If the problem is remedied, reinstall the old P.C. Board to see if the problem still exists. If it does no longer exist with 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 intermittent connection.

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

Voltage

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.

C. 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.

D. 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 LEDʼs are on. If LEDʼs are not on, see P.C. Board Troubleshooting Procedures. If the LEDʼs 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.

a) Frayed or pinched lead insulation.

– 23 –

Page 24

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.

E. 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.

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

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.

G. Remote Control Check

1. The remote control connector pin assignments are: pin G-75A, pin F-76B, pin E77B. 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.

F. 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”.

– 24 –

Page 25

H. 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.

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

– 25 –

Page 26

CONTROL BOARD

219

218

634

667

631

L9259

CONTACTOR

630

EACH

3-18-94

CR3

631

630

503

610A

600

608

610

510

667

621

633

75A

501

509

503A

}

FLASHING

LEADS

503

602

SHUNT

FIELD

610

509

RHEOSTAT

}

115V

+++

666

250

621

219

SHUNT

300 AMP

218

N.A.

600

}

GND

115V

609

610A

510

501

503A

602

503A

501

510

610A

609

GND

75A

633

634

CR4

609

608

NEG

POS

C501 C502 C503

R502

622

25W

CONTACTOR

CV -

TO NEG

BRUSH HOLDER

CC -

CC +

75 VOLT

30000 MFD

CONNECTS TO

ENGINE WELDER

RECEPTACLE J5

R-RED

U-BLUE

W-WHITE

Y-YELLOW

WIRE FEED MODULE - WIRING DIAGRAM

LEAD COLOR CODE

B-BLACK

G-GREEN

N-BROWN

CONNECTOR CAVITY NUMBERING

SEQUENCE VIEWED FROM

COMPONENT SIDE OF BOARD.

ELECTRICAL SYMBOLS PER E1537

J2 J4

MOLEX CONNECTORS

N.B. COMPONENTS VIEWED FROM REAR

N.A. LEADS 31, 32, 602, AND GRD DO NOT GO INSIDE WIRE FEED MODULE BOX.

SEQUENCE VIEWED FROM

CONNECTOR CAVITY NUMBERING

LEAD SIDE OF CONNECTOR

503A

610A

602

510

CC/CV SWITCH S1

SHOWN IN CV MODE

10K

R501

CV CONTROL

76A

77A

501

609

32314A

GND

REMOTE CONNECTOR

GROUND

115 VAC

77B

CONTACTOR

76B

75A

REMOTE

76B

77B

AMPHENOL 1

LOCAL/REMOTE SWITCH S2

– 26 –

76A

77A

SHOWN IN LOCAL MODE

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

Page 27

3-18-94

M17220

WIRE FEED

ON ENGINE WELDER REMOVE JUMPER PLUG

FROM CONNECTOR AND CONNECT W.F.M. PLUG

TO CONNECTOR ON ENGINE WELDER.

#8 LEAD

PLUG

CONNECTOR

W.F.M.

JUMPER PLUG

POS.

MODULE

#2 HEAVY LEAD

NEG.

609

608

#2 HEAVY LEAD

MACHINE MUST NOT BE RUNNING

WHEN MAKING THESE CONNECTIONS.

ASSEMBLY

THERMOSTAT

ENGINE WELDER

INLINE

CONNECTORS

WIRE FEED MODULE / ENGINE WELDER CONNECTION DIAGRAM

THIS UNIT IS PREASSEMBLED WITH A 250 AMP

W.F.M.

CONTROL

PANEL

NEGATIVE CV

OUTPUT TERMINAL

OUTPUT TERMINALS

CONNECT TO POS. & NEG.

PANEL

BRUSH HOLDER

CONNECT TO NEG.

THERMOSTAT ASSEMBLY. INSTALLING THIS UNIT INTO A CLASSIC 1

CAUTION:

AMP THERMOSTAT AS'BLY WITH THE 200 AMP THERMOSTAT AS'BLY

PROVIDED IN THE MOUNTING HARDWARE PACKET.

OR ANY 200 AMP MACHINE REQUIRES REPLACEMENT OF THE 250

– 27 –

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

–

Page 28

CONNECTION DIAGRAM: COMMANDER 400 S & W, CLASSIC ll, lll, lllD, 300D, 300G, SA-250,

350A & SAE-300 ENGINE WELDERS WITH WIRE FEED MODULE TO LN-23P WITH ADAPTER KIT

WORK

ELECTRODE

ENGINE WELDER WITH

115 VAC AUXILIARY

N.A.

CV+

14 PIN AMPHENOL WIRE FEEDER "A"WIRE FEEDER "B" 21

LN-23P

N.D.

N.C.

N.B.

9 CONDUCTOR ADAPTER CABLE

WARNING

CAN KILL

ELECTRIC

SHOCK

ELECTRODE

Turn off input power to the Welding Power Source

using the disconnect switch at the fuse box

Before connecting the wire feeder.

Only qualified persons should install, use or

service this machine.

602

FEEDER "A"FEEDER "B"

604 75 76

LN-23P ADAPTER KIT

77 521

LN-23P

602

K350-1

604 75 76 77 521

N.B. IF ONLY ONE LN-23P IS USED, CONNECT

N.D. BOLT AND TAPE CONNECTION.

N.E. MOUNT ADAPTER IN A CONVENIENT

LOCATION - AS NOT TO INTERFERE

WITH THE NORMAL MACHINE OPERATION.

CAUTION: WHEN MOUNTING ADAPTER TO

WELDER, SPECIAL CARE IS TO BE

TAKEN AS NOT TO DAMAGE ANY

MACHINE COMPONENTS, SUCH AS/BUT

NOT LIMITED TO ELECTRICAL

COMPONENTS, WIRES OR FUEL TANKS.

N.C. REMOTE VOLTAGE SENSING LEAD TO

N.A. WELDING CABLES MUST BE OF PROPER

TO WORK USING #12 OR LARGER RUBBER

WORK LEAD AND TAPE.

COVERED FLEX WIRE. WRAP WIRE AROUND

TO FEEDER "A" TERMINAL STRIP IN

ADAPTER.

BE EXTENDED BY CUSTOMER DIRECTLY

APPLICATIONS. SEE LN-23P OPERATING

MANUAL FOR PROPER SIZES.

DUTY CYCLE OF IMMEDIATE AND FUTURE

CAPACITY FOR THE CURRENT AND THE

M17323

CAPACITY FOR THE CURRENT AND THE

DUTY CYCLE OF IMMEDIATE AND FUTURE

MANUAL FOR PROPER SIZES.

APPLICATIONS. SEE LN-23P OPERATING

N.A. WELDING CABLES MUST BE OF PROPER

TO FEEDER "A" TERMINAL STRIP IN

ADAPTER.

BE EXTENDED BY CUSTOMER DIRECTLY

COVERED FLEX WIRE. WRAP WIRE AROUND

TO WORK USING #12 OR LARGER RUBBER

WORK LEAD AND TAPE.

N.B. IF ONLY ONE LN-23P IS USED, CONNECT

N.C. REMOTE VOLTAGE SENSING LEAD TO

N.E. MOUNT ADAPTER IN A CONVENIENT

LOCATION - AS NOT TO INTERFERE

N.D. BOLT AND TAPE CONNECTION.

WITH THE NORMAL MACHINE OPERATION.

K350-1

CAUTION: WHEN MOUNTING ADAPTER TO

WELDER, SPECIAL CARE IS TO BE

TAKEN AS NOT TO DAMAGE ANY

MACHINE COMPONENTS, SUCH AS/BUT

NOT LIMITED TO ELECTRICAL

COMPONENTS, WIRES OR FUEL TANKS.

521 77 76 75 604 602

LN-23P

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

ELECTRIC

WARNING

CAN KILL

9 CONDUCTOR ADAPTER CABLE

14 PIN AMPHENOL

ENGINE WELDER WITH

115 VAC AUXILIARY

N.D.

CV-

521

LN-23P ADAPTER KIT

77 76 75 604

FEEDER "A" FEEDER "B"

602

N.C.

ELECTRODE

N.B.

LN-23P

WIRE FEEDER "A" WIRE FEEDER "B"

N.A.

350A & SAE-300 ENGINE WELDERS WITH WIRE FEED MODULE TO LN-23P WITH ADAPTER KIT

CONNECTION DIAGRAM: COMMANDER 400 S & W, CLASSIC ll, lll, lllD, 300D, 300G, SA-250,

WORK

ELECTRODE

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

– 28 –

Page 29

AND WORK CABLES AT POWER SOURCE.

N.C.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT

AND DUTY CYCLE OF APPLICATION.

N.D. SPLICE LEADS AND INSULATE.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE

POLARITY, TURN POWER "OFF", REVERSE ELECTRODE

N.E. WELDER OUTPUT STUDS ON OPPOSITE SIDE FOR

CLASSIC II.

SAE-300 ENGINE WELDERS WITH WIRE FEED MODULE TO K867 PLUG TO LN-7.

ENGINE WELDER WITH

115 VAC AUXILIARY ELECTRODE CABLE

TO LN-7

CONNECTION DIAGRAM: CLASSIC II, III, IIID, 300D, 300G, SA-250, 350SA &

WORK

CV+

K867 UNIVERSAL

ADAPTER PLUG

14 PIN

AMPHENOL

WARNING

CAN KILL

ELECTRIC SHOCK

SPARE GND 8281424131

757677 2

N.F. WHEN MACHINE IS IN "REMOTE" MODE, A REMOTE

N.G. IF MACHINE IS IN "LOCAL" MODE, ELECTRODE IS

Turn off input power to the Welding Power Source

using the disconnect switch at the fuse box

Before connecting the wire feeder.

Only qualified persons should install, use or

service this machine.

ALWAYS "HOT".

OUTPUT CONTROL K775 IS REQUIRED.

N.D.

N.C. GND 31

757677

4 GREEN

K291 OR K404

INPUT CABLE K775 OPTIONAL

REMOTE CONTROL

LN-7

CONTROL

BOX

S21036

LN-7

CONTROL

BOX

K775 OPTIONAL

K291 OR K404

INPUT CABLE

REMOTE CONTROL

N.C.

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

828142

SPARE

SHOCK

ELECTRIC

WARNING

CAN KILL

14 PIN

AMPHENOL

GREEN

757677

GND

757677

GND

K867 UNIVERSAL

ADAPTER PLUG

N.D.

OUTPUT CONTROL K775 IS REQUIRED.

ALWAYS "HOT".

N.F. WHEN MACHINE IS IN "REMOTE" MODE, A REMOTE

N.G. IF MACHINE IS IN "LOCAL" MODE, ELECTRODE IS

CONNECTION DIAGRAM: CLASSIC II, III, IIID, 300D, 300G, SA-250, 350SA &

ENGINE WELDER WITH

SAE-300 ENGINE WELDERS WITH WIRE FEED MODULE TO K867 PLUG TO LN-7.

115 VAC AUXILIARY

CV-

N.C.

WORK

TO LN-7

ELECTRODE CABLE

N.E. WELDER OUTPUT STUDS ON OPPOSITE SIDE FOR

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE

POLARITY, TURN POWER "OFF", REVERSE ELECTRODE

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT

AND DUTY CYCLE OF APPLICATION.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

AND WORK CABLES AT POWER SOURCE.

CLASSIC II.

N.D. SPLICE LEADS AND INSULATE.

– 29 –

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

Page 30

N.C.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.E. IF MACHINE IS IN "LOCAL" MODE, GUN IS ALWAYS "HOT".

N.D. WELDER OUTPUT STUDS ON THE OPPOSITE SIDE FOR CLASSIC II.

N.C. WHEN MACHINE IS IN "REMOTE" MODE, A K857 MUST BE USED.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

ENGINE WELDERS WITH WIRE FEED MODULE TO K864 ADAPTER TO LN-7 & REMOTE CONTROL CONNECTION DIAGRAM: CLASSIC II, III, IIID, 300D, 300G, SA-250, 350SA & SAE-300

REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.

ENGINE WELDER WITH

115 VAC AUXILIARY

ELECTRODE CABLE

TO LN-7 TO

WORK

CV+

14 PIN

AMPHENOL

K864

ADAPTER

WARNING

CAN KILL

ELECTRIC

SHOCK

Turn off input power to the Welding Power Source

using the disconnect switch at the fuse box

Before connecting the wire feeder.

Only qualified persons should install, use or

service this machine.

14 PIN

AMPHENOL

6 PIN

AMPHENOL K584-"L" INPUT CABLE

REMOTE CONTROL

K857

LN-7

CONTROL

BOX

S21037

LN-7

CONTROL

BOX

K857

REMOTE CONTROL

K584-"L" INPUT CABLE

6 PIN

AMPHENOL

14 PIN

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

ELECTRIC

WARNING

ENGINE WELDER WITH

115 VAC AUXILIARY

CAN KILL

14 PIN

AMPHENOL

K864

ADAPTER

CV-

WORK

TO LN-7

ELECTRODE CABLE

CONNECTION DIAGRAM: CLASSIC II, III, IIID, 300D, 300G, SA-250, 350SA & SAE-300

REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.

ENGINE WELDERS WITH WIRE FEED MODULE TO K864 ADAPTER TO LN-7 & REMOTE CONTROL

N.C.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

N.C. WHEN MACHINE IS IN "REMOTE" MODE, A K857 MUST BE USED.

N.D. WELDER OUTPUT STUDS ON THE OPPOSITE SIDE FOR CLASSIC II.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.E. IF MACHINE IS IN "LOCAL" MODE, GUN IS ALWAYS "HOT".

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

– 30 –

Page 31

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE

N.C. ENGINE

WELDER

LEADS 2 & 4.

AND WORK CABLE AT POWER SOURCE.

WELDING OUTPUT, USE ISOLATION RELAY TO CLOSE

AND DUTY CYCLE OF APPLICATION.

POLARITY, TURN POWER "OFF", REVERSE ELECTRODE

CONNECTION DIAGRAM: ALL CLASSIC, ALL PIPELINER, SA-250, 350SA & SAE-300

TO LN-7

ELECTRODE CABLE

ENGINE WELDERS WITH WIRE FEED MODULE TO K867 UNIVERSAL ADAPTER

WORK

CV-

K867

K867 UNIVERSAL

ADAPTER PLUG

WIRE FEEDER

14 PIN

AMPHENOL

WARNING

CAN KILL

ELECTRIC SHOCK

N.F. WHEN MACHINE IS IN "REMOTE" MODE, A REMOTE

N.G. IF MACHINE IS IN "LOCAL" MODE, ELECTRODE IS

N.E. WELDER OUTPUT STUDS ON THE OPPOSITE SIDE

SPARE

Turn off input power to the Welding Power Source

using the disconnect switch at the fuse box

Before connecting the wire feeder.

Only qualified persons should install, use or

GND

service this machine.

768281

ALWAYS "HOT".

OUTPUT CONTROL MUST BE CONNECTED.

FOR CLASSIC II.

}}}

}

NOT USED

FRAME CONNECTION CONNECT TOGETHER FOR

WELDING OUTPUT

NOT USED

115 VAC / 2 AMP 10K

MIN.

REMOTE OUTPUT CONTROL

N.C.

}

( NOT USED ON CLASSIC I)

S21038

N.D.

N.C.

NOT USED

CONNECT TOGETHER FOR

WELDING OUTPUT

}

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SPARE

CLASSIC I)

( NOT USED ON

}

115 VAC / 2 AMP

FRAME CONNECTION

GND

NOT USED

}}}

REMOTE OUTPUT CONTROL

MIN.

10K

FOR CLASSIC II.

OUTPUT CONTROL MUST BE CONNECTED.

N.E. WELDER OUTPUT STUDS ON THE OPPOSITE SIDE

N.F. WHEN MACHINE IS IN "REMOTE" MODE, A REMOTE

S21038

ALWAYS "HOT".

N.G. IF MACHINE IS IN "LOCAL" MODE, ELECTRODE IS

SHOCK

ELECTRIC

WARNING

ENGINE WELDERS WITH WIRE FEED MODULE TO K867 UNIVERSAL ADAPTER

CAN KILL

14 PIN

AMPHENOL

WIRE FEEDER

K867 UNIVERSAL

ADAPTER PLUG

CV-

WORK

ELECTRODE CABLE

TO LN-7

K867

CONNECTION DIAGRAM: ALL CLASSIC, ALL PIPELINER, SA-250, 350SA & SAE-300

POLARITY, TURN POWER "OFF", REVERSE ELECTRODE

ENGINE

WELDER

AND DUTY CYCLE OF APPLICATION.

N.C.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT

AND WORK CABLE AT POWER SOURCE.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE

WELDING OUTPUT, USE ISOLATION RELAY TO CLOSE

LEADS 2 & 4.

N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

– 31 –

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

Page 32

ENGINE

WELDER

N.C.

REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE, SWITCH LN-25 POLARITY SWITCH.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.C. WELDER OUTPUT STUDS ON OPPOSITE SIDE FOR CLASSIC II.

CONNECTION DIAGRAM: ALL CLASSIC, ALL PIPELINER, SA-250, 350SA & SAE-300 ENGINE WELDERS WITH WIRE FEED MODULE TO LN-25 WITH K444-2 OPTION

WORK CV+

ELECTRODE CABLE

14 PIN

AMPHENOL

WARNING

CAN KILL

ELECTRIC SHOCK

Turn off input power to the Welding Power Source

using the disconnect switch at the fuse box

Before connecting the wire feeder.

Only qualified persons should install, use or

service this machine.

WIRE FEEDER

LN-25

WITH K444-2 REMOTE

VOLTAGE CONTROL

OPTION

S21039

WITH K444-2 REMOTE

VOLTAGE CONTROL

LN-25

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

WIRE FEEDER

OPTION

SHOCK

ELECTRIC

WARNING

CAN KILL

14 PIN

AMPHENOL

ELECTRODE CABLE

CV-

ENGINE WELDERS WITH WIRE FEED MODULE TO LN-25 WITH K444-2 OPTION

CONNECTION DIAGRAM: ALL CLASSIC, ALL PIPELINER, SA-250, 350SA & SAE-300

ENGINE

WELDER

N.C.

WORK

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.C. WELDER OUTPUT STUDS ON OPPOSITE SIDE FOR CLASSIC II.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE, SWITCH LN-25 POLARITY SWITCH.

– 32 –

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

Page 33

ENGINE WELDER WITH

115 VAC AUXILIARY

N.C.

REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE, SWITCH LN-25 POLARITY SWITCH.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.E. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.C. WELDER OUTPUT STUDS ON OPPOSITE SIDE FOR CLASSIC II.

N.D. MOUNT K433 TO ENGINE WELDER PER INSTRUCTIONS PACKAGED WITH K433.

N.F. SPLICE LEADS AND INSULATE.

ENGINE WELDERS WITH WIRE FEED MODULE TO LN-25 WITH K431, K433 & K432-"L" OPTION

CONNECTION DIAGRAM: CLASSIC ll, lll, lllD, 300D, 300G, SA-250, 350SA & SAE-300

WORK CV+

K867 UNIVERSAL

ADAPTER PLUG

ELECTRODE CABLE 14 PIN

AMPHENOL

SPARE GND 8281424131

757677

21 2

N.F.

GND

N.E.

757677

WARNING

CAN KILL

ELECTRIC

SHOCK

K432-"L" CABLE

Turn off input power to the Welding Power Source

K433

using the disconnect switch at the fuse box

Before connecting the wire feeder.

Only qualified persons should install, use or

service this machine.

LN-25

WIRE

FEEDER

WITH

K431

OPTION

S21053

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

ELECTRIC

WARNING

CAN KILL

N.E.

828142

SPARE

LN-25

WIRE

K433

K432-"L" CABLE

GND

757677

FEEDER

WITH

K431

OPTION

N.F.

S21053

14 PIN

AMPHENOL

ELECTRODE CABLE

K867 UNIVERSAL

ADAPTER PLUG

CV-

CONNECTION DIAGRAM: CLASSIC ll, lll, lllD, 300D, 300G, SA-250, 350SA & SAE-300

ENGINE WELDERS WITH WIRE FEED MODULE TO LN-25 WITH K431, K433 & K432-"L" OPTION

ENGINE WELDER WITH

115 VAC AUXILIARY

N.C.

– 33 –

WORK

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.C. WELDER OUTPUT STUDS ON OPPOSITE SIDE FOR CLASSIC II.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE, SWITCH LN-25 POLARITY SWITCH.

N.F. SPLICE LEADS AND INSULATE.

N.D. MOUNT K433 TO ENGINE WELDER PER INSTRUCTIONS PACKAGED WITH K433.

N.E. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

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

Page 34

ENGINE WELDERS WITH WIRE FEED MODULE TO K867 PLUG TO K487 / K488 / K492 SPOOL GUN

AND WORK CABLES AT POWER SOURCE.

N.C.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT

AND DUTY CYCLE OF APPLICATION.

N.D. SPLICE LEADS AND INSULATE.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE

POLARITY, TURN POWER "OFF", REVERSE ELECTRODE

N.E. WELDER OUTPUT STUDS ON OPPOSITE SIDE FOR

CLASSIC II.

CONNECTION DIAGRAM: CLASSIC ll. lll, lllD, 300D, 300G, SA-250, 350SA & SAE-300

ENGINE WELDER WITH

115 VAC AUXILIARY ELECTRODE CABLE TO

K488 SG CONTROL CABLE TO

WORK

CV+

K867 UNIVERSAL

ADAPTER PLUG

14 PIN

AMPHENOL

SPARE GND 8281424131

757677

21 2

N.F. WHEN MACHINE IS IN "REMOTE" MODE, A REMOTE

N.G. IF MACHINE IS IN "LOCAL" MODE, ELECTRODE IS

WARNING

CAN KILL

ELECTRIC SHOCK

ALWAYS "HOT".

OUTPUT CONTROL K775 IS REQUIRED.

N.D.

N.C. GND

Turn off input power to the Welding Power Source

using the disconnect switch at the fuse box

757677

Before connecting the wire feeder.

Only qualified persons should install, use or

service this machine.

4 GREEN

K488 SG

CONTROL

MODULE K492

INPUT CABLE

K775 OPTIONAL

REMOTE CONTROL

S21268

K487-25

SPOOL

GUN

K487-25

SPOOL

K488 SG

CONTROL

MODULE

GUN

K492

INPUT CABLE

K775 OPTIONAL

REMOTE CONTROL

S21268

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

N.C.

SHOCK

ELECTRIC

WARNING

CAN KILL

828142

SPARE

14 PIN

AMPHENOL

GREEN

757677

GND

757677

GND

K867 UNIVERSAL

ADAPTER PLUG

N.D.

OUTPUT CONTROL K775 IS REQUIRED.

ALWAYS "HOT".

N.F. WHEN MACHINE IS IN "REMOTE" MODE, A REMOTE

N.G. IF MACHINE IS IN "LOCAL" MODE, ELECTRODE IS

ENGINE WELDER WITH

115 VAC AUXILIARY

CV-

WORK

K488 SG CONTROL CABLE

ELECTRODE CABLE TO

CONNECTION DIAGRAM: CLASSIC ll. lll, lllD, 300D, 300G, SA-250, 350SA & SAE-300

N.E. WELDER OUTPUT STUDS ON OPPOSITE SIDE FOR

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE

POLARITY, TURN POWER "OFF", REVERSE ELECTRODE

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT

ENGINE WELDERS WITH WIRE FEED MODULE TO K867 PLUG TO K487 / K488 / K492 SPOOL GUN

N.C.

AND DUTY CYCLE OF APPLICATION.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

AND WORK CABLES AT POWER SOURCE.

CLASSIC II.

N.D. SPLICE LEADS AND INSULATE.

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

– 34 –

Page 35

CLASSIC I and PIPELINER 200D and 200G with WIRE FEED MODULE

Reference Output Curves

For Selected Open Circuit Volts (OCV) at Wire Feeder

= WIRE FEEDER OCV

LOAD VOLTS (DC)

25 50

75 100 125 150 175 200 225 250 275 300

LOAD AMPS (DC)

CLASSIC I and PIPELINER 200D and 200G with WIRE FEED MODULE

Reference Output Curves

For Selected Open Circuit Volts (OCV) at Wire Feeder

= WIRE FEEDER OCV 60

LOAD VOLTS (DC)

0 0

75100125150175200225250275300

2550 LOAD AMPS (DC)

– 35 –

Page 36

For Selected Open Circuit Volts (OCV) at Wire Feeder

= WIRE FEEDER OCV

CLASSIC II with WIRE FEED MODULE

Reference Output Curves

LOAD VOLTS (DC)

CLASSIC II with WIRE FEED MODULE

Reference Output Curves

For Selected Open Circuit Volts (OCV) at Wire Feeder

= WIRE FEEDER OCV 60

LOAD VOLTS (DC)

0 0

75100125150175200225250275300325350375400

2550

LOAD AMPS (DC)

25 50

75 100 125 150 175 200 225 250 275 300 325 350 375 400

LOAD AMPS (DC)

– 36 –

Page 37

CLASSIC III and 300G with WIRE FEED MODULE

For Selected Open Circuit Volts (OCV) at Wire Feeder

= WIRE FEEDER OCV

Reference Output Curves

LOAD VOLTS (DC)

CLASSIC III and 300G with WIRE FEED MODULE

Reference Output Curves

For Selected Open Circuit Volts (OCV) at Wire Feeder

= WIRE FEEDER OCV 60

LOAD VOLTS (DC)

0 0

75100125150175200225250275300325350375400

2550 LOAD AMPS (DC)

25 50

75 100 125 150 175 200 225 250 275 300 325 350 375 400

LOAD AMPS (DC)

– 37 –

Page 38

CLASSIC IIID, CLASSIC 300D, SA250 and SAE-300 (CODES 10890 and above) with WIRE FEED MODULE

For Selected Open Circuit Volts (OCV) at Wire Feeder

= WIRE FEEDER OCV

Reference Output Curves

LOAD VOLTS (DC)

25 50

75 100 125 150 175 200 225 250 275 300 325 350 375 400

LOAD AMPS (DC)

– 38 –

Page 39

LOAD AMPS (DC) 2550

75100125150175200225250275300325350375400 0

LOAD VOLTS (DC)

60 = WIRE FEEDER OCV

For Selected Open Circuit Volts (OCV) at Wire Feeder

Reference Output Curves

350 SA and SA-250 (CODES 10889 AND BELOW) with WIRE FEED MODULE

Reference Output Curves

For Selected Open Circuit Volts (OCV) at Wire Feeder

= WIRE FEEDER OCV

LOAD VOLTS (DC)

25 50

75 100 125 150 175 200 225 250 275 300 325 350 375 400

LOAD AMPS (DC)

– 39 –

Page 40

NOTES

WIRE FEED MODULE

– 40 –

Page 41

NOTES

WIRE FEED MODULE

– 41 –

Page 42

WARNING

Spanish

AVISO DE

PRECAUCION

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground.

• No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

• Aislese del trabajo y de la tierra.

• Keep flammable materials away.

• Mantenga el material combustible

fuera del área de trabajo.

• Wear eye, ear and body protection.

• Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

• Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

• Isolez-vous du travail et de la terre.

• Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

• Isolieren Sie sich von den

Elektroden und dem Erdboden!

• Não toque partes elétricas e electro-

dos com a pele ou roupa molhada.

• Isole-se da peça e terra.

• Gardez à l’écart de tout matériel

• Entfernen Sie brennbarres Material!

• Mantenha inflamáveis bem guarda-

inflammable.

dos.

• Protégez vos yeux, vos oreilles et

votre corps.

• Tragen Sie Augen-, Ohren- und Kör-

perschutz!

• Use proteção para a vista, ouvido e

corpo.

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.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

– 42 –

Page 43

• Keep your head out of fumes.

• Use ventilation or exhaust to

remove fumes from breathing zone.

• Turn power off before servicing.

• Do not operate with panel open or

guards off.

WARNING

• Los humos fuera de la zona de res-

piración.

• Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

• Gardez la tête à l’écart des fumées.

• Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

• Vermeiden Sie das Einatmen von

Schweibrauch!

• Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

• Mantenha seu rosto da fumaça.

• Use ventilação e exhaustão para

remover fumo da zona respiratória.

• Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

• Débranchez le courant avant l’entre-

tien.

• Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

•

Não opere com as tampas removidas.

•

Desligue a corrente antes de fazer serviço.

•

Não toque as partes elétricas nuas.

• No operar con panel abierto o

• N’opérez pas avec les panneaux

• Anlage nie ohne Schutzgehäuse

• Mantenha-se afastado das partes

• Não opere com os paineis abertos

guardas quitadas.

ouverts ou avec les dispositifs de protection enlevés.

oder Innenschutzverkleidung in Betrieb setzen!

moventes.

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

– 43 –

Page 44

• 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

– 44 –

Lincoln Electric IM513 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual