Lincoln Electric SVM125-A User Manual
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SVM125-A
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.
TM
CLASSIC II
For use with machine code numbers 9805 to 10220
October 1996
View Safety Info View Safety Info View Safety Info View Safety Info
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SERVICE MANUAL
World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
Sales and Service through subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
i i
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 W elding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. AFree 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
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
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.
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FOR ENGINE
powered equipment.
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 weld-
ing 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.
2.a. Electric current flowing through any conductor causes
2.b. EMF fields may interfere with some pacemakers, and
2.c. Exposure to EMF fields in welding may have other health
2.d. All welders should use the following procedures in order to
Mar ‘95
CLASSIC II
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
welders having a pacemaker should consult their physician
before welding.
effects which are now not known.
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.
ii ii
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 below Threshold Limit Values (TLV)
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.
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.c. 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.
5.d. 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.
vapors
to
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5.e. Also see item 1.b.
CLASSIC II
Mar ‘95
iii
SAFETY
iii
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
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.
Remember that welding sparks and hot
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.
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Mar ‘95
CLASSIC II
iv iv
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 L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode 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 s’isoler 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 l’eau 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 s’applicuent aussi au pistolet de
soudage.
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soud
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres 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 d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils 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
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc 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” CSAStandard
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 n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, 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
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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
l’électricité 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, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
CLASSIC II
v v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
RETURN TO MAIN INDEX
Safety.................................................................................................................................................i-iv
Installation .............................................................................................................................Section A
Technical Specifications..............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation..............................................................................................................A-3
Pre-operation Engine Service.....................................................................................................A-4
Electrical Output Connections.....................................................................................................A-6
Operation...............................................................................................................................Section B
Safety Instructions.......................................................................................................................B-2
General Description ....................................................................................................................B-2
Recommended Applications........................................................................................................B-3
Operational Features and Controls .............................................................................................B-3
Design Features ..........................................................................................................................B-3
Welding Capability ......................................................................................................................B-4
Page
Limitations .................................................................................................................................B-4
Controls and Settings..................................................................................................................B-5
Engine Operation........................................................................................................................B-8
Welding Operation ....................................................................................................................B-10
Auxiliary Power .........................................................................................................................B-13
Accessories ..........................................................................................................................Section C
Maintenance..........................................................................................................................Section D
Safety Precautions ......................................................................................................................D-2
Routine and Periodic Maintenance .............................................................................................D-2
Major Component Locations.......................................................................................................D-8
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair................................................................................................Section F
Electrical Diagrams..............................................................................................................Section G
Parts Manual ................................................................................................................................P-219
CLASSIC II
Section A-1 Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation
Technical Specifications..............................................................................................................A-2
Input – Diesel Engine ...........................................................................................................A-2
Rated Output – Welder.........................................................................................................A-2
Output – Welder and Generator...........................................................................................A-2
Physical Dimensions.............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation..............................................................................................................A-3
Storing .................................................................................................................................A-3
Stacking................................................................................................................................A-4
Tilting .................................................................................................................................A-4
Lifting .................................................................................................................................A-4
High Altitude Operation.........................................................................................................A-4
Pre-operation Engine Service.....................................................................................................A-4
Oil ........................................................................................................................................A-4
Fuel .......................................................................................................................................A-4
Battery Connections .............................................................................................................A-4
Muffler .................................................................................................................................A-5
Spark Arrester.......................................................................................................................A-5
Undercarriages.....................................................................................................................A-5
Electrical Output Connections.....................................................................................................A-6
Welding Cable Connections.................................................................................................A-6
Cable Installation, Polarity Control, and Cable Sizes..............................................A-6
Machine Grounding ..............................................................................................................A-7
Auxiliary Power Receptacles, Plugs, and Hand-held Equipment .........................................A-7
Circuit Breakers....................................................................................................................A-7
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CLASSIC II
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - CLASSIC II
INPUT - DIESEL ENGINE
Manufacturer Description Speed Displacement Ignition Capacities
Deutz 3 cyl., 1725 RPM 125 cu. in. Electric Fuel: 15 gal.
F3L-1011F Air-cooled Full load (2049 cc) (57 liters)
diesel Oil: 6.3 qt.
28 HP @ 1800 RPM (6.0 liters)
1700 RPM High idle
1350 RPM
Low idle
RATED OUTPUT - WELDER
Duty Cycle Amps Volts at Rated Amperes
100% Duty Cycle 200 DC Constant Current 28V
60% Duty Cycle 250 DC Constant Current 40V
40% Duty Cycle 300 DC Constant Current 32V
OUTPUT - WELDER AND GENERATOR
Welding Ranges Max. Open Circuit Voltage Auxiliary Power
40-325 Amps DC 98.5 3.0 kVA of 115/230 V, 60Hz Power
26 Amps @ 115 V
13 Amps @ 230 V
(1)
PHYSICAL DIMENSIONS
Height Width Depth Weight
49.94 in. 24 in. 60 in. 1340 lb.
1040 mm 610 mm 1524 mm 608 kg
1
CSA machines can draw 15 amps from either half of the receptacle. Non-CSA machines can draw 20 amps from either half of the
receptacle. Total combined load of all receptacles cannot exceed 3.0 kVA.
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CLASSIC II
A-3 A-3
INSTALLATION
Read this entire installation section before you
start installation.
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrodes with your
skin or wet clothing.
• Insulate yourself from the work
and ground.
• Always wear dry insulating
gloves.
LOCATION AND VENTILATION
Always operate the Classic II with the doors closed.
Leaving the doors open changes the designed air flow
and may cause overheating. Always operate the
welder with the case roof on and all machine components completely assembled. This will protect you from
the dangers of moving parts, hot metal surfaces, and
live electrical devices.
Whenever you use the Classic II, be sure that clean
cooling air can flow through the machine’s diesel
engine and the generator. Avoid dusty, dirty areas.
Also, keep the machine away from heat sources. Do
not place the back end of the generator anywhere near
hot engine exhaust from another machine. And of
course, make sure that engine exhaust is ventilated to
an open, outside area.
The Classic II may be used outdoors. Do not set the
machine in puddles or otherwise submerge it in water.
Such practices pose safety hazards and cause improper operation and corrosion of parts.
STORING
ENGINE EXHAUST can kill.
• Use in open, well ventilated
areas or vent exhaust to the outside.
• Do not stack anything on or near
the engine.
MOVING PARTS can injure.
• Do not operate this equipment
with any of its doors open or
guards off.
• Stop the engine before servicing
it.
• Keep away from moving parts.
See additional safety information at the front of this
manual.
Only qualified personnel should install, use, or service this equipment.
1. Store the machine in a cool, dry place when it is not
in use. Protect it from dust and dirt. Keep it where
it can’t be accidentally damaged from construction
activities, moving vehicles, and other hazards.
2. Drain the engine oil and refill with fresh 10W30 oil.
Run the engine for about five minutes to circulate oil
to all the parts. See the
this manual for details on changing oil.
3. Remove the battery, recharge it, and adjust the
electrolyte level. Store the battery in a dry, dark
place.
4. See your engine operation manual for further information on fuel and engine preservation.
Maintenance
section of
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CLASSIC II
A-4 A-4
INSTALLATION
STACKING
Classic II machines CANNOT be stacked.
TILTING
Place the machine on a secure, level surface whenever you use it or store it. Any surfaces you place it on
other than the ground must be firm, non-skid, and
structurally sound.
The diesel engine is designed to run in a level position
for best performance. If you do operate it at a slight
angle, be sure to check the oil regularly and keep the
oil level at the FULL mark as it would be in its normal
level condition. Also, fuel capacity will be a little less at
an angle.
LIFTING
The Classic II weighs 1340 lb./608 kg. A lift bail is
provided for lifting with a hoist.
WARNING
FALLING EQUIPMENT can
cause injury.
Do not lift this machine using lift bail if
it is equipped with a heavy accessory
such as a trailer.
Lift only with equipment of adequate lifting capacity . Be
sure machine is stable when lifting.
WARNING
Keep hands away from the engine muffler or HOT
engine parts.
• Stop the engine when fueling.
• Do not smoke when fueling.
• Remove the fuel cap slowly to release pressure.
• Do not overfill the fuel tank.
• Wipe up spilled fuel and allow the fumes to clear
before starting the engine.
• Keep sparks and flame away from the fuel tank.
OIL
The Classic II is shipped with the engine
filled with SAE 10W-30 oil (API class
CC/DO). This should be fine for most
ambient operating temperature conditions. See the
engine operation manual for specific recommendations. CHECK THE OIL LEVEL BEFORE YOU
START THE ENGINE. This is an added precaution.
When full, the oil level should be up to but not over the
FULL mark on the dipstick. If it is not full, add enough
oil to fill it to the full mark. DO NOT overfill.
NOTE: This unit is equipped with an Engine Protection
Package. An internal kill switch will shut down the
engine if the oil pressure drops below a minimum operating specification or if the oil temperature reaches an
excessive level.
For more oil fill and service information, see the
Maintenance
FUEL
section of this manual.
HIGH ALTITUDE OPERATION
It may be necessary to derate welder output at higher
altitudes. Some engine adjustment may be required.
Contact a Deutz Service Representative.
PRE-OPERATION ENGINE SERVICE
Read and understand the information about the diesel
engine in the
this manual before you operate the Classic II.
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Operation
and
Maintenance
sections of
CLASSIC II
Fill the fuel tank with clean, diesel fuel only.
The Classic II has a 15 gallon (57 liter) fuel
tank with a top fill and fuel gauge mounted
on the control panel. See the
and
Maintenance
details about fuel.
sections of this manual for more
Operation
BATTERY CONNECTIONS
The Classic II is shipped with the negative
battery cable disconnected. Before you
operate the machine, make sure the
IGNITION switch is in the OFF position and attach the
disconnected cable securely to the battery terminal. If
the battery is discharged and won't start the engine,
see the battery charging instructions in the
Maintenance
section.
A-5 A-5
INSTALLATION
UNDERCARRIAGES
MUFFLER
This welder is supplied with an adjustable rain cap for
the muffler. Install the rain cap using the clamp provided with the outlet facing away from the direction in
which this unit will be transported. This will minimize
the amount of water and debris that could enter the
muffler during transportation.
If you use a non-Lincoln undercarriage, you must
assume responsibility that the method of attachment
and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be
considered are as follows:
1. Design capacity of the undercarriage vs. the weight
of the Lincoln equipment and likely additional
attachments.
SPARK ARRESTER
Diesel engine mufflers may emit sparks when the
engine is running. Some federal, state, or local laws
require spark arresters in locations where unarrested
sparks could present a fire hazard.
Standard mufflers (like the one included with the
Classic II) do not act as spark arresters. When local
laws require it, a spark arrester must be installed on the
machine and properly maintained. An optional spark
arrester kit is available for your Classic II. See the
Accessories
tion.
section of this manual for more informa-
CAUTION
An incorrect spark arrester may lead to damage to the
engine or reduce performance.
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
3. Proper placement of the equipment on the undercarriage to ensure stability side to side and front to
back. This includes when being moved and when
standing by itself for operation or service.
4. Typical conditions of use, such as travel speed,
roughness of the surfaces where the undercarriage
will be used, environmental conditions, likely maintenance.
5. Conformance with federal, state, and local laws.
Consult applicable federal, state, and local laws
about specific requirements for use on public highways.
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CLASSIC II
A-6 A-6
INSTALLATION
ELECTRICAL OUTPUT
CONNECTIONS
See Figure A.1 for the location of the 115 and 230 volt
receptacles, weld output terminals, and ground stud.
WELDING CABLE CONNECTIONS
CABLE INSTALLATION, POLARITY CONTROL,
AND CABLE SIZES
With the engine off, route the electrode and work
cables through the strain relief bracket on the base and
connect to the terminals located below the fuel tank
mounting rail. (See size recommendations below.) For
positive polarity, connect the electrode cable to the terminal marked Positive (+). For Negative polarity, connect the electrode cable to the Negative (-) terminal.
These connections should be checked periodically and
tightened if necessary.
FIGURE A.1 - CLASSIC II OUTPUT CONNECTIONS
CAUTION
• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.
• Do not cross the welding cables at the output terminal
connection. Keep the cables isolated and separate
from one another.
When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
Lincoln Electric offers a welding accessory kit with the
properly specified welding cables. See the
Accessories
information.
section of this manual for more
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1
2
TABLE A.1 - RECOMMENDED COPPER WELDING CABLE SIZE AND LENGTH
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES
Amps Duty Cycle Up to 200 ft. 200 to 250 ft.
200 100% 1 1/0
250 60% 1 1/0
300 40% 1/0 2/0
3
5
CLASSIC II
1. 230 VOLT RECEPTACLE
2. 115 VOLT RECEPTACLE
3. WELD OUTPUT TERMINALS (2)
4. GROUND STUD (LOCATION)
5. CABLE STRAIN RELIEF BRACKET
Cable sizes for combined length of
electrode plus work cable
4
A-7 A-7
INSTALLATION
MACHINE GROUNDING
Because the Classic II creates its own
power from its diesel-engine driven generator, you do not need to connect the
machine frame to an earth ground.
However, for best protection against electrical shock, connect a heavy gauge wire (#8 AWG or
larger) from the ground stud located on the welding
generator frame foot. (See Figure A.2) to a suitable
earth ground such as a metal pipe driven into the
ground. The US National Electrical Code lists a number
of alternate means of grounding electrical equipment.
WARNING
Do not ground the machine to a pipe that carries
explosive or combustible material.
Some state, local, or other codes or unusual operating
circumstances may require the machine frame to be
grounded. It is recommended that you determine the
extent to which such requirements may apply to your
particular situation and follow them explicitly.
When the Classic II is mounted on a truck or a trailer,
the machine generator ground stud MUST be securely connected to the metal frame of the vehicle. See
Figure A.2. The ground stud is marked with the ground
symbol.
For further protection against electric shock, any electrical equipment connected to the generator receptacles must use a three-blade, grounded type plug or an
Underwriter's Laboratories (UL) approved double insulation system with a two-blade plug. Lincoln offers an
accessory plug kit that has the right type of plugs. See
the
Accessories
section of this manual for details.
AUXILIARY POWER RECEPTACLES,
PLUGS, AND HAND-HELD EQUIPMENT
The AC auxiliary power, supplied as a standard, has a
rating of 3.0 kVA of 115/230V AC (60 hertz).
With the 3.0 kVA, 115/230V AC auxiliary power, one
115V duplex and one 230V grounding type receptacle
are provided. The circuit is protected with circuit breakers.
The rating of 3.0 kVA permits a maximum continuous
current of 13 amps to be drawn from the 230 volt
duplex receptacle. Or a total of 26 amps can be drawn
from the 115 volt duplex receptacle. The 115 volt
duplex receptacle has a configuration which permits 15
amps on CSA machines and 20 amps on non-CSA
machines. The total combined load of all receptacles
is not to exceed 3.0 kVA.
CIRCUIT BREAKERS
Classic II welders are equipped with
circuit breakers on the 115 and the
230 volt receptacles for overload protection. Under high heat a breaker
may tend to trip at lower loads than it would normally.
Operation with high ambient temperatures may cause
the breakers to trip at lower than normal loads.
CAUTION
Never bypass the circuit breakers. Without overload
protection, the Classic II could overheat and/or cause
damage to the equipment being used.
FIGURE A.2 - GROUND STUD LOCATION
If you need ground fault protection for hand-held equipment, refer to the
for the GFCI Receptacle kit.
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Accessories
section of this manual
1
1. Ground Stud
CLASSIC II
A-8 A-8
NOTES
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CLASSIC II
Section B-1 Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Safety Instructions.......................................................................................................................B-2
General Description ....................................................................................................................B-2
Recommended Applications........................................................................................................B-3
Welder .................................................................................................................................B-3
Generator..............................................................................................................................B-3
Operational Features and Controls .............................................................................................B-3
Design Features ..........................................................................................................................B-3
Welding Capability ......................................................................................................................B-4
Limitations .................................................................................................................................B-4
Controls and Settings..................................................................................................................B-5
Welder/Generator Controls...................................................................................................B-5
Control of Welding Current...................................................................................................B-6
Diesel Engine Controls:........................................................................................................B-7
Engine Operation........................................................................................................................B-8
Before Starting the Engine ...................................................................................................B-8
Starting the Engine...............................................................................................................B-8
Stopping the Engine.............................................................................................................B-9
Cold Weather Starting..........................................................................................................B-9
Break-in Period.....................................................................................................................B-9
Welding Operation ....................................................................................................................B-10
General Information............................................................................................................B-10
Idler Operation....................................................................................................................B-10
Classic II DC Constant Current Stick or TIG Welding........................................................B-11
Classic II DC Wire Feed Welding (Constant Voltage)........................................................B-12
Auxiliary Power .........................................................................................................................B-13
Using Auxiliary Power and Welding at the Same Time......................................................B-13
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CLASSIC II
B-2 B-2
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section before operating your Classic II.
SAFETY INSTRUCTIONS
WARNING
Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet clothing.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
WARNING
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust to the outside.
• Do not stack anything on or near the
engine.
MOVING PARTS can injure.
• Do not operate this equipment with any
of its doors open or guards off.
• Stop the engine before servicing it.
• Keep away from moving parts.
Only qualified personnel should install, use, or service this equipment.
GENERAL DESCRIPTION
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held
combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
The Classic II is a heavy duty engine driven DC arc
welding power source capable of providing constant
current output for stick welding or DC TIG welding. The
Classic II is wound with all copper coils and is configured in a new shorter case with no exciter stickout and
setup for one side service. With the addition of the
optional Wire Feed Module, the Classic II will provide
constant voltage output for running the LN-7 or LN-25.
This unit uses the Deutz F3L-1011F three-cylinder,
industrial air cooled diesel engine.
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CLASSIC II
B-3 B-3
OPERATION
RECOMMENDED APPLICATIONS
WELDER
The Classic II provides excellent constant current DC
welding output for stick (SMAW) welding and for DC
TIG welding. It also offers constant voltage output for
DC semiautomatic wire feed welding. For more details
on using the machine as a welder, see
Operation
in the
Operation
section of this manual.
Welding
GENERATOR
The Classic II is also capable of providing 3.0 kVA of
115/230 volts of 60 Hertz AC auxiliary power.
OPERATIONAL FEATURES AND
CONTROLS
The Classic II was designed for simplicity. Therefore,
it has very few operating controls. Two switches are
used for welding operations:
• A five-position CURRENT RANGE SELECTOR
switch selects current output for constant current
stick or TIG applications and constant voltage wire
feed applications (with optional Wire Feed Module see the
• A FINE CURRENT ADJUSTMENT switch for fine
adjustment of current from minimum to maximum
within each range
Controls for the diesel engine control include a twoposition IGNITION ON/OFF toggle switch, a START
pushbutton, and a two-position IDLER switch that
selects engine speed for welding or auxiliary power
applications. See
section of this manual for details about starting, running, stopping, and breaking in the diesel engine.
Accessories
Engine Operation
section)
in the
Operation
DESIGN FEATURES
• Constant current DC Stick welding (SMAW) process
capability with output range from 40 - 325 DC amps.
• Constant current DC TIG Welding with output across
the entire range of settings.
• Work and Electrode welding cable mounting terminals.
• Separate ground stud for safe connection of case to
earth ground.
• Duplex, 230 volt auxiliary power receptacle.
• Duplex, 115 volt auxiliary power receptacles.
• Integrated generator output overload protection
through two 20 amp circuit breakers (CSA versions).
• Electric starting.
• Battery Charging Ammeter.
• Engine Oil Pressure Gauge.
• Engine Hour Meter for determining periodic maintenance.
• Top-of-the-line 28.5 HP Deutz diesel engine.
• Top-mounted 15 gallon (57.0 litter) fuel tank with
convenient top fill.
• All copper alternator windings and high quality insulation for dependable long life.
• Automatic engine shutdown protection for low oil
pressure.
• Automatic engine idler goes to low idle approximately 15 seconds after welding for greater fuel economy;
includes high idle switch.
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CLASSIC II
B-4 B-4
OPERATION
WELDING CAPABILITY
The Classic II is rated 250 amps, 30 volts constant current DC at 60% duty cycle based on a ten minute time
period. Longer duty cycles at lower output currents are
possible.
The current is continuously variable from 40 to 325
amps DC.
LIMITATIONS
• The Classic II is not recommended for any processes besides those that are normally performed using
DC stick welding (SMAW) and DC TIG welding.
Specific limitations on using the Classic II for these
processes are described in the Welding Operation
section of this manual. Constant voltage welding is
available with the optional wire feed module.
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CLASSIC II
B-5 B-5
OPERATION
CONTROLS AND SETTINGS
The welder/generator controls are located on the
Output Control Panel of the machine case front. Diesel
engine idler control and start/stop controls are also on
FIGURE B.1 – OUTPUT CONTROLS
1
2
3
4
5
6
the case front. Welding output terminals and ground
stud are located on the machine right side, under the
door. See Figure B.1 and the explanations that follow.
7
1. CURRENT RANGE SELECTOR
2. FINE CURRENT ADJUSTMENT
3. 230 VOLT RECEPTACLE
4. 115 VOLT RECEPTACLE
5. WELD OUTPUT TERMINAL (–)
6. WELD OUTPUT TERMINAL (+)
7. GROUND STUD
WELDER/GENERATOR CONTROLS
See Figure B.1 for the location of the following features:
1. CURRENT RANGE SELECTOR: Selects continu-
ous current output for constant current stick or TIG
applications and constant voltage wire feed applications. The amperages on the dial correspond to the
average amperages needed for specific Lincoln
welder rods. See
more information.
2. FINE CURRENT ADJUSTMENT: Allows fine
adjustment of current within the selected output
range. See
information.
3. 230 VOLT DUPLEX RECEPTACLE: Connection
point for supplying 230 volt power to operate one or
two electrical devices.
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Control of Welding Current
Control of Welding Current
for
for more
CLASSIC II
4. 115 VOLT DUPLEX RECEPTACLE: Connection
point for supplying 115 volt power to operate one or
two electrical devices.
5. WELD OUTPUT TERMINAL (–) WITH FLANGE
NUT: Provides the connection point for either the
electrode holder or the work cable.
6. WELD OUTPUT TERMINAL (+) WITH FLANGE
NUT: Provides the connection point for either the
electrode holder or the work cable.
7. GROUND STUD: Provides a connection point for
connecting the machine case to earth ground for
the safest grounding procedure.
B-6 B-6
OPERATION
CONTROL OF WELDING CURRENT
CAUTION
DO NOT turn the CURRENT RANGE SELECTOR
while welding because the current may arc between
the contacts and damage the switch.
See Figure B.2. The CURRENT RANGE SELECTOR
provides five overlapping current ranges. The FINE
CURRENT ADJUSTMENT adjusts the current from
minimum to maximum within each range. Open circuit
voltage is also controlled by the FINE CURRENT
ADJUSTMENT, permitting control of the arc characteristics.
A high open circuit voltage setting provides the soft
"buffering" arc with best resistance to pop-outs preferred for most welding. To get this characteristic, set
the CURRENT RANGE SELECTOR to the lowest setting that still provides the current you need and set the
FINE CURRENT ADJUSTMENT near maximum. For
example: to obtain 175 amps and a soft arc, set the
CURRENT RANGE SELECTOR to the 190 -120 position and then adjust the FINE CURRENT ADJUSTMENT for 175 amps.
When a forceful "digging" arc is required, usually for
vertical and overhead welding, use a higher CURRENT
RANGE SELECTOR setting and lower open circuit
voltage. For example: to obtain 175 amps and a forceful arc, set the CURRENT RANGE SELECTOR to 240160 position and the FINE CURRENT ADJUSTMENT
setting to get 175 amps.
Some arc instability may be experienced with EXX10
electrodes when trying to operate with long arc techniques at settings at the lower end of the open circuit
voltage range.
CAUTION
DO NOT attempt to set the CURRENT RANGE
SELECTOR between the five points designated on the
nameplate. These switches have a spring loaded cam
which almost eliminates the possibility of setting this
switch between the designated points.
CURRENT
RANGE
SELECTOR
FIGURE B.2 – CURRENT CONTROLS
CURRENT RANGE
SELECTION
90
MIN.
ENGINE
PROTECTION
115 VOLTAC230 VOLTAC
FINE CURRENT
ADJUSTMENT
lassic
C
80
START
70
90
REMOTE
CONTROL
60 50
40
30
20
10100
240-160
220
MAX.
190-120
IDLER IGNITION
130-80
FINE CURRENT
ADJUSTMENT
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CLASSIC II
B-7 B-7
OPERATION
FIGURE B.3 – DIESEL ENGINE CONTROLS
CURRENT RANGE
SELECTION
90
MIN.
ENGINE
PROTECTION
115 VOLTAC230 VOLTAC
FINE CURRENT
ADJUSTMENT
lassic
C
80
START
70
90
REMOTE
CONTROL
60 50
40
30
20
10100
4
5
1. IDLER CONTROL TOGGLE SWITCH
2. IGNITION TOGGLE SWITCH
3. ENGINE PROTECTION WARNING LIGHT
4. START PUSHBUTTON
5. ENGINE HOUR METER
6. AMMETER
7. OIL PRESSURE GAUGE
DIESEL ENGINE CONTROLS
190-120
240-160
130-80
220
MAX.
IDLER IGNITION
1
2
3
6
7
See Figure B.3 for the location of the following features:
1. IDLER CONTROL TOGGLE SWITCH: Adjusts the
running speed of the engine. The switch has two
positions, "HIGH" and "AUTO." In "HIGH," the
engine runs continuously at high idle. In "AUTO,"
the idler control works as follows:
Welding: The engine accelerates to high speed
when the electrode touches the work and strikes a
welding arc. The engine returns to low idle approximately 15 seconds after welding stops, as long as
no auxiliary power is being drawn.
Auxiliary Power: The engine accelerates to high
speed when power is drawn at the receptacles for
lights or tools. The engine returns to low idle
approximately 15 seconds after demand for
auxiliary power stops.
2. IGNITION CONTROL TOGGLE SWITCH: Has
two positions, ON and OFF. When the switch is in
the ON position, the diesel engine can be started
by pressing the START pushbutton. When the
switch is placed in the OFF position, the engine
stops.
3. ENGINE PROTECTION WARNING LIGHT: Lights
when the engine protection system (an internal kill
switch) has shut down the engine. The system
activates in response to low oil pressure or high oil
temperature. If the light comes on during
startup cranking or after the engine starts, the
IGNITION switch must be placed in the OFF
position to reset the engine protection system.
4. START PUSHBUTTON: Press this button to start
the diesel engine. The IGNITION switch must be
in the ON position.
NOTE: If you press the START pushbutton when
the engine is running, you may damage the engine
flywheel gear or starter motor.
5. ENGINE HOUR METER: Records engine running
time. Use the meter to determine when to
perform required maintenance.
6. AMMETER: Shows whether the charging circuit
is performing its job of charging the battery when
the engine is running. The meter will register
discharge during starting, but then the needle
should return to a position slightly toward positive
during running. The needle will hold position in the
center when the engine stops.
7. OIL PRESSURE GAUGE: Indicates engine oil
pressure. If no oil pressure shows on the gauge
within 30 seconds after startup, the engine should
be stopped by placing the IGNITION switch in the
OFF position.
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CLASSIC II
B-8 B-8
OPERATION
ENGINE OPERATION
WARNING
DO NOT RUN THE ENGINE AT EXCESSIVE
SPEEDS. The maximum allowable high idle speed for
the Classic II is 1800 RPM, no load. Do NOT increase
the idle speed on the engine. Severe personal injury
and damage to the machine can result if it is operated
at speeds above the maximum rated speed.
Read and understand all safety instructions included in
the Deutz engine instruction manual that is shipped
with your Classic II.
BEFORE STARTING THE ENGINE
Check and fill the engine oil level:
1. Be sure the machine is on a level
surface.
2. Remove the engine oil dipstick and wipe it with a
clean cloth. Reinsert the dipstick and check the
level on the dipstick. See
Maintenance section of this manual.
Figure D.1
in the
Check and fill the engine fuel tank:
WARNING
Do not add 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. Remove the fuel tank cap.
2. Fill the tank to allow approximately 1/4 inch (5 mm)
of tank space for fuel expansion. DO NOT FILL
THE TANK TO THE POINT OF OVERFLOW.
3. Replace the fuel tank cap and tighten securely.
NOTE: USE DIESEL FUEL ONLY. Purchase diesel
fuel in quantities that will be used within 30 days, to
assure freshness.
3. Add oil (if necessary) to bring the level up to the full
mark. Do not overfill.
4. Replace the dipstick.
STARTING THE ENGINE
NOTE: Remove all loads connected to the AC power
receptacles before starting the diesel engine.
1. Place the IDLER switch in the "HIGH" position, the
IGNITION switch in the ON position and then press
the START button.
2. When the engine starts running, observe the oil
pressure. If no pressure shows within 30 seconds,
stop the engine and consult the engine operating
manual.
If the engine protection warning light comes on during
cranking or after start up, the IGNITION switch must be
placed in the OFF position to reset the engine protection system.
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CLASSIC II
B-9 B-9
OPERATION
STOPPING THE ENGINE
1. Remove all welding and generator power loads
and let the engine cool by running it for several
minutes at low idle.
2. Place the IGNITION switch in the OFF position.
When an engine is started for the first time, some of the
oil will be needed to fill the passages of the lubricating
system. Therefore, on initial starting, run the engine for
about five minutes and then stop the engine and
recheck the oil. If the level is down, fill to the full mark
again.
The engine controls were properly set at the factory
and should require no adjusting when received.
At the end of each day’s welding, drain accumulated
dirt and water from the sediment bowl under the fuel
tank and from the fuel filter per instructions in the
engine manufacturer’s operating manual. Refill the
fuel tank to minimize moisture condensation in the
tank. Also, running out of fuel tends to draw dirt into the
fuel system. Check the crankcase oil level.
In diesel engines, if the fuel supply is cut off or runs out
while the fuel pump is operating, air may be entrapped
in the fuel distribution system. If this happens, bleeding of the fuel system should not be required, since the
Deutz F3L-1011F engine is equipped with a self-prim-
ing feature.
COLD WEATHER STARTING
Follow the instructions on the nameplate and in the
engine manual shipped with the welder. With a fully
charged battery and the proper weight oil, the engine
should start satisfactorily even when the air temperature is down to about 0oF.
If the engine is frequently started below 10oF, you may
want to install the optional ether starter kit. Installation
and operating instructions are included in the kit. Use
ether starting only when required because excessive
use shortens engine life.
It is important to follow the engine manufacturer’s recommendations for oil and fuel to obtain satisfactory
cold weather performance. Consult the engine manual and the
Maintenance
section of this manual.
BREAK-IN PERIOD
Any engine will use a small amount of oil during its
break-in period. For the diesel engine on the Classic
II, break-in is about 200 running hours.
Check the oil twice a day during break-in. Change the
oil and oil filter cartridge after the first 50 hours of operation. Also change the fuel filter cartridge. For more
details, see the
Maintenance
section of this manual.
CAUTION
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During break-in, subject the Classic II to only moderate
loads. Avoid long periods running at idle. Before stopping the engine, remove all loads and allow the engine
to cool several minutes.
CLASSIC II
B-10 B-10
OPERATION
WELDING OPERATION
GENERAL INFORMATION
The Classic II can deliver from 40 to 325 amps of constant current for DC stick welding or DC semiautomatic wire feed welding (with wire feed module). DC TIG
welding is possible across the entire range from 40 to
325 amps. Output can be adjusted by setting the CURRENT RANGE SELECTOR and the FINE CURRENT
ADJUSTMENT on the output control panel to the settings that are best for your selected welding process.
IDLER OPERATION
Start the engine with the IDLER switch in the "HIGH"
position. Allow it to run at high idle speed for several
minutes to warm the engine. See
Specifications
speeds.
The idler is controlled by the IDLER toggle switch on
the welder control panel. The switch has two positions
as follows:
1 . In the "HIGH" position, the idler is off, and the
engine high speed is controlled by the governor.
in the
Installation
section for operating
Technical
2. In the "AUTO" position, the idler operates as follows:
a. When welding or drawing power for lights or
tools (approximately 100-150 watts minimum)
from the receptacles, the engine operates at
full speed.
b. When welding ceases or the power load is
turned off, a preset time delay of about 15 seconds starts. This time delay cannot be adjusted.
c. If the welding or power load is not re-started
before the end of the time delay, the idler
reduces the engine to low idle speed.
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CLASSIC II
B-11 B-11
OPERATION
TO USE THE CLASSIC II FOR DC
CONSTANT CURRENT STICK OR TIG
WELDING:
1. Remove the flange nuts from the weld output terminals and place the work and electrode welding
cables over the terminals. For positive electrode,
connect the electrode cable to the + terminal and
the work cable to –. For negative electrode,
reverse the electrode and work cables at the
welder’s output terminals. See Figure B.4.
Replace and tighten the flange nuts securely. Be
sure the connections are tight.
2. Select the appropriate electrode.
3. Attach the work clamp securely to the work you are
welding.
4. Insert the electrode into the electrode holder.
5. Start the Diesel Engine. See
this section of the manual.
6. Set the Idler Switch to "AUTO."
FIGURE B.4 – WELDING CIRCUIT CONNECTIONS FOR STICK WELDING
Engine Operation
in
7. Set the CURRENT RANGE SELECTOR to a setting equal to or slightly higher than the desired
welding current.
8. Set the FINE CURRENTADJUSTMENT to the setting that gives the best arc characteristics for the
range selected. See
in this section of the manual.
9. Strike an arc and begin welding.
After you finish welding:
1. Stop the engine. See
section of the manual.
2. Allow the electrode and work to cool completely.
3. Remove the work clamp from the work.
4. Remove any remaining piece of electrode from the
electrode holder.
Control of Welding Current
Engine Operation
in this
80
1. OUTPUT TERMINALS
2. ELECTRODE CABLE
3. ELECTRODE HOLDER
4. ELECTRODE
5. WORK PIECE
6. WORK CLAMP
7. WORK CABLE
1
2
34
5
7
6
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CLASSIC II
B-12 B-12
OPERATION
TO USE THE CLASSIC II FOR DC WIRE
FEED WELDING (CONSTANT VOLTAGE)
WITH WIRE FEED MODULE:
1. Connect the LN-25 or LN-7 Wire Feeder (with wire
feed module). Follow the installation instructions
provided with the wire feeder.
2. Select the appropriate electrode.
3. Start the diesel engine. See
this section of the manual.
Diameter (inches) Wire Speed Range Appropriate Current Range
Engine Operation
TABLE B.1
RANGE SETTINGS FOR WIRE SIZE/SPEED
(inches/minute)
4. Set the Idler Switch to "AUTO."
5. Set the CURRENT RANGE SELECTOR to a setting appropriate for your wire size and speed. See
Table B.1 for recommended settings.
6. Set the VOLTAGE ADJUSTMENT to the setting
that gives the best arc characteristics for the range
selected. See
section of the manual.
in
7. Strike an arc and begin welding.
Control of Welding Current
in this
.035 80-110 75 to 120 Amps
.045 70-130 120 to 170 Amps
.068 40-90 125 to 210 Amps
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CLASSIC II
B-13 B-13
OPERATION
AUXILIARY POWER
WARNING
Be sure that any electrical equipment plugged into the
generator AC power receptacles can withstand a ±10%
voltage and a ±3% frequency variation.
The AC auxiliary power, supplied as a standard, has a
rating of 3.0 kVA of 115/230V AC power (60 hertz).
One 115V duplex and one 230V grounding type receptacle are provided. The circuit is protected with circuit
breakers.
The rating of 3.0 kVA permits a maximum continuous
current of 13 amps to be drawn from the 230 volt
duplex receptacle. Or a total of 26 amps can be drawn
from the 115 volt duplex receptacle. The 115 volt
duplex receptacle has a configuration which permits 15
amps on CSA machines and 20 amps on non-CSA
machines to be drawn from either half. The total combined load of all receptacles is not to exceed 3.0 kVA.
You can use Table B.2,
Applications,
of the most common types of loads you can power with
the Classic II. Be sure to read the notes at the bottom
of the table.
to determine the wattage requirements
Generator Power
An optional power plug kit is available. When this kit is
specified, the customer is supplied with a plug for each
receptacle. See the
ual.
An optional GFCI 115 volt receptacle kit is also available. Note that the use of this GFCI kit reduces available current to 15 Amps from each half of the duplex
receptacle and to a total of 20 Amps of available 115 volt
power. See the
To use the generator as an auxiliary power supply:
1. Start the diesel engine. See
this section of the manual.
2. Set the IDLER switch to AUT O. Set the CURRENT
RANGE SELECTOR to "MAX." See
3. Plug the load(s) into the appropriate 1 15 volt or 230
volt power receptacle.
Accessories
Accessories
section of this man-
section of this manual.
Engine Operation
Figure B.1.
in
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CLASSIC II
B-14 B-14
OPERATION
TABLE B.2 – GENERATOR POWER APPLICATIONS
Suggested Power Applications Running Watts *Start-up Watts
*Air Compressor - 3/4 HP 1,250 3,100 - 5,000
*Airless Sprayer - 1/3 HP 600 1,500 - 2,400
Chain Saw 1,200
Circular Saw 1,200
Coffee Maker 1,000
*Deep Freezer 500 750 - 2,000
*Electric Motor - 1 HP 1,000 2,500 - 4,000
Electric Range (1 element) 1,500
Electric Skillet 1,250
*Furnace Fan - 1/3 HP 1,200 3,000 - 4,800
Portable Grinder (4 1/2”) 600
Portable Grinder (7”) 2,000
Halogen Work Light 500
Hand Drill - 1/4” 500
Hand Drill - 3/8” 700
1500 Watt Heater 1,750
Hedge Trimmer 450
Light Bulb 100
Reciprocating Saw 900
Radial Arm Saw 2,600
Radio 50
*Refrigerator/Freezer (small) 600 1,500 - 2,400
Slow Cooker 200
*Submersible Pump - 1 HP 1,000 2,500 - 4,000
*Sump Pump 600 1,500 - 2,400
Toaster 1,100
Weed Trimmer 500
Lincoln 100 or 125 Amp Wire Feeder/Welder 4,000
NOTES:
Wattages listed are approximate. Check your equipment for actual wattage. Equipment with unusually high
*START-UP WATTS are listed. For start-up of other equipment listed in the table, multiply RUNNING
WATTS by 2.
Multiple loads can be used as long as the total load does not exceed 3,000 watts. Be sure to start the
largest loads first. For example, a 1 HP motor needs approximately 1,000 watts while running but may
require 2,500 watts to start. Some inductive motors may require as much as 4 times running watts to start.
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CLASSIC II
Section C-1 Section C-1
TABLE OF CONTENTS
- ACCESSORIES -
Accessories...........................................................................................................................Section C
Options/Accessories ...................................................................................................................C-2
TIG Welding..........................................................................................................................C-3
Semiautomatic FCAW and MIG Welding.............................................................................C-3
Connection of Lincoln Electric Wire Feeders..............................................................................C-4
Connection of the LN-7 using K867 Universal Adapter........................................................C-4
Connection of the LN-7 using K584 Input Cable Assembly .................................................C-5
Connection of the LN-25 using K867 Universal Adapter......................................................C-6
Connection of the LN-25 “Across the Arc”...........................................................................C-7
Connection of the K488 SG Control Module and K487 Magnum Spool Gun......................C-8
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CLASSIC II
C-2 C-2
ACCESSORIES
OPTIONS/ACCESSORIES
The following options/accessories are available for
your Classic II from your local Lincoln Distributor.
Undercarriage - Under 10 MPH (K768) - For in-plant
or yard towing of the Classic II. Not intended for highway towing.
Undercarriage (K913-1) - Two-wheeled undercarriage
for in-plant and yard towing. Includes fender and light
kit; three optional hitch choices. For highway use, consult applicable federal, state, and local laws.
Power Plug Kit (K802-C) - Provides four 20 amp, 115
volt plugs and one 50 amp, dual voltage (115/230V),
full kV Aplug. NOTE: For CSAmachines and machines
with GFCI receptacles, use Power Plug Kit K802-R.)
Power Plug Kit (K802-D) - Provides four 15 amp, 115
volt plugs and one 50 amp, dual voltage (115/230V),
full kVA plug. (For non-CSA machines.)
CV Adapter - Below Code 10050 - (K384) - Provides
constant voltage output for semiautomatic welding.
Ether Start Kit (K887-1) - Automatic ether start kit provides cold weather starting assistance in temperatures
below 10oF (-12.2oC). Requires an ether tank that must
be purchased locally.
NOTE: Ether starting can contribute to shortened
engine life. Avoid unnecessary or indiscriminate use.
Linc Thaw™ Control Unit (L2964-5) - Includes meter
and fuses to protect the welder when thawing frozen
water pipes.
Wire Feed Module - Above Code 10050 (K623-1) -
Provides constant voltage output for semiautomatic
welding. Includes remote for CV mode and internal
“Cold Tip Contactor” for the LN-7 and LN-23P.
Accessory Kit (K703) - Includes the following:
• Thirty-five feet (10.5 meters) of #2 AWG electrode
cable
• Thirty feet (9.1 meters) of #2 AWG work cable
• Headshield with No. 12 filter.
• GC300 work clamp
• Cooltong™ 300 insulated electrode holder
The cables are rated at 250 amps, 40% duty cycle.
Spark Arrester Kit (K899-1) - A field-installed kit for
the Classic II diesel engine muffler exhaust pipe.
Includes a heavy-gauge steel, approved spark arrester,
mounting clamp and adapter.
Remote Control - 100 Feet, Below Code 10050 (K888-2) - Includes a control box with 100 ft. (7.5
meters) of 4-conductor cable. Allows output to be controlled remotely.
Remote Control Kit - Above Code 10050 - (K924-1)
- Includes a control box with 100 ft. (7.5 meters) of 4-
conductor cable. Allows output to be controlled
remotely.
GFCI Receptacle Kit (K896-2) - Includes a UL
approved 1 15 volt ground fault circuit interrupter receptacle (duplex type) with covers and installation instructions. Each half of the receptacle is rated 15 amps, but
the maximum total current from the GFCI duplex is limited to 20 amps. The GFCI receptacle replaces the
factory installed 115 volt duplex receptacle.
PIPE THAWING can result in fire, explosion, damage
to pipes, wiring, and the welder as well as other unsafe
or hazardous conditions. Do not use a welder to thaw
pipes before reviewing Lincoln Bulletin E695.1 (dated
October 1987 or later).
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WARNING
CLASSIC II
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