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Lincoln Electric CLASSIC IM553-C manual

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Table of contents for the manual

  • Page 1

    OPERA TOR’S MANUAL For use with machines having Code Numbers 10219, 10219CV, 10220, 10220CV, 10628, 10629,10872 and 10910 IM553-C July, 2003 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation [...]

  • Page 2

    CLASSIC II DEUTZ 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. _______________________________[...]

  • Page 3

    CLASSIC II DEUTZ ii SAFETY ii ARC RA YS 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 [...]

  • Page 4

    CLASSIC II DEUTZ FOR ELECTRICALL Y 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. Nati[...]

  • Page 5

    CLASSIC II DEUTZ iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse é[...]

  • Page 6

    v v 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

  • Page 7

    vi vi T ABLE OF CONTENTS Page Safety ......................................................................................................................... i-iv ______________________________________________________________________________ Installation ..............................................................................................[...]

  • Page 8

    A-1 CLASSIC II DEUTZ A-1 TECHNICAL SPECIFICA TIONS - CLASSIC II DEUTZ K1406-( ) Make/Model Description Speed (RPM) Bore x Stroke Starting Capacities System Deutz 3 cylinder High Idle 1800 3.58” x 4.13 12VDC battery Fuel: 15gal. F3L 1011F 28.5 HP Low Idle 1350 (91mm x 105mm) & Starter 57 L Diesel Engine @ 1700 RPM Full Load 1725 SA-250 Oil: 6.[...]

  • Page 9

    A-2 CLASSIC II DEUTZ A-2 SAFETY PRECAUTIONS Exhaust Spark Arrester Some federal, state or local laws may require that diesel engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard mufflers included with these welders do not qualify as spark arreste[...]

  • Page 10

    A-3 CLASSIC II DEUTZ A-3 Undercarriages If the user adapts a non-Lincoln undercarriage, he must assume responsibility that the method of attach- ment 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 undercarriage vs. weight of Lincoln equipment[...]

  • Page 11

    A-4 CLASSIC II DEUTZ A-4 Battery Charging The Classic II is equipped with a wet charged battery. The charging current is automatically regulated when the battery is low (after starting the engine) to a trickle current when the battery is fully charged. When replacing, jumping or otherwise connecting the battery to the battery cables, the proper pol[...]

  • Page 12

    B-1 CLASSIC II DEUTZ B-1 SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. ---------------------------------------------------[...]

  • Page 13

    B-2 OPERA TION B-2 Auxiliary Power 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 c[...]

  • Page 14

    D-1 CLASSIC II DEUTZ D-1 Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be neces- sary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is com- plete. Always use the [...]

  • Page 15

    D-2 D-2 Commutator and Brushes The generator brushes are properly adjusted when the welder is shipped. They require no particular attention. DO NOT SHIFT THE BRUSHES or adjust the rocker set- ting. Shifting of the brushes may result in: • change in machine output • commutator damage • excessive brush wear Periodically inspect the commutator, [...]

  • Page 16

    E-1 TROUBLESHOOTING E-1 CLASSIC II DEUTZ ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet cloth- ing. • Insulate yourself from work and ground • Always wear dry insulating gloves. ------------------------------------------------------------------------ ENGINE EXHAUST can kill. • Use in open, well[...]

  • Page 17

    E-2 TROUBLESHOOTING E-2 CLASSIC II DEUTZ Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLE[...]

  • Page 18

    E-3 TROUBLESHOOTING E-3 CLASSIC II DEUTZ Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLE[...]

  • Page 19

    E-4 CLASSIC II DEUTZ E-4 ELECTRONIC IDLER TROUBLESHOOTING GUIDE Engine Will Not Return To Idle In Approximately 15 Seconds Set Idler Control Switch To The Auto Position Remove All Weld and Auxiliary Power Loads Check Continuity of Idler Control Switch Engine Will Not Pick Up Speed When: 1 . Check for break in Red lead and repair. 2 . Replace reed s[...]

  • Page 20

    F-1 CLASSIC II DEUTZ F-1 CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR. LEAD COLOR CODE B-BLACK G-GREEN N-BROWN B R + - + - Y R W B B W W SLIP RINGS TO IRON R N A 54 3 2 1 ALTERNATOR AUXILIARY POWER WINDINGS CURRENT TRANSFORMER CB1 115 VOLT RECEPTACLE 230 VOLT RECEPTACLE Y NEGATIVE SELECTOR SWITCH WELDER LEAD BLOCK AC AC CR2 REED RELAY 42 602A[...]

  • Page 21

    F-2 CLASSIC II DEUTZ F-2 R SWITCH START STARTING MOTOR + ENGINE + 52 D+ D- B+ W 1 + A FUEL SOLENOID IDLER SOLENOID SENSOR 7 8 3 4 5 6 ALTERNATOR OIL PRESSURE GAUGE SI GND OIL TEMP. - HOUR METER - 50A 50 51 51A 60 56 55 60B L9920 CLASSIC II - WIRING DIAGRAM 60E 1 2 3 4 1 2 3 45 6 7 8 9 10 IDLER/ENGINE PROTECTION P.C. BOARD 53B 56A 57 60A ENGINE FAIL[...]

  • Page 22

    F-3 CLASSIC II DEUTZ F-3 CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR. LEAD COLOR CODE B-BLACK G-GREEN N-BROWN B R + - + - Y R W B B W W SLIP RINGS TO IRON R N A 54 3 2 1 ALTERNATOR AUXILIARY POWER WINDINGS CURRENT TRANSFORMER CB1 115 VOLT RECEPTACLE 230 VOLT RECEPTACLE Y NEGATIVE SELECTOR SWITCH WELDER LEAD BLOCK AC AC CR2 REED RELAY 42 602A[...]

  • Page 23

    F-4 DIAGRAMS F-4 CLASSIC II DEUTZ C L11863 CLASSIC II - W IRING D IAGRAM LEAD COLOR CODE B-BLACK G-GREEN N-BROWN R-RED U-BLUE W- WHI TE Y-YELLOW ELECTRICAL SY MBOLS PER E1537 CONTRO L PANEL COMPONENTS SHOWN AS VIEW ED FROM REAR. NEUTRAL BONDED TO FRAME NEUTRE RACCORD E AU BATI ’ 700B 700A + - + - Y R 400D B 10 W W SLIP RINGS TO IRON 346 347 A 54 [...]

  • Page 24

    F-5 CLASSIC II DEUTZ F-5 PART NO. WELDER A B C D E F G H A CONTROL PANEL F G B H D E C O HOLE O MOUNTING HOLE N.A. N.B. NOTES: OIL AND WATER IN ENGINE, BUT NO FUEL. N.A. CENTER OF GRAVITY WITH O S10766-6 J J K K L DIMENSION PRINT S10766 METRIC cm (ENGLISH in.) 150.7 (59.32) 4.8 (1.90) 58.4 (23.00) 79.2 (31.19) 43.8 (17.25) 105.8 (41.66) 19.1 (7.51)[...]

  • Page 25

    NOTES CLASSIC II DEUTZ[...]

  • Page 26

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabi READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE PARA EL [...]

  • Page 27

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

  • Page 28

    • 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 • World's Leader in Welding and Cutting Products •[...]