RETURN TO MAIN MENU CLASSIC III & CLASSIC III D ® ® IM529-A October, 1999 For Machines with Code Numbers 10033, 10061, 10072 or 10156 Supersedes IM482 Safety Depends on You Lincoln arc welding 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.
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 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 ARC WELDING CAN BE HAZARDOUS.
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.
iii iii SAFETY 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. 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.
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.
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! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 General Description..............................................................................................................A-2 Design Features ...............................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – CLASSIC III AND IIID Machine Product Name Ordering Information Classic III K1428-2 CSA@ Description DC Current Range Rated DC Output * (Fine Adjustment in Each Range) Amps / Volts / Duty Cycle 40 - 350 Amps Auxiliary Power Dimensions & Weight 3000 Watts, 60 Hz. AC 40.94 x 24.0 x 66.
A-2 INSTALLATION A-2 DESIGN FEATURES GENERAL DESCRIPTION The Classic® III and Classic® III D are heavy duty, engine driven, DC arc welding power sources capable of providing constant current output for stick welding or DC TIG welding. These welders are wound with all copper coils, rated at 300 amps/32 Volts, and provide other Classic features such as improved door latches and stainless hinges.
A-3 INSTALLATION PRE-OPERATION INSTALLATION WARNING A-3 STACKING Classic III and III D machines cannot be stacked. 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. -----------------------------------------------------------------------ELECTRIC SHOCK can kill.
A-4 A-4 INSTALLATION Lift Bail Polarity Control and Cable Sizes A lift bail is provided for lifting with a hoist. With the engine off, route the electrode and work cables through the strain relief bracket on the base and connect to the studs located below the fuel tank mounting rail. (See size recommendations below.) For positive polarity, connect the electrode cable to the terminal marked “+”. For Negative polarity, connect the electrode cable to the “-” stud.
A-5 A-5 INSTALLATION Battery Charging PRE-OPERATION SERVICE WARNING CAUTION GASES FROM BATTERY can explode. • Keep sparks, flame and cigarettes away. READ the engine operating and maintenance instructions supplied with this machine. WARNING BATTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when boosting, charging or working near battery. Fuel can cause fire or explosion. • Stop engine while fueling. • Do not smoke when fueling. • Do not overfill tank.
B-1 B-1 OPERATION ENGINE OPERATION Starting the Classic III D Continental TMD27 Diesel Engine WARNING 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. -----------------------------------------------------------------------ELECTRIC SHOCK can kill.
B-2 B-2 OPERATION Range Selector” to the 190-120 position and then adjust the “Fine Current Adjustment” for 175 amps. WELDER OPERATION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. FUMES & GASES can be dangerous. • Keep your head out of the fumes. • Use ventilation or exhaust to remove fumes from breathing zone. WELDING SPARKS can cause fire or explosion. • Keep flammable material away.
B-3 B-3 OPERATION Auxiliary Power The AC auxiliary power, supplied as a standard, has a rating of 3.0 kVA of 115/230 VAC (60 hertz). With the 3.0 kVA, 115/230 VAC 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.
B-4 OPERATION IMPORTANT: 1/2” clearance between the FLEXIBLE HOSE and the fuel tank edge is required. Also 2” clearance between FLEXIBLE HOSE and roof. 4. Reconnect negative battery cable. FIGURE 2 A B C A. FLEXIBLE HOSE B. HEAT COLLECTOR SHIELD C.
C-1 ACCESSORIES OPTIONAL FEATURES C-1 (Field Installed) Accessory Set (K703) - Includes electrode and work cables, headshield, work clamp and electrode holder. Hi-Freq™ (K799) - Provides high frequency plus gas valve for DC TIG welding. Wire Feed Module (K623-1) - Provides constant voltage (CV) output with improved arc stability for Innershield welding. Excellent for MIG welding. Recommended wire feeders are the LN-7, LN-23P and LN-25. (Factory installed on the K1428-3 and K1433-2).
D-1 D-1 MAINTENANCE 4. When necessary, remove the sediment bowl, if so equipped, from beneath the fuel tank and clean out any accumulated dirt and water. MAINTENANCE WARNING Have qualified personnel do the maintenance work. Turn the 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 their removal is complete.
D-2 MAINTENANCE Replace brushes when they wear within 1/4” of the pigtail. A complete set of replacement brushes should be kept on hand. Lincoln brushes have a curved face to fit the commutator. Have an experienced maintenance man seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact is made across the full face of the brushes. After stoning, blow out the dust with low pressure air.
MAINTENANCE D-3 D-3 ENGINE SERVICE Hours Between Servicing Daily 50 250 500 I Maintenance Item Type or Capacity Engine Oil (1) R Engine Oil (1) 7 qts (Including Filter) R Oil Filter Fram #PH-8A Purolator #PER-1A I Air Cleaner C Air Cleaner R Air Cleaner Cartridge C PCV System I Fan Belt Tension C Throttle or Governor Linkage C or R Spark Plugs (Gap=.032”) (4) I Donaldson #P181050 Nelson #70206N Champion #RN12YC Cooling System (3) I = Inspect C Cooling System 9.
E-1 TROUBLESHOOTING E-1 TROUBLESHOOTING WARNING Have qualified personnel do the troubleshooting work. Turn the 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 their removal is complete. Always use the greatest care when working near moving parts. Do not put your hands near the engine cooling blower fan.
E-2 E-2 TROUBLESHOOTING WELDER TROUBLESHOOTING TROUBLE 1. 2. (1) Machine fails to hold the heat consistently. Welder starts but fails to generate current. CAUSES WHAT TO DO a. Rough or dirty commutator. a. Commutator should be turned or cleaned. b. Brushes may be worn down to limit. b. Replace brushes. c. Field circuit may have variable resistance connection or intermittent open circuit due to loose connection or broken wire. c.
E-3 E-3 TROUBLESHOOTING ELECTRONIC IDLER TROUBLESHOOTING GUIDE Engine Will Not Return to Idle in Approximately 15 Seconds Set Idler Control Switch to the Auto Position Check Continuity of Idler Control Switch Continuity Good 1. 2. 3. 4. Open Reed Switch in Weld Circuit May be Closed. Check Continuity of Idler Solenoid Coil (8.5 - 9.0 ohms) & Leads. Check Ground Connections in Idle Circuit. Replace P.C. Board.
E-4 E-4 TROUBLESHOOTING ENGINE TROUBLESHOOTING - (TM27 Gasoline Engine Only) TROUBLE 1. 2. 3. 4. 5. 6. Engine fails to start Low oil pressure. Light not lit when engine is running. Lack of power. Overheating. Knocking. Surging. CAUSES WHAT TO DO a. Out of fuel. a. Fill with gasoline. b. Clogged fuel system. b. Check all lines to the carburetor. c. Choke not closing tightly. c. Loosen choke cable screw and slack off choke wire. d. Ignition switch shorted or open. d. Replace.
E-5 E-5 TROUBLESHOOTING ENGINE TROUBLESHOOTING - (TM27 Gasoline Engine Only) TROUBLE CAUSES WHAT TO DO 7. Large decrease in speed. a. Misadjusted governor spring adjusting screw. a. Adjust screw until speed does not drop more than 100 rpm ± 25 rpm when arc is struck. If surge occurs, eliminate it with the control rod. If high idle speed changes, readjust the high idle speed screw. ** 8. Unable to strike an arc. a. Idle speed screw is misadjusted. a.
GROUND CLASSIC III AND IIID K924-1 TO ENGINE GROUND R 602 4 G - S B MOTOR STARTING H G OIL PRESSURE LIGHT CONNECT TO CASE U RESISTORS B Y W X 60D CONNECTORS INLINE OUTPUT TERMINALS NEGATIVE CV DAMAGE TO THE REMOTE CONTROL AND/OR MACHINE WILL RESULT IF THE RED AND BLACK LEADS ARE CONNECTED IN THE CLASSIC III. CONNECTED ON THIS MACHINE. THE RED AND BLACK LEADS ARE USED ON CLASSIC I CONNECTOR "J8" ON MACHINE. PLUG "P8" ON REMOTE CONTROL TO MACHINE FROM CONNECTOR "J8".
CLASSIC III AND IIID 50 - 602 4 60A 58B A - 50C B 51 CONNECT TO CASE CONNECTORS INLINE G #2 HEAVY LEAD LEAD MODULE FEED WIRE TRANSFORMER CURRENT * B CB3 K924-4 B W * SEE BELOW 1 602 42 600 41 SWITCH FOR LOCAL OR P8 6 5 4 3 2 R B DAMAGE TO THE REMOTE CONTROL AND/OR MACHINE WILL RESULT IF THE RED AND BLACK LEADS ARE CONNECTED IN THE CLASSIC III D. CONNECTED ON THIS MACHINE. THE RED AND BLACK LEADS ARE USED ON CLASSIC I CONNECTOR "J8" ON MACHINE.
CENTER OF GRAVITY WITH CLASSIC III AND IIID PART NO. S10766-5 WELDER CLASSIC III & IIID MOUNTING HOLES. G J K (4.00) 10.2 F A B C 146.6 168.3 22.1 (66.25) (57.70) (8.70) D METRIC cm (ENGLISH in.) HOLE SKID MOUNTING O 1.54 (.56) 1.54 (.56) TRAILER BUT NO FUEL. OIL AND WATER IN ENGINE, N.B. O N.A. NOTES: H E N.B. A B D C (4.00) 10.2 HOLE E F G H J K 1.54 (.56) SKID MOUNTING O 94.3 (37.12) N.A. 8.26 105.8 58.4 71.0 32.6 (23.00) (27.94) (12.82) (41.66) (3.
NOTES CLASSIC III AND IIID
NOTES CLASSIC III AND IIID
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● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el 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 your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● 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- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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