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RETURN TO MAIN INDEX
SVM 137-A
January, 1998
CLASSIC III/IIID
Gasoline & Diesel Engine Driven DC Arc Welding Power Source
For use with machine code numbers 10061, 10072 or 10156.
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be in-
creased by proper installation . . .
and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PR
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Safety.................................................................................................................................................i-iv Installation.............................................................................................................................Section A Technical Specifications.....................................................................................................
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Section A-1 Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Installation Technical Specifications..............................................................................................................A-2 Safety Precautions ......................................................................................................................A-3 Location and Ventilation ..............................................................................................................A-3 St
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - CLASSIC III AND IIID INPUT - ENGINE Manufacturer Description Speed Displacement Ignition Capacities Classic III: 4 cyl., 4 cycle 1725 RPM 164.7 cu. in. Electric Fuel: 15 gal. Continental Water-cooled Full load (2700 cc) (57 liters) TM27 Gasoline 38.9 HP @ 1800 RPM Oil: 7 qt. 1700 RPM High idle (6.7 liters) Classic IIID: 4 cyl., 4 cycle 1350 RPM Water/coolant: 9.3 qt. Continental Water-cooled Low idle (8.8 liters) TMD27 Diesel 45 HP @ 1700 RPM RATE
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A-3 A-3 INSTALLATION Read this entire installation section before you LOCATION AND VENTILATION start installation. Always operate the Classic III and Classic IIID with the doors closed. Leaving the doors open changes the designed air flow and may cause overheating. Always SAFETY PRECAUTIONS operate the welder with the case roof on and all machine components completely assembled. WARNING Whenever you use the welder, be sure that clean cool- Do not attempt to use this equipment until you have ing
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A-4 A-4 INSTALLATION STACKING WARNING Classic III and Classic IIID machines CANNOT be Keep hands away from the engine muffler or HOT stacked. engine parts. • Stop the engine when fueling. TILTING • Do not smoke when fueling. Place the machine on a secure, level surface whenev- • Remove the fuel cap slowly to release pressure. er you use it or store it. Any surfaces you place it on • Do not overfill the fuel tank. other than the ground must be firm, non-skid, and structurally sound. • Wipe u
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A-5 A-5 INSTALLATION COOLING SYSTEM TRAILER The cooling system has been filled at the factory with a If you use a non-Lincoln trailer, you must assume 50-50 mixture of ethylene glycol antifreeze and water. responsibility that the method of attachment and usage Check the radiator level and add a 50-50 solution as does not result in a safety hazard nor damage the needed. (See your engine manual or antifreeze con- welding equipment. Some of the factors to be consid- tainer for alternate antifreeze
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A-6 A-6 INSTALLATION ELECTRICAL OUTPUT CAUTION CONNECTIONS • Loose connections will cause the output terminals to See Figure A.1 for the location of the 115 and 230 volt overheat. The terminals may eventually melt. receptacles, weld output terminals, and ground stud. • Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another. WELDING CABLE CONNECTIONS CABLE INSTALLATION AND CABLE SIZES With the engine off, connect the electrode an
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A-7 A-7 INSTALLATION For further protection against electric shock, any elec- MACHINE GROUNDING trical equipment connected to the generator recepta- According to the United States National Electrical cles must use a three-blade, grounded type plug or an Code, the frame of this portable generator is not Underwriter's Laboratories (UL) approved double insu- required to be grounded and is permitted to serve as lation system with a two-blade plug. Lincoln offers an the grounding means for cord conne
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A-8 A-8 NOTES Classic III and IIID Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION - Operation...............................................................................................................................Section B Safety Instructions.......................................................................................................................B-2 General Description ....................................................................................................................B-2 Recommen
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B-2 B-2 OPERATION WARNING OPERATING INSTRUCTIONS Read and understand this entire section before operat- ing your Classic III or Classic IIID. ENGINE EXHAUST can kill. SAFETY INSTRUCTIONS • Use in open, well ventilated areas or vent exhaust to the outside. WARNING • Do not stack anything on or near the engine. Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include MOVING PARTS can injure. important saf
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B-3 B-3 OPERATION RECOMMENDED APPLICATIONS DESIGN FEATURES • All copper windings for long life and dependable WELDER operation. The Classic III and Classic IIID provide excellent con- • Constant current DC Stick welding (SMAW) process stant current DC welding output for stick (SMAW) weld- capability with output range from 40 - 350 DC amps. ing and for DC TIG welding. When equipped with the wire feed module, they also offer constant voltage out- • Constant current DC TIG Welding with output a
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B-4 B-4 OPERATION WELDING CAPABILITY LIMITATIONS The Classic III and Classic IIID are rated 300 amps, 32 The Classic III and Classic IIID are not recommended volts constant current DC at 50% duty cycle based on for any processes besides those that are normally per- a ten minute time period. Longer duty cycles at lower formed using DC stick welding (SMAW) and DC TIG output currents are possible. welding. Specific limitations on using the Classic III and Classic IIID for these processes are descr
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B-5 B-5 OPERATION CONTROLS AND SETTINGS The welder/generator controls are located on the the case front. Welding output terminals and ground Output Control Panel of the machine case front. stud are located on the machine left side, under the Engine idler control and start/stop controls are also on door. See Figures B.1, B.2 and B.3 and the explana- tions that follow. FIGURE B.1 – OUTPUT CONTROLS 1 8 2 3 6 4 5 1 7 1. CURRENT RANGE SELECTOR 2. FINE CURRENT ADJUSTMENT 3. 230 VOLT DUPLEX RECEPTACLE
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B-6 B-6 OPERATION A high open circuit voltage setting provides the soft CONTROL OF WELDING CURRENT "buttering" arc with best resistance to pop-outs pre- ferred for most welding. To get this characteristic, set CAUTION the CURRENT RANGE SELECTOR to the lowest set- ting that still provides the current you need and set the FINE CURRENT ADJUSTMENT near maximum. For • DO NOT turn the CURRENT RANGE SELECTOR example: to obtain 175 amps and a soft arc, set the while welding because the current may arc
