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IM 513-B
February, 2011
™
WIRE FEED MODULE
For Wire Feed Module Code Number: 10066, 10914, 11806
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
OPERATOR’S MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
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.
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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
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.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
• AC Welder with Reduced Voltage Control.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum-
stances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
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.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
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.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
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.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Jan ‘09
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
process used and properly operating
regulators designed for the gas and
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.
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.
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.
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.
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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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 though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
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.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
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 cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Jan ‘09
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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
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
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 lev-
age, 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.
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.
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.
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.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
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.
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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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 ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
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.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
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, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Mar. ‘93
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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!
Thank You
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
for any updated information.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
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vi
TABLE OF CONTENTS
PAGE
SPECIFICATIONS.........................................................................................................................................8
GENERAL DESCRIPTION ............................................................................................................................8
DESIGN FEATURES.....................................................................................................................................8
RECOMMENDED WIRE FEEDERS AND ACCESSORIES..........................................................................8
INSTALLATION INSTRUCTIONS
Safety Precautions...............................................................................................................................9
Machine Grounding..............................................................................................................................9
Assembly into Engine Driven Welders
Classic Series (K6090-5, K1406-3 and -4, K1428-2, K1433-1, K1643-1, K1754-1), K1643-3, K1643-5,
K1643-7, K1643-9
Pipeliner Series (K6090-7 and -9), K6090-10, K6090-11
SA-250 (K1283-4 & -8) or 350SA (K1314-4), SAE-300 (K3003-1)..........................................................9
Pre-Installation........................................................................................................................9
Tools Required........................................................................................................................9
Assemble into Classic Series Pipeliner, SA-250 and 350SA Installation Sequence (Codes 10066, 10914) ...........10 thru 15
Assemble into SAE-300 Installation Sequence (Code11806) ..................................................................................16 thru 18
Connection of Lincoln Electric Wire Feeders......................................................................................19
Connection of the LN-25 to the Wire Feed Module................................................................19
Connection of the LN-7, LN-7 GMA to the Wire Feed Module...............................................19
Connection of the LN-23P to the Wire Feed Module .............................................................19
OPERATING INSTRUCTIONS
Additional Safety Precautions.............................................................................................................20
Wire Feed Module Operation..............................................................................................................20
Output ........................................................................................................................................20
Controls ........................................................................................................................................20
Recommended Processes............................................................................................................20
MAINTENANCE
Engine Speed Adjustments.................................................................................................................20
TROUBLESHOOTING
Troubleshooting Chart ..................................................................................................................20 thru 22
Troubleshooting Procedures.........................................................................................................23 thru 25
DIAGRAMS
Wire Feed Module Wiring Diagram.....................................................................................................26
Wire Feed Module / Engine Welder - Connection Diagram................................................................27
Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250, 350SA & SAE-300 w/WFM to LN-23P w/ Adapter kit...........28
Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250, 350SA & SAE-300 w/WFM to K867 Plug to LN-7 ...............29
Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250, 350SA & SAE-300 w/WFM to K864 Adapter to LN-7 & Remote Control..........................30
Connection Diagram-All Classic, All Pipeliner, SA-250, 350SA & SAE-300 w/WFM to K867 Universal Adapter .................31
Connection Diagram-All Classic, All Pipeliner, SA-250, 350SA & SAE-300 w/WFM to LN-25 w/ K444-2 Option.................32
Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250
,
350SA & SAE-300 w/WFM to LN-25 w/ K431, K433 & K432-”L” Option .............................33
Connection Diagram-Classic II, III, IIID, 300D, 300G, SA-250, 350SA & SAE-300 w/WFM to K867 Plug to K487 / K488 / K492 Spool Gun....................34
OUTPUT CURVES
Classic I, Pipeliner 200D and 200G with Wire Feed Module Output Curves......................................35
Classic II with Wire Feed Module Output Curves ...............................................................................36
Classic III and 300G with Wire Feed Module Output Curves..............................................................37
Classic IIID, Classic 300D, SA250 & SAE-300 (Codes 10890 & above) with Wire Feed Module Output Curves..................38
350SA and SA-250 (Codes 10889 and below ) Perkins with Wire Feed Module Output Curves......39
PARTSꢀLIST..................................................................................................................................P-231 Series
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SPECIFICATIONS
K623-1 Wire
Module to be Field-
Installed
Feed
Factory-Installed
Wire Feed Module
& Welder Per:
Rating @ 60%
Duty Cycle
Max. Output
@ 35% Duty
Cycle
Auxiliary
Power
On: (1)
K6090-6
K6090-5 (CSA)
K6090-7
Classic I
Not Available
200 Amps
@ 35V
250 Amps
@ 30V
Pipeliner 200G
Pipeliner 200D
Classic II
K6090-9,-10,11(CSA)
K1406-4
K1406-3 (CSA)
K1406-6
K1406-5 (CSA)
250 Amps
@ 35V
310 Amps
@ 32V
K1283-4 (CSA)
K1283-8 (CSA)
K1283-5 (CSA)
Not Available
SA250
Auxiliary Power
is Reduced 25%
in the CVꢀMode
300 Amps
@ 35V
325 Amps
@ 34V
K1314-5 (CSA)
K1428-3 (CSA)
250 Amps
@ 35V
310 Amps
@ 32V
350SA
(International)
K1314-4 (CSA)
K1428-2 (CSA)
Classic III
Classic IIID
Classic 300D
K1433-2 (CSA)
K1643-2 (CSA)
K1643-4 (CSA)
K1643-6 (CSA)
K1643-8 (CSA)
K1643-10 (CSA)
Not Available
K1433-1 (CSA)
K1643-1 (CSA)
K1643-3 (CSA)
K1643-5 (CSA)
K1643-7 (CSA)
K1643-9 (CSA)
K3003-1 (CSA)
K1754-1
300 Amps
@ 35V
325 Amps
@ 34V
SAE-300
Classic 300G
Not Available
(1) K623-1 Wire Feed Module can only be installed on welders with code 10061 and above.
• Greatly enhanced welding arc performance. Now a
wider range of wire electrodes and processes are
supported by this device.
• Improved arc starting characteristics.
• Low spatter MIG welding with CO Gas.
2
GENERAL DESCRIPTION
The Wire Feed Module (WFM) is an additional output
control device designed to be easily installed into the
Classic® and Pipeliner Series of Engine Welders or
the SA-250 Perkins or 350SA Perkins engine driven
welders (with code 10061 and above). The WFM
modifies the dynamic output characteristics of the
welder to provide excellent voltage control for semiau-
tomatic wire electrode welding and other open arc
processes. With the module installed, the welder can
be easily set to operate in either the constant voltage
or the standard constant current modes. The constant
voltage mode is adjusted with the controls convenient-
ly mounted on the control panel or with an optional
remote control. The main module contains a capacitor
bank, electronic control circuit and a “COLDꢀTIP” con-
tactor. This module easily attaches to the welders fuel
tank support. Field installation takes approximately 60
minutes.
• Built into the WFM is a power contactor that pro-
vides a “COLD” electrode when the gun trigger is
released.
• Simplified field installation process. All control wiring
connections between the welder, the control panel,
and the WFM are easily made with in-line plug type
connections.
• Includes thermostatic protection to protect the
welder from over current and over temperature.
RECOMMENDED WIRE FEEDERS
AND ACCESSORIES
The WFM is designed to work with the complete
family of LN-7, LN-25, and LN-23P wire feeders.
DESIGN FEATURES
• Easy access to the controls located on the welder
control panel.
Please refer to the connection diagram in the back of
this manual for details.
– 8 –
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Where an engine driven welder is connected to
premises wiring such as that in your home or shop, its
frame must be connected for the system earth
ground. See further connection instructions in the
section entitled “Standby Power Connections” as well
as the article on grounding in the latest U.S. National
Electrical Code and the local code.
INSTALLATION INSTRUCTIONS
Safety Precautions
WARNING
Do not attempt to use this equipment until you
have thoroughly read all operating and mainte-
nance manuals supplied with your machine. They
include important safety precautions, detailed
engine starting, operating and maintenance
instructions and parts lists.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a
solid earth ground such as a metal water pipe going
into the ground for at least 10 feet and having no insu-
lated joints or to the metal framework of a building
which has been effectively grounded. The U.S.
National Electrical Code lists a number of alternate
means of grounding electrical equipment. A machine
Have a qualified technician do the maintenance
and troubleshooting work. Turn engine off before
working inside the machine. In some cases it may
be necessary to remove safety guards to perform
required maintenance. Remove guards only when
necessary and replace them when the mainte-
nance requiring removal is complete. Always use
the greatest care when working near moving
parts.
grounding stud marked with the symbol
on the Generator Mount of the welder.
is provided
ASSEMBLY INTO ENGINE DRIVEN WELDERS:
CLASSIC SERIES (K6090-5, K1406-3, -4,
K1428-2, K1433-1, K1643-1, -3, -5, -7, -9, K1754-1)
Pipeliner (K6090-7, -9, -10, -11) and
SA-250 (K1283-4, -8) or 350SA (K1314-4).
SAE-300 (K3003-1
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
Pre Installation
Unpack WFM and check the contents against the
listed items.
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
ITEM
DESCRIPTION
QTY.
1
2
3
4
5
6
Control Module Assembly
Control Panel Assembly
CV Negative Output Panel Assembly
Mounting Hardware Packet
Instruction Manual and Literature
WFM Nameplate SAE-300
1
1
1
1
1
1
Only qualified personnel should install, use, or
service this equipment.
------------------------------------------------------------------------
Machine Grounding
Because a portable engine driven welder or generator
creates its own power, it is not necessary to connect
its frame to an earth ground, unless the machine is
connected to premises wiring (your home, shop, etc.)
Tools Required
• Large and Small Flat Head Screwdriver
• Pliers
• 3/32” Allen Wrench
• 3/8” Drive Ratchet with Small Extension
• 1/2” Socket
To prevent dangerous electric shock, other equipment
to which an engine driven welder supplies power
must:
• 9/16” Deep Well Socket
• 3/4” Socket
• 5/16” Nut Driver and Socket
• 1/2” Open End Wrench
• 9/16” Open End Wrench
• Voltmeter
a) Be grounded to the frame of the welder using a
grounded type plug,
or
b) Be double insulated.
When a welder is mounted on a truck or trailer, its
frame must be securely connected to the metal frame
of the vehicle.
– 9 –
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ASSEMBLE INTO CLASSIC SERIES
PIPELINER, SA-250 and 350SA INSTALLA-
TION SEQUENCE:
(For codes 10066, 10914)
1) Remove current range selector and fine current
adjustment control knobs from front of machine.
(small flat screwdriver and 3/32” Allen wrench.)
2) Remove 5 upper nameplate screws, or fastener
buttons.
3) Break-off upper half of machine nameplate.
Nameplate is scored for easy bending and break-
off.
4) Install control panel assembly. (Wiring connec-
tions will be made later).
5) Secure control panel assembly with (7) screws
from the mounting hardware packet.(5/16” Nut
Driver)
6) Reinstall current range selector and fine current
adjustment control knobs to front of machine.
(Small flat screwdriver and 3/32” Allen wrench).
7) (For Classic II models ONLY) Remove the side
panel. (3/8” Socket wrench).
– 10 –
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8) Remove 2 screws from brush wraparound cover.
Loosen and rotate the wraparound cover until neg-
ative brushholder is exposed. (Large flat head
screwdriver and pliers).
9) The negative brushholder is in the 11:00 position
looking at the control panel end of the generator.
Remove negative brushholder 5/16” bolt. (1/2”
Socket, ratchet, and small extension.)
10) (NOTE:) If you are installing the WFM on the
Classic I, you must change the “250H” thermostat
to the thermostat marked “200”, (provided in the
mounting hardware packet). Make certain the nut
and bolt is tightened and the 608 and 609 leads
are connected to the thermostat. (1/2” Socket,
ratchet, and 1/2” open end.)
11) Position Wire Feed Module control box next to
the right side of the machine (as shown). Place
one plain washer (provided in the mounting hard-
ware packet) over each mounting stud.
– 11 –
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12) Feed power cable assembly through the rectan-
gular window on the bottom of the generator.
13) Connect power cable/thermostat assembly and
the existing cables to the negative brushholder
using the .75” long 5/16” hex head cap screw,
(provided in the mounting hardware packet).
Make certain the thermostat assembly does not
touch the brushholder spring and the cable is
clear of any moving parts. Make certain the ther-
mostat is assembled under the cable connec-
tions. (1/2” socket, ratchet, small extension).
14) Reposition the brush wraparound cover and
tighten with the hardware removed in step 8.
Keep the tightening flanges below the 3:00
position. (Large flat head screwdriver and pliers.)
– 12 –
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15) Locate and remove 12-pin jumper plug and install
12-pin connector from control box to 12-pin con-
nector. Connect control box 6-pin connector to
control panel 6-pin connector. Connect control
box 9-pin connector to control panel 9-pin con-
nector.
For Classic 300D with Codes (11547, 11548,
11572, 11573) and Pipeliner 200D Code 11591.
Remove U (BLUE) and 602C wires from flyback
bridge. See machine wiring diagram. Keep U and
602C lead terminals connected and insulate with
electrical tape.
16) For Classic I, III, IIID, 300D, 300G and SA250
(Codes 10889 and Below), 350 SA, Pipeliner
200D and 200G remove two (2) fuel tank hold
down bolts on the right side of the machine and
save hardware. (9/16” deep well socket, ratchet,
and 9/16” open end wrench.) For the Classic II
and SA250 (Codes 10890 and Above), do not
remove the fuel tank hold down bolts. On these
machines, the WFM mounts to the adjacent holes
with two (2) 1” spacers, flat washer, lock washer
and hex nuts, (provided in the mounting hardware
packet).
17) For the Classic I & III, the carburetor choke cable
must be unclamped at the frame. Reclamp at the
flange provided on the WFM.
– 13 –
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18) Position control box into place. On some models,
the control box must be maneuvered out, up and
back to clear the door latch catch. On Classic II
machines, make sure the battery cable is not
caught between the wire feed module and generator.
19) Install flat washer, lockwasher, and hex nut to
control box mounting studs and tighten. (9/16”
Socket, ratchet, and 9/16” open end wrench).
20) Remove both the positive and negative output
terminal bolts. (3/4” Socket wrench).
NOTE: On the Classic II machines, the weld out-
put terminals are located on the right side (facing
the control panel) of the machine under the side
access door. On all other machines the weld out-
put terminals are located on the left side (facing
the control panel) of the machine under the left
access door.
21) Using bolts from step 20, connect control box’s
positive and negative power cables and
machine’s positive and negative output cables to
the respective output terminals. Tighten bolts.
(3/4” Socket wrench).
NOTE: Use caution when routing the CV power
cables; ensure that there is adequate clearance
from any sharp surfaces.
22) Connect the remaining lead from the control box
to CV output terminal, using bolt supplied with the
output terminal assembly. Output panel leg attach-
es to the front of the machine (3/4” Socket
wrench).
– 14 –
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23) Drive three (3) self-tapping screws into output
panel. (5/16” Nut driver or socket wrench).
NOTE: The CV outout terminal assembly mounts
under the weld output terminals on all machines.
24) With the CC/CV switch set to CC, start the engine
and check the open circuit voltage on the output
terminals. The voltage should be 80 to 100 volts
with the thermostat and range switch set at maxi-
mum. NOTE: OCV may be slightly higher when
the unit is cold. (Voltmeter)
25) Switch the CC/CV switch to CV and check the
voltage between the Positive output terminal and
the CV output terminal. The voltage should be 45
to 55 volts at maximum output position and 7 to
12 volts at minimum output position. (Voltmeter)
26) (For Classic II’s only) Reassemble the side
panel. (3/8” Socket wrench)
– 15 –
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5. Remove 2 screws from brush wraparound cover.
Loosen and rotate the wraparound cover until neg-
ative brushholder is exposed. (Large flat head
screwdriver and pliers).
ASSEMBLY INTO SAE-300 WELDER:
INSTALLATION SEQUENCE:
(For Code 11806 )
1. Remove the bottom 3 mounting screws from the
upper control nameplate. Keep the screws for later
use to fasten the WFM nameplate. Once, the
screws have been removed snap / break off the
lower section of the nameplate (the section with the
welder name on it).
1.
R
m
s
B
e
o
n
s
e
c
o
6. The negative brushholder is in the 11:00 position
looking at the control panel end of the generator.
Remove negative brushholder 5/16” bolt. (1/2”
Socket, ratchet, and small extension.)
1. Remove 3 mounting screws.
2. Snap or Break off lower section
on this dotted line.
2. Attach the WFM nameplate to the upper control
panel on the welder below the original nameplate
with 5 mounting screws.
5
i
c
s
5 mounting screws.
3. Remove the 2 toggle switches, amphenol & cap
and the potentiometer with knob from the original
control panel assembly. DO NOT disconnect the
wiring from the switches.
7. Position Wire Feed Module control box next to the
right side of the machine (as shown). Place one
plain washer (provided in the mounting hardware
packet) over each mounting stud.
4. Insert the local / remote toggle switch (most wires
connected to it) first into the upper control panel on
the welder with the mounting tab down. Next mount
the potentiometer and secure the knob. Next mount
the cv / cc toggle switch with the mounting tab
down. Mount the amphenol and cap.
– 16 –
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8. Feed power cable assembly through the rectangu-
lar window on the bottom of the generator.
11 Locate and remove 12-pin jumper plug and install
12-pin connector from control box to 12-pin con-
nector. Connect control box 6-pin connector to
control panel 6-pin connector. Connect control
box 9-pin connector to control panel 9-pin connec-
tor.
9. Connect power cable/thermostat assembly and the
existing cables to the negative brushholder using
the .75” long 5/16” hex head cap screw, (provided
in the mounting hardware packet). Make certain
the thermostat assembly does not touch the brush-
holder spring and the cable is clear of any moving
parts. Make certain the thermostat is assembled
under the cable connections. (1/2” socket, ratchet,
small extension).
12. Remove two (2) fuel tank hold down bolts on the
right side of the machine and save hardware.
13. Position control box into place. On some models,
the control box must be maneuvered out, up and
back to clear the door latch catch. On SAE-300 4
plastic fuel tank mounting bolts require loosening
to slide the tank towards the engine.
10. Reposition the brush wraparound cover and
tighten with the hardware removed in step 5.
Keep the tightening flanges below the 3:00
position. (Large flat head screwdriver and pliers.)
– 17 –
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14. Mount the WFM using .62 spacers, flat washer,
lock washer and hex nuts provided in the mount-
ing hardware packet. Tighten all fuel tank bolts to
rail.
18. Drive three (3) self-tapping screws into output
panel. (5/16” Nut driver or socket wrench).
NOTE: The CV outout terminal assembly mounts
under the weld output terminals on all machines.
15. Remove both the positive and negative output ter-
minal bolts. (3/4” Socket wrench).
19. With the CC/CV switch set to CC, start the engine
and check the open circuit voltage on the output
terminals. The voltage should be 80 to 100 volts
with the thermostat and range switch set at maxi-
mum. NOTE: OCV may be slightly higher when
the unit is cold. (Voltmeter)
16. Using bolts from step 15, connect control box’s
positive and negative power cables and
machine’s positive and negative output cables to
the respective output terminals. Tighten bolts.
(3/4” Socket wrench).
NOTE: Use caution when routing the CV power
cables; ensure that there is adequate clearance
from any sharp surfaces.
20. Switch the CC/CV switch to CV and check the
voltage between the Positive output terminal and
the CV output terminal. The voltage should be 45
to 55 volts at maximum output position and 7 to
12 volts at minimum output position. (Voltmeter)
17. Connect the remaining lead from the control box
to CV output terminal, using bolt supplied with the
output terminal assembly. Output panel leg attach-
es to the front of the machine (3/4” Socket
wrench).
– 18 –
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Connection of the LN-7, LN-7 GMA to the Wire
Feed Module
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
Requires K584-(L) input cable, K864 adapter and
optionally the K857 for remote control. See the con-
nection diagram in the Diagrams section.
WARNING
Shut off welder before making any electrical
connections.
a) Shut the welder off.
b) Connect the electrode cable from the LN-7 to the
positive stud of the welder. Connect the work
cable to the CV negative stud of the welder.
(NOTE: Reverse the connections for negative
electrode polarity.)
Connection of LN-25 to the Wire Feed Module
The LN-25 with internal “COLDꢀTIP” contactor requires
the K444-2 Control Cable for voltage control at the feed-
er.
c) Connect the LN-7 per the instructions on the
appropriate connection diagram.
The LN-25 with internal “Cold Tip” Contactor can be
operated without a control cable (Volt sensing mode) if
voltage control at the wire feeder is not desired.
d) Set the “Current Range” switch to the “190-120”
position for most common processes, this may be
changed if a different arc characteristic is desired.
See the appropriated connection diagrams in the
Diagrams section.
e) Set the “LOCAL/REMOTE” control toggle switch to
“REMOTE”.
a) Shut off the welder.
b) Connect the electrode cable from the LN-25 to the
positive stud of the welder. Connect the work cable
to the CV negative stud of the welder. (NOTE:
reverse the connections for negative electrode polari-
ty.)
f) Set the “IDLER” switch to the “AUTO” position. The
“HIGH” position may be required when used with
some low current processes.
Connection of the LN-23P to the Wire Feed Module
c) For LN-25’s with internal contactor, connect the K444-
2 remote voltage control cable from the LN-25 to
the14-pin receptacle on the control panel.
Requires the K350-1 adapter kit. Adapter kit provides
an isolated trigger voltage and allows connection of
two wire feeders. See connection diagram in the
Diagrams section.
d) Attach the single lead from the front of the LN-25 to
the work using the spring clip on the end of the lead.
This is a control lead to supply current to the wire
feeder motor; it does not carry welding current. Set
the polarity switch on the LN-25 to the proper polarity.
a) Shut the welder off.
b) Connect the electrode cable from the LN-23P to
the CV negative output stud of the engine welder.
Connect the work cable to the positive output stud.
e) Set the “Current Range Selector” switch to the “190-
120” position for most common processes, this may
be changed if a different arc characteristic is pre-
ferred.
c) Mount K350-1 adapter per instructions included
with adapter.
d) Connect LN-23P per instructions on appropriate
connection diagram.
f) Set the “LOCAL/REMOTE” Control switch to the
“REMOTE” position. If operating an LN-25 with inter-
nal “Cold Tip” Contactor but without the K444-2
Remote Voltage Control Cable set the “Local/Remote”
Control Switch to the “Local” position.
e) Connect control lead marked “21” to work connec-
tion. Refer to connection diagram in Diagrams
section for routing instructions and wire size.
f) Set the “Current Range Selector” switch to the
“190-120” (middle position) for most common
processes, this may be changed if a different arc
characteristic is preferred.
g) Set the “IDLER” switch to the “HIGH” position. The
“AUTO” position may be used with some high current
processes.
g) Set the “LOCAL/REMOTE” control toggle switch to
“REMOTE”.
h) Set the idler switch to the “AUTO” position. The
“HIGH”ꢀposition may be required when welding
with low current processes.
– 19 –
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Recommended Processes
OPERATING INSTRUCTIONS
Additional Safety Precautions
Refer to latest Lincoln Bulletins on (Gas Metal Arc
Welding) and (Innershield Welding) with the fol-
lowing electrodes:
WARNING
The output terminals are energized when the
engine is running. The CV output will be de-ener-
gized only if WFM mode switch is in remote posi-
tion.
.030” Super Arc L-50, 56 with C-25 or CO2 Gas
.035” Super Arc L-50, 56 with C-25 or CO2 Gas
.045” Super Arc L-50, 56 with C-25 or CO2 Gas
WIRE FEED MODULE OPERATION
.068” NR-203MP
5/64” NR-203MP
5/64” NR-207
Output
5/64” NR-203Nil%
For constant voltage welding, place the CC/CV mode
switch in the CV position. Connect the wire feeder to
the CV negative output terminal and connect the work
to the positive standard output terminal. For electrode
positive, reverse the output leads. The negative stan-
dard output terminal is not used for CV welding of
either polarity. Refer to diagrams section to determine
the correct connection to the remote control recepta-
cle.
MAINTENANCE
Engine Speed Adjustments
CAUTION
When the WFM is in the “CV” mode, the maximum
auxiliary power will be reduced by 25%. To obtain
maximum auxiliary output, place the CC/CV switch in
the CC position.
Any increase in the engine RPM by changing the
governor setting or overriding the throttle linkage
will cause an increase in the A.C. auxiliary volt-
age. If this voltage goes above 140 volts, the con-
trol circuits of the WFM and wire feeders will be
damaged. The engine governor setting is pre-set
at the factory -- do not adjust above RPM specifi-
cations listed in the engine welder operating man-
ual.
If the current rating of the welder is exceeded, a ther-
mostat will reduce the output voltage to approximately
5 volts. The thermostat will reset automatically as the
machine cools. If the thermostat trips, lower the wire
feed speed and output voltage or reduce Duty Cycle.
Controls
TROUBLESHOOTING CHART
WARNING
The output voltage is set with the voltage control dial
mounted on the control panel. Set the “Current
Range Selector" to the “190-120” position for optimum
welding characteristics. Changing the "Current Range
Selector” affects arc characteristics. Setting the
“Current Range Selector” one position to the right of
the "190-120” position will give a softer arc. If this
switch is placed one position to the left from the "190-
120” set point, the machine will produce a crisp arc
characteristic. The setting of the “Fine Current
Adjustment" has no effect on the operation in “CV”
mode.
Have qualified personnel do the maintenance and
troubleshooting work. Turn the engine off before
beginning to troubleshoot.
For Coarse Current Control on the SAE-300 see oper-
ator manual.
– 20 –
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TROUBLESHOOTING
TROUBLE
CAUSES
WHATꢀꢀTOꢀꢀDO
1. Machine has no output a. Electrode or work lead loose or
with machine switch in
CV mode.
a. Repair Connection.
broken.
b. No generator output.
b. Refer to quick check procedure for
generator only.
c. CR4 is not working, or no input to
CR4.
c. Refer to procedure for Checking the
Cold Tip Contactor (CR4).
d. Protective circuits operating due to
output short circuit.
d. Turn engine off. Remove short
circuit.
e. Broken or loose wiring connec-
tions.
e. Broken or loose connections from
WFM to control panel and engine
welder. Refer to wiring diagram to
check.
f. Defective P.C. Board
f. Refer to P.C. Board Troubleshooting
Procedure.
2. Machine has minimum a. No shunt field voltage.
output and no control.
a. In CV mode, check for 10-60 VDC
across pin 8 of J3 and pin 1 of J4 on
WFM P.C. Board.
-- Check for loose or broken
connections in wiring harness.
-- Refer
to
Troubleshooting Procedure.
P.C.
Board
b. Excessive current, thermal shut-
down.
b. Remove load and allow machine to
cool down. If output returns after
cool down, reduce output or duty
cycle.
-- Check for continuity at quick con-
nects between leads 609 and 608
inside the WFM.
-- Check wiring harness with these
connections.
-- Check continuity of the thermostat
located on the generator negative
brushholder.
c. Open in feedback circuitry.
c. Check in-line connector, P.C. Board,
and wiring harness plugs, especially
leads 667 and 621.
d. Voltage adjust potentiometer circuit
open or misconnected.
d. Refer to procedure for checking
Voltage Control Potentiometer on
Machine. Check wiring of lead num-
bers 75, 76, and 77.
e. Defective P.C. Board.
e. Refer to P.C. Board Troubleshooting
Procedure.
– 21 –
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TROUBLESHOOTING
TROUBLE
CAUSES
WHATꢀꢀTOꢀꢀDO
3. Machine does not have a. Voltage adjust potentiometer leads
maximum output.
a. Check and repair broken leads.
open.
b. Voltage adjust potentiometer
defective.
b. Refer to procedure for checking
Voltage Control Potentiometer on
Machine.
c. Faulty P.C. Board.
c. Refer to Procedure for Replacing
P.C. Boards.
4. Poor welding charac- a. Poor work or electrode connection.
teristics. Poor arc
striking with sticking or b. Improper settings for wire feed
a. Check and clean all connections.
b. Refer to a welding procedures guide
for proper settings.
“blast-offs”,weld poros-
ity, narrow and ropey
speed and volts.
looking
electrode stubbing into
the plate.
bead,
or c. Capacitor Bank Contactor not
working.
c. Refer to the procedure for Checking
the Capacitor Bank Contactor CR3.
d. Capacitors in power source output
circuit failed. A failure is indicated
if the small vent plug on the top of
a capacitor is raised or blown out.
d. Replace entire bank of capacitors,
observe correct polarity. Do not
replace individual capacitors.
WARNING: The liquid electrolyte in
these capacitors is toxic. Avoid con-
tact with any portion of your body.
Clean up vented electrolyte using
rubber gloves and a water damp-
ened cloth. Any electrolyte which
gets on skin, clean with soap and
water.
e. Opening in feedback circuit.
f. Faulty P.C. Board.
e. Check wiring and P.C. Board wiring
harness plugs. Pay special attention
to leads 667 and 621.
f. Refer to procedure for replacing P.C.
Board.
– 22 –
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b) Poor lead termination, such as a poor
contact or a short to adjacent connection
or surface.
TROUBLESHOOTING PROCEDURES
A.
P.C. Board Troubleshooting Procedures
c) Shorted or open leads, or other external
leads.
Perform the following checks before replacing the
P.C. Board.
d) Foreign matter or interference behind the
P.C. Boards.
1. Remove the cover to the Wire Feed Module
box located on the right side of the machine.
With the engine running the green and red
LED on the P.C. Board must be glowing. If
not, check the following:
3. If P.C. Board is visibly damaged mechanically,
inspect for cause then remedy before
installing a replacement P.C. Board.
a) Check for loose connections in the P.C.
Board plugs, pay close attention to J3.
If there is damage to the P.C. Board or if
replacing P.C. Board corrects problem, return
it to the local Lincoln Electric Field Service
Shop.
b) With machine running at high idle, check
the following voltages accessible at P.C.
Board plug J3:
C.
Output Voltage
Lead Number
610 - 600
Voltage
Constant Voltage Mode -- The open circuit
voltage in CV mode is 7-55 volts DC. If any
other conditions exist, refer to the
Troubleshooting Chart.
120 + 13/-10 Volts DC
If these voltages are not present, check the
wiring connections between the engine welder
and the Wire Feed Module. If wiring is good,
then refer to the “Quick Check Procedure for
Generator Only”. If generator is operating
properly, refer to “Procedure for Replacing
P.C. Boards”.
D.
Procedure for Checking the Cold Tip
Contactor (CR4)
1. If there is no output during the initial start
up of the machine, check to see if the
“Local/Remote” switch is in “LOCAL”, if so,
switch to “REMOTE” and then back to
“LOCAL” and check for output voltage. If
switch is in “Remote” switch to the
“LOCAL” position and check for output
voltage.
B.
Procedures for Replacing P.C. Boards
Before replacing a P.C. Board which is suspected of
being defective, visually inspect the P.C. Board in
question for any electrical or mechanical damage to
any of its components and conductors on the back of
the board.
2. Open side panel of wire feed module.
With machine running, verify the P.C.
Board is working by checking to see if the
green and red LED’s are on. If LED’s are
not on, see P.C. Board Troubleshooting
Procedures. If the LED’s are on, check
the voltage between the top left stud of
the cold tip contactor (CR4) and the posi-
tive output stud. The voltage should mea-
sure between 7 and 55 volts DC depend-
ing on the position of the CV voltage con-
trol setting. Try adjusting the voltage con-
trol to see if this voltage changes. If volt-
age is present, go to step 3. If no voltage
is present, check for loose cable or wiring
connections. If voltage is still not present,
refer to Troubleshooting Chart.
1. If there is no visible damage to the P.C.
Board, install a new one and see if this reme-
dies the problem. If the problem is remedied,
reinstall the old P.C. Board to see if the prob-
lem still exists. If it does no longer exist with
the old P.C. Board:
a) Check the P.C. Board harness connector
pins for corrosion, contamination, or loose-
ness.
b) Check leads in the plug harness for loose
or intermittent connection.
2. If P.C. Board is visibly damaged electrically,
before possibly subjecting the new P.C. Board
to the same cause of failure, check for possi-
ble shorts, opens, or grounds caused by:
a) Frayed or pinched lead insulation.
– 23 –
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3. Check to see that leads 2 and 4 are con-
nected. Put a voltmeter across these
leads and the meter should read close to
zero volts. If voltage reads approximately
15 volts, then the trigger circuit (leads 2-4)
is open. Check the wiring from the WFM
control box to the WFM control panel for
loose or broken connections. Turn
machine off and check the operation of
the “LOCAL/REMOTE” switch by connect-
ing an ohmmeter across leads 2 and 4 at
the switch with switch positioned in
“LOCAL” mode, if resistance is high or
open replace the switch.
3. Disconnect P.C. Board harness plug P2
from the P.C. Board.
4. With an ohmmeter on X1K, connect it to
lead 76A and 77A on S2. Rotate the volt-
age control potentiometer. The resistance
reading should be from approximately
zero to 10K ohms. Check the resistance
reading between lead 75 on potentiometer
and 77A on switch S2. The reading must
be 10K ohms. No reading will indicate an
open potentiometer and a low reading will
indicate a shorted or partially shorted
potentiometer; in either case, replace.
Reconnect P.C. Board plug P2.
4. Check for coil voltage across leads 633
and 634 at P2 plug to the P.C. Board. If
voltage is present, check for loose or bro-
ken leads from the plug to the contactor
coil. If connections are good and voltage
correct, replace contactor CR4.
G.
Remote Control Check
1. The remote control connector pin assign-
ments are: pin G-75A, pin F-76B, pin E-
77B. Make sure remote control connec-
tions are tight and check for any physical
damage to the control cable. Connect an
ohmmeter across lead 75 and 76B on
switch S2. With S2 in remote mode,
rotate the potentiometer in the remote
control. The resistance reading should
vary from zero to 10K ohms. Repeat with
ohmmeter across 77B and 76B with the
same results. Connect an ohmmeter
across 75 and 77B. The reading should
be 10K ohms. If an open or short is mea-
sured replace the potentiometer.
5. If no voltage is present at CR4 contactor
coil, see Procedure for Replacing P.C.
Boards.
E.
Procedure for Checking the Capacitor
Bank Contactor (CR3)
1. Verify machine is in CV (wire) mode.
Measure voltage across leads 630 and
631 at the contactor. The voltage should
be approximately 120 +/- 15V DC with
engine set on high idle. If voltage is not
present, go to step 3 of this procedure.
2. If the proper voltage is present at leads
630 - 631, measure the voltage between
L2 terminal and terminal opposite L2. If
the voltage is equal to the output voltage
across the positive and negative output
terminals, replace the contactor CR3.
3. If the proper voltage is not present at
leads 630 - 631, check the wiring to CR3
coil for loose or broken connections. If
connections are good, see Procedure for
Replacing P.C. Boards.
F.
Checking Voltage Control Potentiometer
on Machine
1. Turn machine off.
2. Remove the control panel screws and
open the front cover.
Turn the
“LOCAL/REMOTE” switch (S2) to
“REMOTE”.
– 24 –
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H.
Quick Check Procedure for Generator Only
1. Try running the machine with the mode
switch on STICK (CC mode), and check
output at CC+ and CC- studs. If a voltage
of 45 to 100 volts DC is measured, the
generator is working properly. If the gen-
erator is working properly, the problem
exists in the Wire Feed Module. Refer to
Troubleshooting chart.
2. If there is no generator output in step 1,
proceed with the following:
a) If jumper plug P10 is available, a quick
check can be performed to see if the
generator is operating properly.
Disconnect P5 and connect P10.
When P10 is connected, the machine
will only run in Stick (CC mode). If
generator voltage is present between
CC+ and CC- studs, then the genera-
tor is operating properly.
b) The measured voltage should be
between 43-100 volts DC. This level
may be higher when the machine is
cold. If the generator is operating
properly, disconnect P10 and recon-
nect P5. Refer to Wire Feed Module
Troubleshooting chart.
3. If the generator is not working with the
jumper plug P10, then refer to the engine
welder Troubleshooting chart.
– 25 –
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5 0 R 2
N E G
O P S
– 26 –
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–
– 27 –
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2
0 5
1
1 2 5
7 7
6 7
5 7
4 0 6
2 0 6
1 2 5
7 7
6 7
5 7
4 0 6
2 0 6
– 28 –
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– 34 –
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CLASSIC I and PIPELINER 200D and 200G with WIRE FEED MODULE
Reference Output Curves
For Selected Open Circuit Volts (OCV) at Wire Feeder
= WIRE FEEDER OCV
60
55
50
45
40
35
30
25
20
15
10
5
0
0
75 100 125 150 175 200 225 250 275 300
LOAD AMPS (DC)
25
50
C
A
I
For
n
S
c
E
O
I
e
R
20
u
D
and
s
2
0
a
W
I
e
der
D
M
U
60
=
R
F
DE
R
CV
354045
20530
1
L
– 35 –
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CLASSIC II with WIRE FEED MODULE
Reference Output Curves
For Selected Open Circuit Volts (OCV) at Wire Feeder
= WIRE FEEDER OCV
60
55
50
45
40
35
30
25
20
15
10
5
F
C
A
S
R
f
t
e
W
E
E
D
M
D
L
56
1
L
0
0
75 100 125 150 175 200 225 250 275 300 325 350 375 400
LOAD AMPS (DC)
25
50
– 36 –
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CLASSIC III and 300G with WIRE FEED MODULE
Reference Output Curves
For Selected Open Circuit Volts (OCV) at Wire Feeder
= WIRE FEEDER OCV
60
55
50
45
40
35
30
25
20
15
10
5
C
A
S
C
a
f
n
03
G
w
t
u
C
I
E
F
E
60
4055055
2053035
=
I
E
D
O
V
1
L
A
A
P
(
)
0
0
75 100 125 150 175 200 225 250 275 300 325 350 375 400
LOAD AMPS (DC)
25
50
– 37 –
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CLASSIC IIID, CLASSIC 300D, SA250 and SAE-300
(CODES 10890 and above) with WIRE FEED MODULE
Reference Output Curves
For Selected Open Circuit Volts (OCV) at Wire Feeder
= WIRE FEEDER OCV
60
55
50
45
40
35
30
25
20
15
10
5
0
0
75 100 125 150 175 200 225 250 275 300 325 350 375 400
LOAD AMPS (DC)
25
50
– 38 –
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0
0
2
0
7
1
L
25
D
1
S
75
2
25
2
75
3
3
5
3
3
400
152205
30540
4505
60
=
F
D
O
V
R
f
e
O
t
t
u
e
3
0
S
a
S
-2
(
D
1
8
9
N
E
W
w
h
IR
F
D
D
EL
350 SA and SA-250 (CODES 10889 AND BELOW) with WIRE FEED MODULE
Reference Output Curves
For Selected Open Circuit Volts (OCV) at Wire Feeder
= WIRE FEEDER OCV
60
55
50
45
40
35
30
25
20
15
10
5
0
0
75 100 125 150 175 200 225 250 275 300 325 350 375 400
LOAD AMPS (DC)
25
50
– 39 –
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NOTES
WIRE FEED MODULE
– 40 –
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NOTES
WIRE FEED MODULE
– 41 –
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•
•
Do not touch electrically live parts or
electrode with skin or wet clothing.
Insulate yourself from work and
ground.
•
•
Keep flammable materials away.
•
•
Wear eye, ear and body protection.
WARNING
Spanish
•
No toque las partes o los electrodos
bajo carga con la piel o ropa moja-
da.
Mantenga el material combustible
fuera del área de trabajo.
Protéjase los ojos, los oídos y el
cuerpo.
AVISO DE
PRECAUCION
French
•
•
Aislese del trabajo y de la tierra.
Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
Isolez-vous du travail et de la terre.
•
•
Gardez à l’écart de tout matériel
inflammable.
•
•
Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
•
•
German
Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
Isolieren Sie sich von den
Entfernen Sie brennbarres Material!
Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
•
Elektroden und dem Erdboden!
Portuguese
•
•
Não toque partes elétricas e electro-
dos com a pele ou roupa molhada.
Isole-se da peça e terra.
•
Mantenha inflamáveis bem guarda-
dos.
•
Use proteção para a vista, ouvido e
corpo.
ATENÇÃO
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE
CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE
ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU
SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT
ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE
EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO-
DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS
SIND EBENFALLS ZU BEACHTEN.
– 42 –
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•
•
Keep your head out of fumes.
Use ventilation or exhaust to
remove fumes from breathing zone.
•
•
Turn power off before servicing.
•
•
Do not operate with panel open or
guards off.
WARNING
Spanish
•
•
Los humos fuera de la zona de res-
piración.
Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
•
•
Débranchez le courant avant l’entre-
tien.
•
•
N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
•
•
Gardez la tête à l’écart des fumées.
Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ATTENTION
German
Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen;
Maschine anhalten!)
Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
•
•
Vermeiden Sie das Einatmen von
Schweibrauch!
Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
•
•
Não opere com as tampas removidas.
Desligue a corrente antes de fazer
serviço.
•
•
Mantenha-se afastado das partes
moventes.
Não opere com os paineis abertos
ou guardas removidas.
•
•
Mantenha seu rosto da fumaça.
Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
•
Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES
DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
– 43 –
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• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com
– 44 –
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