IM553

OPERATOR’S MANUAL

For use with machines having Code Numbers 10219, 10219CV, 10220, 10220CV, 10628, 10629,10872 and 10910

IM553-CJuly, 2003

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.

CLASSIC™ IIDC ARC WELDER WITH DEUTZ F3L-1011F ENGINE

• 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 •

Copyright © 2003 Lincoln Global Inc.

CLASSIC II DEUTZ

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework 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.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, coversand devices in posi-

tion and in good repair.Keep hands, hair, clothing and toolsaway from V-belts, gears, fans and all other moving partswhen starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

CLASSIC II DEUTZ

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.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 bareskin 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 fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating products.

5.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b. Mar ‘95

CLASSIC II DEUTZ

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

CLASSIC II DEUTZ

ivSAFETYiv

Mar. ‘93

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui parraissentdans ce manuel aussi bien que les précautions de sûretégénérales suivantes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles unegrande partie du corps peut être en contact avec lamasse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à soud-er parce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se pro-téger contre les chutes dans le cas ou on recoit un choc. Nejamais enrouler le câble-électrode autour de n’importe quellepartie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux durayonnement de l’arc et des projections quand on soudeou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflamma-bles.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protectionlibres de l’huile, tels que les gants en cuir, chemise épaisse,pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec lesvapeurs du solvant pour produire du phosgéne (gas forte-ment toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au codede l’électricité et aux recommendations du fabricant. Le dis-positif de montage ou la piece à souder doit être branché àune bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du posteseront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’ interieur de poste, ladebrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

vv

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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 ithandy 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:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound 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 youhave 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 packetaccompanying 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.

vivi

TABLE OF CONTENTSPage

Safety .........................................................................................................................i-iv______________________________________________________________________________

Installation .......................................................................................................Section ATechnical Specifications ........................................................................................A-1Safety Precautions.................................................................................................A-2Spark Arrester........................................................................................................A-2Location / Ventilation .............................................................................................A-2

Grounding .......................................................................................................A-2Lift Bail ............................................................................................................A-2Undercarriages................................................................................................A-2Polarity Control and Cable Sizes ....................................................................A-3

Pre-Operation Engine Service ...............................................................................A-3Oil ....................................................................................................................A-3Fuel .................................................................................................................A-3Battery Charging .............................................................................................A-3Muffler .............................................................................................................A-3

______________________________________________________________________________Operation ............................................................................................................Section B

Safety Precautions.................................................................................................B-1General Description ...............................................................................................B-1

Starting and Stopping the Engine ..................................................................B-1Cold Weather Starting ...........................................................................................B-1

Duty Cycle.......................................................................................................B-1Control of Welding Current..............................................................................B-1Idler ................................................................................................................B-2Auxiliary Power Operation...............................................................................B-2

______________________________________________________________________________Maintenance........................................................................................................Section D

General Instructions ..............................................................................................D-1Cooling System .....................................................................................................D-1Bearings ................................................................................................................D-1Commutator and Brushes......................................................................................D-2Idler Maintenance..................................................................................................D-2Nameplates ...........................................................................................................D-2

______________________________________________________________________________Troubleshooting .................................................................................................Section E______________________________________________________________________________Diagrams .............................................................................................................Section F______________________________________________________________________________Parts List ....................................................................................................P219, P78, P25______________________________________________________________________________

A-1

CLASSIC II DEUTZ

A-1

TECHNICAL SPECIFICATIONS - CLASSIC II DEUTZ K1406-( )

Make/Model Description Speed (RPM) Bore x Stroke Starting CapacitiesSystem

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 LDiesel Engine @ 1700 RPM Full Load 1725SA-250 Oil: 6.3 Qts.

6.0 L

INPUT - DIESEL ENGINE

RATED OUTPUT - WELDER

HEIGHT WIDTH DEPTH WEIGHT

42.94 in. 24 in. 60 in. 1340 lbs.(608 kg)

(1040 mm) (610 mm) (1524 mm)

OUTPUT - WELDER AND GENERATOR

Duty Cycle Constant Current Volts at Rated Amps

Current Range NEMA Output Rating Auxiliary Power

40-325 Amps 250 amps 30 volts 115/250 VAC@60% Duty Cycle 3kVA

60% Duty Cycle

PHYSICAL DIMENSIONS

40% 300 amps (DC ) 32 volts60% 250 amps (DC ) 30 volts100% 200 amps (DC ) 28 volts

INSTALLATION

A-2

CLASSIC II DEUTZ

A-2

SAFETY PRECAUTIONS

Exhaust Spark Arrester

Some federal, state or local laws may require thatdiesel engines be equipped with exhaust sparkarresters when they are operated in certain locationswhere unarrested sparks may present a fire hazard.The standard mufflers included with these welders donot qualify as spark arresters. When required by localregulations, install the optional spark arrester kit.Spark arresters must be installed and properly main-tained, instructions are included in the kit.

Use of an incorrect arrester may lead to engine damageor performance loss.-----------------------------------------------------------Location/VentilationAlways operate the welder with the doors closed.Leaving the doors open changes the designed air flowand may cause overheating.

The welder should be located to provide an unrestrict-ed flow of clean, cool air. Also, locate the welder sothat engine exhaust fumes are properly vented to anoutside area.

DO NOT MOUNT OVER COMBUSTIBLE SUR-FACES.Where there is a combustible surface directly understationary or fixed electrical equipment, the surfaceshall be covered with a steel plate at least.06”(1.6mm) thick, which shall extend not more than5.90”(150mm) beyond the equipment on all sides.------------------------------------------------------------------------Grounding

According to the United States National ElectricalCode, the frame of this portable generator is notrequired to be grounded and is permitted to serve asthe grounding means for cord connected equipmentplugged into its receptacle.

Some state, local, or other codes or unusual operatingcircumstances may require the machine frame to begrounded. It is recommended that you determine theextent to which such requirements may apply to yourparticular situation and follow them explicitly. Amachine grounding stud marked with the symbolis provided on the welding generator frame foot. (If anolder portable welder does not have a grounding stud,connect the ground wire to an unpainted frame screwor bolt.) In general, if the machine is to be grounded,it should be connected with a #8 or larger copper wireto a solid earth ground such as a metal water pipegoing into the ground for at least ten feet and havingno insulated joints, or to the metal framework of abuilding which has been effectively grounded. TheU.S. National Electrical Code lists a number of alter-nate means of grounding electrical equipment.

Lift Bail

A lift bail is provided for lifting with a hoist.

Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.------------------------------------------------------------------------

ELECTRIC SHOCK can kill.• Do not touch electrically live parts or

electrode with skin or wet clothing.• Insulate yourself from work and

ground• Always wear dry insulating gloves.

------------------------------------------------------------------------ENGINE EXHAUST can kill.• Use in open, well ventilated areas or

vent exhaust outside.

------------------------------------------------------------------------MOVING PARTS can injure.• Do not operate with doors open or

guards off.• Stop engine before servicing.• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at thefront of this operator’s manual.

-----------------------------------------------------------

WARNING

CAUTION FALLING EQUIPMENT can causeinjury.• Do not lift this machine using lift bale

if it is equipped with a heavy accesso-ry such as a trailer or gas cylinder.

• Lift only with equipment of adequatelifting capacity.

• Be sure machine is stable when lifting.----------------------------------------------------------------------

WARNING

INSTALLATION

CAUTION

A-3

CLASSIC II DEUTZ

A-3

Undercarriages

If the user adapts a non-Lincoln undercarriage, hemust assume responsibility that the method of attach-ment and usage does not result in a safety hazard nordamage the welding equipment. Some of the factorsto be considered are as follows:

1. Design capacity of undercarriage vs. weight ofLincoln equipment and likely additional attach-ments.

2. Proper support of, and attachment to, the base ofthe welding equipment so there will be no unduestress to the framework.

3. Proper placement of the equipment on the under-carriage to ensure stability side to side and front toback when being moved and when standing byitself while being operated or serviced.

4. Typical conditions of use, i.e., travel speed, rough-ness of surface on which the undercarriage will beoperated; environmental conditions, likely mainte-nance.

5. Conformance with federal, state and locallaws.Consult applicable federal, state and locallaws regarding specific requirements for use onpublic highways.

Polarity Control and Cable Sizes

With the engine off, route the electrode and workcables through the strain relief bracket on the baseand connect to the studs located below the fuel tankmounting rail. (See size recommendations below.)For positive polarity, connect the electrode cable tothe terminal marked “Positive (+)”. For Negativepolarity, connect the electrode cable to the “Negative(-)” stud. These connections should be checked peri-odically and tightened if necessary.

When welding at a considerable distance from the

welder, be sure you use ample size welding cables. PRE-OPERATION SERVICEREAD the engine operating and maintenance instruc-tions supplied with this machine.-------------------------------------------------------------------

RECOMMENDED COPPER CABLE SIZESCables Sizes for Combined Lengthof Electrode Plus Work Cable

Amps Duty Cycle Up to 200 ft. 200 to 250 ft.

200 100% 1 1/0250 60% 1 1/0300 40% 1/0 2/0

INSTALLATION OilThis unit is supplied from the factory with the enginecrankcase filled with a high quality SAE 10W/30 oil.This oil should be acceptable for most typical ambienttemperatures. Consult the engine operation manualfor specific engine manufacturer's recommendations.Upon receipt of the welder, check the engine dipstickto be sure the oil is at the “full” mark. DO NOT overfill.Note: A optional Oil Drain Kit is available for thisengine. (Order K1604-1)

NOTE: This unit is equipped with an EngineProtection Package, an internal kill switch willshut down the engine if the oil pressure dropsbelow a minimum operating specification, or if theoil temperature reaches an excessive level.

FuelFill the fuel tank with the grade of fuel recommendedin the Engine Operator’s manual. Make sure the fuelvalve on the sediment bowl is in the open position.

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 whenthe battery is low (after starting the engine) to a tricklecurrent when the battery is fully charged.

When replacing, jumping or otherwise connecting thebattery to the battery cables, the proper polarity mustbe observed. This system is NEGATIVE GROUND.

Muffler

This welder is supplied with an adjustable rain cap forthe muffler. Install the rain cap using the clamp pro-vided with the outlet facing away from the direction inwhich this unit will be transported. This will minimizethe amount of water and debris which could enter themuffler during transportation.

GASES FROM BATTERY can explode.• Keep sparks, flame and cigarettes

away.

BATTERY ACID can burn eyes andskin.• Wear gloves and eye protection and

be careful when boosting, charging orworking near battery.

To prevent EXPLOSION when:a) Installing a new battery - disconnect the

negative cable from the old battery first and connect the negative cable to the new battery last.

b) Connecting a battery charger - remove the battery from the welder by disconnecting the negative cable first, then the positive cable andbattery clamp. When reinstalling, connect the negative cable last.

c) Using a booster - connect the positive lead to the battery first, then connect the negative lead to the ground lead on the base.

To prevent ELECTRICAL DAMAGE when:a) Installing a new battery.b) Using a booster.

Use correct polarity - Negative Ground.

To prevent BATTERY DISCHARGE, if you have an ignition switch, turn it off when engine is notrunning.

• To prevent BATTERY BUCKLING, tighten nuts on battery clamp until snug.

------------------------------------------------------------------------

WARNING

B-1

CLASSIC II DEUTZ

B-1

SAFETY PRECAUTIONS

Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.------------------------------------------------------------------------

ELECTRIC SHOCK can kill.• Do not touch electrically live parts or







------------------------------------------------------------------------See additional warning information at thefront of this operator’s manual.

-----------------------------------------------------------

WARNING

GENERAL DESCRIPTION

The Classic™ II is a heavy duty engine driven DC arcwelding power source capable of providing constantcurrent output for stick welding or DC TIG welding.The Classic II is wound with all copper coils and isconfigured in a new shorter case with no exciter stick-out and setup for one side service. With the additionof the optional Wire Feed Module on models K1406-3and K1406-4 the Classic II will provide constant volt-age output for running the LN-7 or LN-25.

This unit uses the Deutz F3L-1011F industrial aircooled diesel engine.

Starting the Deutz F3L-1011F EngineTo start the engine, place the “IDLER” switch in the “HIGH” position,the “IGNITION” switch in the “ON” position and then press the“START” button. When the engine starts running, observe the oilpressure. If no pressure shows within 30 seconds, stop the engineand consult the engine operating manual. To stop the engine, placethe “IGNITION” switch in the “OFF” position. If the engine protectionwarning light comes on during cranking or after start up, the “igni-tion” switch must be placed in the “OFF” position to reset the engineprotection system.

When an engine is started for the first time, some of the oil will beneeded to fill the passages of the lubricating system. Therefore, oninitial starting, run the engine for about five minutes and then stopthe engine and recheck the oil. If the level is down, fill to the fullmark again. The engine controls were properly set at the factoryand should require no adjusting when received.

At the end of each day’s welding, drain accumulated dirt and waterfrom the sediment bowl under the fuel tank and from the fuel filterper instructions in the engine manufacturer’s operating manual.Refill the fuel tank to minimize moisture condensation in the tank.Also, running out of fuel tends to draw dirt into the fuel system.Check the crankcase oil level.

In diesel engines, if the fuel supply is cut off or runs out while thefuel pump is operating, air may be entrapped in the fuel distributionsystem. If this happens, bleeding of the fuel system should not berequired since the Deutz F3L-1011F engine is equipped with a selfpriming feature.

Cold Weather Starting

Follow the instructions on the nameplate and in the engine manualshipped with the welder. With a fully charged battery and the properweight oil, the engine should start satisfactorily even down to about0°F.

If the engine must be frequently started below 10°F, it may be desir-able to install the optional ether starter kit. Installation and operatinginstructions are included in the kit. Use ether starting only whenrequired because excessive use shortens engine life.

It is important that the Engine Manufacturer’s recommendations foroil and fuel are followed to obtain satisfactory cold weather perfor-mance. Consult the engine manual.

Duty Cycle

The NEMA output rating of the Classic II is 250 amperes at 30(1)

arc volts on a 60% duty cycle (consult SPECIFICATIONS foralternate ratings). Duty cycle is based on a ten minute period; thus,the welder can be loaded at rated output for six minutes out of everyten minute period.

(1) The Lincoln “plus output” rating at 60% duty cycle is 250amperes at 40 volts.

Control of Welding Current

DO NOT TURN THE “CURRENT RANGE SELECTOR” WHILEWELDING because the current may arc between the contactsand damage the switch.------------------------------------------------------------------------------------------The “Current Range Selector” provides five overlapping currentranges. The “Fine Current Adjustment” adjusts the current from min-imum to maximum within each range. Open circuit voltage is alsocontrolled by the “Fine Current Adjustment” permitting control of thearc characteristics.

CAUTION

OPERATION

B-2OPERATIONB-2

Auxiliary PowerThe AC auxiliary power, supplied as a standard, has arating of 3.0 kVA of 115/230V AC (60 hertz).

With the 3.0 kVA, 115/230V AC auxiliary power, one115V duplex and one 230V grounding type receptacleare provided. The circuit is protected with circuitbreakers.

The rating of 3.0 kVA permits a maximum continuouscurrent of 13 amps to be drawn from the 230 voltduplex receptacle. Or a total of 26 amps can bedrawn from the 115 volt duplex receptacle. The 115volt duplex receptacle has a configuration whichpermits 15 amps on the K1406-3 & -5 and 20 amps onthe K1406-4 &-6 to be drawn from either half. Thetotal combined load of all receptacles is not to exceed3.0 kVA.

An optional power plug kit is available. When this kitis specified, the customer is supplied with a plug foreach receptacle.

An optional GFCI 115 volt receptacle kit is also avail-able. Note that the use of this GFCI kit reduces avail-able current to 15 Amps from each half of the duplexreceptacle and to a total of 20 Amps of available 115volt power.

CLASSIC II DEUTZ

A high open circuit voltage setting provides the soft“buttering” arc with best resistance to pop-outs pre-ferred for most welding. To get this characteristic, setthe “Current Range Selector” to the lowest setting thatstill provides the current you need and set the “FineCurrent Adjustment” near maximum. For example: toobtain 175 amps and a soft arc, set the “CurrentRange Selector” to the 190-120 position and thenadjust the “Fine Current Adjustment” for 175 amps.

When a forceful “digging” arc is required, usually forvertical and overhead welding, use a higher “CurrentRange Selector” setting and lower open circuit volt-age. For example: to obtain 175 amps and a forcefularc, set the “Current Range Selector” to 240-160 posi-tion and the “Fine Current Adjustment” setting to get175 amps.

Some arc instability may be experienced with EXX10electrodes when trying to operate with long arc tech-niques at settings at the lower end of the open circuitvoltage range.

DO NOT attempt to set the “Current RangeSelector” between the five points designated onthe nameplate. These switches have a springloaded cam which almost eliminates the possibili-ty of setting this switch between the designatedpoints.------------------------------------------------------------------------

Idler OperationStart the engine with the “Idler” switch in the “High”position. Allow it to run at high idle speed for severalminutes to warm the engine. See SPECIFICATIONSfor operating speeds.

The idler is controlled by the “Idler” toggle switch onthe welder control panel. The switch has two posi-tions as follows:

1. In the “High” position, the idler is off, and theengine high speed is controlled by the governor.

2. In the “Auto” position, the idler operates as follows:a. When welding or drawing power for lights or

tools (approximately 100-150 watts minimum)from the receptacles, the engine operates atfull speed.

b. When welding ceases or the power load isturned off, a preset time delay of about 15seconds starts. This time delay cannot beadjusted.

c. If the welding or power load is not re-startedbefore the end of the time delay, the idlerreduces the engine to low idle speed.

CAUTION

D-1

CLASSIC II DEUTZ

D-1

Have qualified personnel do the maintenancework. Turn the engine off before working insidethe machine. In some cases, it may be neces-sary to remove safety guards to performrequired maintenance. Remove guards onlywhen necessary and replace them when themaintenance requiring their removal is com-plete. Always use the greatest care when work-ing near moving parts.

Do not put your hands near the engine coolingblower fan. If a problem cannot be corrected byfollowing the instructions, take the machine tothe nearest Lincoln Field Service Shop.

-----------------------------------------------------------------------ELECTRIC SHOCK can kill.• Do not touch electrically live parts or







------------------------------------------------------------------------

See additional warning information at thefront of this operator’s manual.

-----------------------------------------------------------

WARNING

4. Inspect the air filter daily - more often in dusty condi-tions. When necessary, clean or replace. The filtershould never be removed while the engine is running.The air filter element part number is Donaldson#181050 or Nelson #70206N.

5. Drain any accumulated water from the engine fuel fil-ter/water separator daily. Change the filter every 1000hours of operation. Order Deutz fuel filter #117-4482from your local Deutz Service Center. A fuel filter ele-ment without the water separator may be used inplace of the standard element. Order Deutz #117-4696.

6. Fan belts tend to loosen after the first 50 hours ofoperation. Check engine Operation Manual andtighten if necessary. DO NOT OVER TIGHTEN.

7. Put a drop of oil on the “Current Range Selector” shaftat least once every month.

8. See the engine manufacturer’s Operation Manual fordetailed engine maintenance and troubleshootinginstructions.

COOLING SYSTEM

The Classic II is equipped with an air cooled Deutzengine. Clean the engine cooling system periodically toprevent clogging the air passages on the cylinder headsand oil cooler and overheating the engine. Consult theEngine Operation Manual. It is important that thewelder is located in a manner which will provide an unre-stricted flow of clean, cool air.

BEARINGS

This welder is equipped with a double-shielded ball bear-ing having sufficient grease to last indefinitely under nor-mal service. Where the welder is used constantly or inexcessively dirty locations, it may be necessary to addone half ounce of grease per year. A pad of grease oneinch wide, one inch long, and one inch high weighsapproximately one half ounce. Over-greasing is far worsethan insufficient greasing.

When greasing the bearings, keep all dirt out of the area.Wipe the fittings completely clean and use clean equip-ment. More bearing failures are caused by dirt introducedduring greasing than from insufficient grease.

GENERAL INSTRUCTIONS1. Blow out the welder and controls with an air hose

at least once every two months. In particularlydirty locations, this cleaning may be necessaryonce a week. Use low pressure air to avoid drivingdirt into the insulation.

2. ”Current Range Selector” contacts should not begreased. To keep the contacts clean, rotate thecurrent control through its entire range frequently.Good practice is to turn the handle from maximumto minimum setting twice each morning beforestarting to weld.

3. Change the crankcase oil and oil filter after the first50 hours of operation and thereafter at 750 hourintervals using the proper grade of oil. See recom-mendations in the engine Operation Manual.Order Deutz oil filter #117-4416 or #117-4417 from

SAFETY PRECAUTIONSMAINTENANCE

D-2D-2

Commutator and Brushes

The generator brushes are properly adjusted when thewelder 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, slip rings, andbrushes by removing the covers. DO NOT remove orreplace these covers while the machine is running.

Commutators and slip rings require little attention.However, if they are black or appear uneven, have themcleaned by an experienced maintenance man using finesandpaper or a commutator stone. Never use emerycloth or paper for this purpose.

NOTE: If the welder is used in dirty or dusty locations, orif the welder is not used for prolonged periods of time, itmay be necessary to clean the commutator and slip ringsmore often.

Replace brushes when they wear within 1/4” of thepigtail. A complete set of replacement brushes shouldbe kept on hand. Lincoln brushes have a curved faceto fit the commutator. Have an experienced mainte-nance man seat these brushes by lightly stoning thecommutator as the armature rotates at full speed untilcontact is made across the full face of the brushes.After stoning, blow out the dust with low pressure air.

To seat slip ring brushes, position the brushes inplace. Then slide one end of a piece of fine sandpa-per between slip rings and brushes with the coarseside against the brushes. With slight additional fingerpressure on top of the brushes, pull the sandpaperaround the circumference of the rings - in direction ofrotation only - until brushes seat properly. In addition,stone slip ring with a fine stone. Brushes must be

seated 100%.Uncovered rotating equipment can be dangerous.Use care so your hands, hair, clothing or tools donot catch in the rotating parts. Protect yourselffrom particles that may be thrown out by the rotat-ing armature when stoning the commutator.------------------------------------------------------------------------Arcing or excessive exciter brush wear indicates apossible misaligned shaft. Have an authorized FieldService Shop check and realign the shaft.

Idler Maintenance1. The solenoid plunger must work freely and not bind.

Dust the plunger about once a year with graphitepowder.

2. Proper operation of the idler requires good ground-ing of the printed circuit board, reed switch, and battery.

3. If desired, the welder can be used without automat-ic idling by setting the “Idler” switch to the “High” position.

Before doing electrical work on the idler printedcircuit board, disconnect the battery. Wheninstalling a new battery or using a jumper batteryto start the engine, be sure the battery polarity isconnected properly. The correct polarity is nega-tive ground. Damage to the engine alternator andthe printed circuit board can result from incorrectconnection.------------------------------------------------------------------------

Nameplates

Whenever routine maintenance is performed on thismachine - or at least yearly - inspect all nameplatesand labels for legibility. Replace those which are nolonger clear. Refer to the parts list for the replace-ment item number.

WARNING

CAUTION

CLASSIC II DEUTZ

MAINTENANCE

E-1TROUBLESHOOTINGE-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 andground

• Always wear dry insulating gloves.------------------------------------------------------------------------

ENGINE EXHAUST can kill.• Use in open, well ventilated areas or




------------------------------------------------------------------------See additional warning information at thefront of this operator’s manual

------------------------------------------------------------

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING


CLASSIC II DEUTZ

Observe all Safety Guidelines detailed throughout this manual


CAUTION

PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENT(S)

RECOMMENDEDCOURSE OF ACTION

Machine fails to hold the “heat” con-stantly.

Welder starts but fails to generatecurrent.

a. Rough or dirty commutator.

b. Brushes may be worn down tolimit.

c. Field circuit may have variableresistance connection or intermit-tent open circuit due to loose con-nection or broken wire.

d. Electrode lead or work lead con-nection may be poor.

e. Wrong grade of brushes mayhave been installed on generator.

f. Field rheostat may be makingpoor contact and overheating.

a. Generator or exciter brushes maybe loose or missing.

b. Exciter may not be operating.

c. Field circuit of generator orexciter may be open.

d. Exciter may have lost excitation.

Flash Fields(1)

e. Series field and armature circuitmay be open-circuited.

Contact your Local Lincoln AuthorizedField Service Facility for technicaltroubleshooting assistance.

(1)FLASHING THE FIELDS:

1. Stop the engine welder and remove the cover fromthe exciter.

2. Turn the “Fine Adjustment Control” (rheostat) to“100” on the dial.

3. Using a 12 volt automotive battery, connect itsnegative terminal to the negative brush holder. Thenegative brush holder is the one nearest to therotor lamination. See the wiring diagram. With theengine NOT running, touch the positive battery ter-minal to the positive brush holder. Remove the bat-tery from the circuit.

4. Replace the exciter cover. Start the welder and thegenerator voltage should build up.


CLASSIC II DEUTZ

Observe all Safety Guidelines detailed throughout this manual


CAUTION

PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENT(S)

RECOMMENDEDCOURSE OF ACTION

Welding arc is loud and spattersexcessively.

Welding current too great or toosmall compared to indication on thedial.

Engine shuts down and engineprotection light comes on.

a. Current setting may be too high.b. Polarity may be wrong.

a. Exciter output low causing lowoutput compared to dial indica-tion.

b. Operating speed too low or high.

a. Low oil pressure.b. High oil temperature.

c. Broken fan belt.

d. Battery charging alternator is notoperating.

e. Fuel solenoid coil shortedContact your Local Lincoln AuthorizedField Service Facility for technicaltroubleshooting assistance.

E-4

CLASSIC II DEUTZ

E-4

ELECTRONIC IDLER TROUBLESHOOTING GUIDE

Engine Will Not Return To IdleIn Approximately 15 Seconds

Set Idler Control Switch To TheAuto Position

Remove All Weld and AuxiliaryPower Loads

Check Continuity of Idler ControlSwitch

Engine Will Not Pick Up Speed When:

1. Check for break in Redlead and repair.

2. Replace reed switch inweld circuit.

Replace PC Board

Engine Picks Up Speed Engine Does Not PickUp Speed

Replace P.C. Board

Engine Does Not Pick Up SpeedCheck Connections And Continuity

Of Current Transformer

The Auxiliary Power Load Is Turned On

Power Load Too Small Try Load Above 150 Watts

The Arc Is Struck

Reed Switch In Weld CircuitDefective - Will Not Close

To Check: Short The Red LeadOn P.C. Board To Welder Frame

Open

Replace Switch

Continuity Good

1. Reed switch in weld circuit may be stuckclosed.

2. Check continuity of idler solenoid coil(8.5 - 9.0 ohms) & leads.

3. Check ground connections in idle circuit.4. Replace P.C. Board

TROUBLESHOOTING

F-1

CLASSIC II DEUTZ

F-1

CO

NTR

OL

PAN

EL C

OM

PON

ENTS

SHO

WN

AS

VIEW

ED F

RO

M R

EAR

.LE

AD C

OLO

R C

OD

E

B-B

LAC

KG

-GR

EEN

N-B

RO

WN

B

R

+-

+ -

Y

R W B

B

WW

SLIP

RIN

GS

TO IR

ON

R

N

A

54

32

1

ALTE

RN

ATO

RAU

XILI

ARY

POW

ERW

IND

ING

S

CU

RR

ENT

TRAN

SFO

RM

ER

CB

1

115

VOLT

REC

EPTA

CLE

230

VOLT

REC

EPTA

CLE

Y

NEG

ATIV

E

SELE

CTO

R

SWIT

CH

WEL

DER

LEAD

BLO

CK

ACAC

CR

2 R

EED

REL

AY

42 602A

G

U

CB

2

F

USE

15A.

12

34

56

78

910

1112

1 2 3 4 5 6

600A41

GEN

ERAT

OR

N-W

+Y

G

G

B

600B

610

610

602B

R

SWIT

CH

STAR

T

STAR

TIN

GM

OTO

R

+

ENG

INE

+

52

D+

D-

B+

W21

IDLE

RSW

ITC

H

+A

FUEL

SOLE

NO

ID

IDLE

RSO

LEN

OID

SEN

SOR

7 83 4 56

ALTE

RN

ATO

R

OIL

PR

ESSU

RE

GAU

GES

I GN

D

ALTE

RN

ATO

R

RO

TOR

SLIP

RIN

G

NEA

RES

T

OIL

TEM

P.

-

HO

UR

M

ETER

J5

P9J8

POSI

TIVE

ELEC

TRIC

AL S

YMB

OLS

PER

E15

37P1

0

+Y-W

NU

WB

-

50A

50

51

51A

60

56

55

60B

RH

EOST

AT

(CC

- )

(CC

+) &

(CV+

WIT

H W

.F.M

.)

(30A

MP)

(15A

MP)

L111

26

60E

B

B

Y

G

NEU

TRAL

BO

ND

ED T

O F

RAM

EN

EUTR

E R

ACC

OR

DE

AU B

ATI

'

1 2 3 4

12

34

56

78

910

IDLE

R/E

NG

INE

PRO

TEC

TIO

NP.

C. B

OAR

D53

B

56A

57

60A

ENG

INE

FAIL

UR

ELA

MP

54B

59

58A

54

J1J2

53

53A

61 60C

IGN

ITIO

N

109

J3P3

ENG

INE

CO

NN

ECTO

R

OIL

PR

ESSU

RE

SE

NSO

R

62

10-2

-98D

Y

B

SEE

BEL

OW

*W

G

PLU

G F

OR

REM

OTE

CO

NTR

OL

POTE

NTI

OM

ETER

B

*

P81 2 3 4 5 6

X

41 600

42 602

R

W

RB

ELO

WSE

E*

REM

OTE

CO

NTR

OL

REC

EPTA

CLE

& S

WIT

CH

XY

CO

NN

ECT

TO C

ASE

WIT

H M

ACH

INE

NO

T R

UN

NIN

G,

REM

OVE

PLU

G "

P9"

ON

MAC

HIN

E FR

OM

CO

NN

ECTO

R "

J8".

TH

EN C

ON

NEC

TPL

UG

"P8

" O

N R

EMO

TE C

ON

TRO

L TO

CO

NN

ECTO

R "

J8"

ON

MAC

HIN

E.

K92

4-1

REM

OTE

CO

NTR

OL

(OPT

ION

AL)

REM

OTE

CO

NTR

OL

POTE

NTI

OM

ETER

BO

X

SWIT

CH

FO

R L

OC

AL O

R

REM

OTE

CO

NTR

OL

SHO

WN

IN

LO

CAL

PO

SITI

ON

.

#2 H

EAVY

LEA

D

WIR

E FE

ED M

OD

ULE

(OPT

ION

AL)

WIR

E

FEED

MO

DU

LEN

EG.

POS.

OU

TPU

T TE

RM

INAL

SC

ON

NEC

T TO

PO

S. &

NEG

.

CO

NN

ECT

TO N

EG.

BR

USH

HO

LDER

608

609

#2 H

EAVY

LEA

D

#8 L

EAD

MAC

HIN

E M

UST

NO

T B

E R

UN

NIN

GW

HEN

MAK

ING

TH

ESE

CO

NN

ECTI

ON

S.

*

ON

MAC

HIN

E, R

EMO

VE P

LUG

"P1

0" F

RO

M C

ON

NEC

TOR

"J5

".C

ON

NEC

T PL

UG

"P5

" O

N W

.F.M

. TO

CO

NN

ECTO

R "

J5"

ON

MAC

HIN

E.

250

AMP

THER

MO

STAT

ASSE

MB

LY

INLI

NE

CO

NN

ECTO

RS

W.F

.M.

CO

NTR

OL

PAN

EL

NEG

ATIV

E C

VO

UTP

UT

TER

MIN

ALPA

NEL

PLU

G(P

5)Y

B

SEE

BEL

OW

*W

G

B

*

P81 2 3 4 5 6

X

41 600

42 602

W

RB

ELO

WSE

E*

REM

OTE

CO

NTR

OL

REC

EPTA

CLE

& S

WIT

CH

XY

CO

NN

ECT

TO C

ASE

K92

4-4

REM

OTE

CO

NTR

OL

(OPT

ION

AL)

REM

OTE

CO

NTR

OL

POTE

NTI

OM

ETER

BO

X

SWIT

CH

FO

R L

OC

AL O

R

REM

OTE

CO

NTR

OL

SHO

WN

IN

LO

CAL

PO

SITI

ON

.

RES

ISTO

RS

1 2 3 4 5 6 7 8 9 10 11 12

P11 SE

EB

ELO

W**

* *

PLU

G F

OR

REM

OTE

CO

NTR

OL

POTE

NTI

OM

ETER

WIT

H M

ACH

INE

OFF

, R

EMO

VE P

LUG

"P9

" O

N M

ACH

INE

FRO

M C

ON

NEC

TOR

"J8

". T

HEN

CO

NN

ECT

PLU

G "

P8"

ON

REM

OTE

CO

NTR

OL

KIT

TO

CO

NN

ECTO

R "

J8"

ON

MAC

HIN

E.

IF A

WIR

E FE

ED M

OD

ULE

IS IN

STAL

LED

, WIT

H T

HE

MAC

HIN

E O

FF, D

ISPO

SE O

F TH

E U

NC

ON

NEC

TED

PL

UG

"P1

0" (I

F O

NE

IS O

N T

HE

MAC

HIN

E). F

ASTE

N T

HE

NEW

PLU

G "

P11"

NEA

RB

Y, L

EAVI

NG

ITU

NC

ON

NEC

TED

.IF

NO

WIR

E FE

ED M

OD

ULE

IS IN

STAL

LED

, WIT

H T

HE

MAC

HIN

E O

FF, D

ISC

ON

NEC

T PL

UG

"P1

0" O

N T

HE

MAC

HIN

E FR

OM

CO

NN

ECTO

R "

J5".

CO

NN

ECT

PLU

G "

P11"

FR

OM

TH

E R

EMO

TE C

ON

TRO

L K

IT T

O C

ON

NEC

TOR

"J5"

ON

TH

E M

ACH

INE.

THE

RED

AN

D B

LAC

K L

EAD

S AR

E U

SED

ON

CLA

SSIC

I M

ACH

INES

ON

LY A

ND

AR

E N

OT

CO

NN

ECTE

D O

N T

HIS

MAC

HIN

E. D

AMAG

E TO

TH

E R

EMO

TE C

ON

TRO

L AN

D/O

R M

ACH

INE

WIL

L R

ESU

LT IF

TH

E R

ED A

ND

BLA

CK

LEAD

S AR

E C

ON

NEC

TED

IN T

HE

CLA

SSIC

II.

RED

AN

D B

LAC

K L

EAD

S N

OT

CO

NN

ECTE

D O

N T

HIS

MAC

HIN

E.C

AU

TIO

N:

PLU

G IN

STAL

LED

OR

A W

IRE

FEED

MO

DU

LE IN

STAL

LED

.D

AMAG

E C

AN O

CC

UR

TO

TH

E R

EMO

TE C

ON

TRO

L SW

ITC

H IF

IT IS

USE

D W

ITH

OU

T TH

E "P

11"

NO

TE

: T

his

dia

gra

m is

fo

r re

fere

nce

onl

y.

It m

ay n

ot

be

accu

rate

fo

r al

l mac

hine

s co

vere

d b

y th

is m

anua

l. T

he s

pec

ific

dia

gra

m f

or

a p

artic

ular

co

de

is p

aste

d in

sid

eth

e m

achi

ne o

n o

ne o

f th

e en

clo

sure

pan

els.

If

the

dia

gra

m is

ille

gib

le, w

rite

to

the

Ser

vice

Dep

artm

ent

for

a re

pla

cem

ent.

Giv

e th

e eq

uip

men

t co

de

num

ber

..

WIRING DIAGRAM - CODE 10628 & 10629DIAGRAMS

F-2

CLASSIC II DEUTZ

F-2

R

SW

ITC

H

STA

RT

STA

RTI

NG

MO

TOR

+

ENG

INE

+

52

D+

D-

B+

W

1

+A

FUEL

SO

LEN

OID

IDLE

RS

OLE

NO

ID

SEN

SO

R

7 83 4 56

ALT

ERN

ATO

R

OIL

PR

ESS

UR

EG

AU

GES

I GN

D

OIL

TEM

P.

-

HO

UR

M

ETER

-

50A

50

51

51A

60

56

55

60B

L992

0

CLA

SS

IC I

I

- W

IRIN

G D

IAG

RA

M

60E

1 2 3 4

12

34

56

78

910

IDLE

R/E

NG

INE

PR

OTE

CTI

ON

P.C

. B

OA

RD

53B

56A

57

60A

ENG

INE

FAIL

UR

ELA

MP

54B

59

58A

54

J1J2

53

53A

61 60C

IGN

ITIO

N

CO

NTR

OL

PA

NEL

CO

MP

ON

ENTS

SH

OW

N A

S V

IEW

ED F

RO

M R

EAR

.LE

AD

CO

LOR

CO

DE

B-B

LAC

KG

-GR

EEN

N-B

RO

WN

B

R

+-

+ -

Y

R W B

B

SLI

P R

ING

S

TO IR

ON

R

N

A

54

32

1

ALT

ERN

ATO

RA

UXI

LIA

RY

PO

WER

WIN

DIN

GS

CB

3C

B1

115

VOLT

REC

EPTA

CLE

230

VO

LTR

EC

EP

TAC

LE

Y

NEG

ATI

VE

SEL

ECTO

R

SW

ITC

H

WEL

DER

LEA

D B

LOC

K

AC

AC

CR

2 R

EED

REL

AY

42 602A

G

U

CB

2C

B4

FU

SE15

A.

12

34

56

78

910

1112

1 2 3 4 5 6

600A41

GEN

ERA

TOR

N-W

+Y

G

G

B

600B

610

610

602B

ALT

ERN

ATO

R

RO

TOR

SLI

P R

ING

N

EAR

EST

J5

P9

J8

PO

SIT

IVE

ELEC

TRIC

AL

SY

MB

OLS

PER

E15

37P

10

+Y

-WN

U

WB

RH

EOS

TAT

(CC

- )

(CC

+) &

(CV+

WIT

H W

.F.M

.)

Y

B

B

B

B

B

G

NEU

TRA

L B

ON

DED

TO

FR

AM

EN

EUTR

E R

AC

CO

RD

E A

U B

ATI

CU

RR

ENT

TRA

NS

FOR

MER

W W

SW

ITC

HID

LER P3

J3

OIL

PR

ESS

UR

E

SEN

SO

R

9 10EN

GIN

EC

ON

NEC

TOR

2

58

CB

1

62

Y

B

SEE BEL

OW

*W

G

PLU

G F

OR

REM

OTE

CO

NTR

OL

PO

TEN

TIO

MET

ER

B

*

P81 2 3 4 5 6

X

41 600

42 602

R

W

RB

ELO

WS

EE*

REM

OTE

CO

NTR

OL

REC

EPTA

CLE

& S

WIT

CH

XY

CO

NN

ECT

TO C

AS

E

WIT

H M

AC

HIN

E N

OT

RU

NN

ING

, R

EMO

VE P

LUG

"P

9" O

NM

AC

HIN

E FR

OM

CO

NN

ECTO

R "

J8".

TH

EN C

ON

NEC

TP

LUG

"P

8" O

N R

EMO

TE C

ON

TRO

L TO

CO

NN

ECTO

R "

J8"

ON

MA

CH

INE.

K92

4-1

RE

MO

TE C

ON

TRO

L (O

PTI

ON

AL) R

EMO

TE C

ON

TRO

LP

OTE

NTI

OM

ETER

BO

X

SW

ITC

H F

OR

LO

CA

L O

R

REM

OTE

CO

NTR

OL

SH

OW

N

IN L

OC

AL

PO

SIT

ION

.

#2 H

EA

VY

LE

AD

WIR

E F

EE

D M

OD

ULE

(OP

TIO

NA

L)

WIR

E

FEED

MO

DU

LEN

EG.

PO

S.

OU

TPU

T TE

RM

INA

LSC

ON

NEC

T TO

PO

S.

& N

EG.

CO

NN

ECT

TO N

EG.

BR

US

H H

OLD

ER

608

609

#2 H

EAVY

LEA

D

#8

LEA

D

MA

CH

INE

MU

ST

NO

T B

E R

UN

NIN

GW

HEN

MA

KIN

G T

HES

E C

ON

NEC

TIO

NS

.

*

ON

MA

CH

INE,

REM

OVE

PLU

G "

P10

" FR

OM

CO

NN

ECTO

R "

J5".

CO

NN

ECT

PLU

G "

P5"

ON

W.F

.M.

TO C

ON

NEC

TOR

"J5

" O

N M

AC

HIN

E.

250

AM

PTH

ER

MO

STA

TA

SS

EM

BLY

INLI

NE

CO

NN

ECTO

RS

W.F

.M.

CO

NTR

OL

PA

NEL

NEG

ATI

VE C

VO

UTP

UT

TER

MIN

AL

PA

NEL

PLU

G(P

5)Y

B

SEE BEL

OW

*W

G

B

*

P81 2 3 4 5 6

X

41 600

42 602

W

RB

ELO

WS

EE*

REM

OTE

CO

NTR

OL

REC

EPTA

CLE

& S

WIT

CH

XY

CO

NN

ECT

TO C

AS

E

K92

4-4

RE

MO

TE C

ON

TRO

L (O

PTI

ON

AL)

REM

OTE

CO

NTR

OL

PO

TEN

TIO

MET

ER B

OX

SW

ITC

H F

OR

LO

CA

L O

R

REM

OTE

CO

NTR

OL

SH

OW

N

IN L

OC

AL

PO

SIT

ION

.

RES

ISTO

RS

1 2 3 4 5 6 7 8 9 10 11 12

P11 S

EEB

ELO

W**

**

PLU

G F

OR

REM

OTE

CO

NTR

OL

PO

TEN

TIO

MET

ER

WIT

H M

AC

HIN

E O

FF,

REM

OVE

PLU

G "

P9"

ON

MA

CH

INE

FRO

M C

ON

NEC

TOR

"J8

". T

HEN

CO

NN

ECT

PLU

G "

P8"

ON

REM

OTE

CO

NTR

OL

KIT

TO

CO

NN

ECTO

R "

J8"

ON

MA

CH

INE.

IF A

WIR

E FE

ED M

OD

ULE

IS IN

STA

LLED

, W

ITH

TH

E M

AC

HIN

E O

FF,

DIS

PO

SE

OF

THE

UN

CO

NN

ECTE

D

PLU

G "

P10

" (IF

ON

E IS

ON

TH

E M

AC

HIN

E).

FAS

TEN

TH

E N

EW P

LUG

"P

11"

NEA

RB

Y,

LEA

VIN

G IT

UN

CO

NN

ECTE

D.

IF N

O W

IRE

FEED

MO

DU

LE IS

INS

TALL

ED,

WIT

H T

HE

MA

CH

INE

OFF

, D

ISC

ON

NEC

T P

LUG

"P

10"

ON

TH

EM

AC

HIN

E FR

OM

CO

NN

ECTO

R "

J5".

CO

NN

ECT

PLU

G "

P11

" FR

OM

TH

E R

EMO

TE C

ON

TRO

L K

IT T

O C

ON

NEC

TOR

"J5"

ON

TH

E M

AC

HIN

E.

THE

RED

AN

D B

LAC

K L

EAD

S A

RE

US

ED O

N C

LAS

SIC

I M

AC

HIN

ES O

NLY

AN

D A

RE

NO

T C

ON

NEC

TED

ON

TH

ISM

AC

HIN

E.

DA

MA

GE

TO T

HE

REM

OTE

CO

NTR

OL

AN

D/O

R M

AC

HIN

E W

ILL

RES

ULT

IF T

HE

RED

AN

D B

LAC

K

RED

AN

D B

LAC

K L

EAD

S N

OT

CO

NN

ECTE

D O

N T

HIS

MA

CH

INE.

LEA

DS

AR

E C

ON

NEC

TED

IN T

HE

CLA

SS

IC II

.

RES

ISIT

OR

S

G

CA

UT

ION

:"P

11"

PLU

G IN

STA

LLED

OR

A W

IRE

FEED

MO

DU

LE IN

STA

LLED

.

D

AM

AG

E C

AN

OC

CU

R T

O T

HE

REM

OTE

CO

NTR

OL

SW

ITC

H IF

IT IS

US

ED W

ITH

OU

T TH

E

10-9

7L

NO

TE

: T

his

dia

gra

m is

fo

r re

fere

nce

onl

y.

It m

ay n

ot

be

accu

rate

fo

r al

l mac

hine

s co

vere

d b

y th

is m

anua

l. T

he s

pec

ific

dia

gra

m f

or

a p

artic

ular

co

de

is p

aste

d in

sid

eth

e m

achi

ne o

n o

ne o

f th

e en

clo

sure

pan

els.

If

the

dia

gra

m is

ille

gib

le, w

rite

to

the

Ser

vice

Dep

artm

ent

for

a re

pla

cem

ent.

Giv

e th

e eq

uip

men

t co

de

num

ber

..

WIRING DIAGRAM - CODE 10219 & 10219CVDIAGRAMS

F-3

CLASSIC II DEUTZ

F-3

CO

NTR

OL

PA

NE

L C

OM

PO

NE

NTS

SH

OW

N A

S V

IEW

ED

FR

OM

RE

AR

.LE

AD

CO

LOR

CO

DE

B-B

LAC

KG

-GR

EE

NN

-BR

OW

N

B

R

+-

+ -

Y

R W B

B

WW

SLI

P R

ING

S

TO IR

ON

R

N

A

54

32

1

ALT

ER

NA

TOR

AU

XILI

AR

YP

OW

ER

WIN

DIN

GS

CU

RR

EN

T TR

AN

SFO

RM

ER

CB

1

115

VO

LTR

EC

EP

TAC

LE23

0 V

OLT

RE

CE

PTA

CLE

Y

NE

GA

TIV

E

SE

LEC

TOR

S

WIT

CH

WE

LDE

RLE

AD

BLO

CK

AC

AC

CR

2 R

EE

DR

ELA

Y

42 602A

G

U

CB

2

FU

SE15

A.

12

34

56

78

910

1112

1 2 3 4 5 6

600A41

GE

NE

RA

TOR

N-W

+Y

G

G

B

600B

610

610

602B

R

SW

ITC

H

STA

RT

STA

RTI

NG

MO

TOR

+

EN

GIN

E

+

52

D+

D-

B+

W21

IDLE

RS

WIT

CH

+A

FUE

LS

OLE

NO

ID

IDLE

RS

OLE

NO

ID

SE

NS

OR

7 83 4 56

ALT

ER

NA

TOR

OIL

PR

ES

SU

RE

GA

UG

ESI G

ND

ALT

ER

NA

TOR

R

OTO

R

SLI

P R

ING

N

EA

RE

ST

OIL

TE

MP

.

-

HO

UR

M

ETE

R

J5

P9

J8

PO

SIT

IVE

ELE

CTR

ICA

L S

YM

BO

LSP

ER

E15

37P

10

+Y

-WN

U

WB

-

50A

50

51

51A

60

56

55

60B

RH

EO

STA

T

(CC

- )

(CC

+) &

(CV

+ W

ITH

W.F

.M.)

(30A

MP

)(1

5AM

P)

L991

9

CLA

SS

IC I

I

- W

IRIN

G D

IAG

RA

M

60E

B

B

Y

G

NE

UTR

AL

BO

ND

ED

TO

FR

AM

EN

EU

TRE

RA

CC

OR

DE

AU

BA

TI'

1 2 3 4

12

34

56

78

910

IDLE

R/E

NG

INE

PR

OTE

CTI

ON

P.C

. B

OA

RD

53B

56A

57

60A

EN

GIN

EFA

ILU

RE

LAM

P58

54B

59

58A

54

J1J2

53

53A

61 60C

IGN

ITIO

N

109

J3P

3

EN

GIN

EC

ON

NE

CTO

R

OIL

PR

ES

SU

RE

S

EN

SO

R

CB

1

62

10-9

7L

Y

B

SEE BEL

OW

*W

G

PLU

G F

OR

REM

OTE

CO

NTR

OL

PO

TEN

TIO

MET

ER

B

*

P81 2 3 4 5 6

X

41 600

42 602

R

W

RB

ELO

WS

EE*

REM

OTE

CO

NTR

OL

REC

EPTA

CLE

& S

WIT

CH

XY

CO

NN

ECT

TO C

AS

E

WIT

H M

AC

HIN

E N

OT

RU

NN

ING

, R

EMO

VE P

LUG

"P

9" O

NM

AC

HIN

E FR

OM

CO

NN

ECTO

R "

J8".

TH

EN C

ON

NEC

TP

LUG

"P

8" O

N R

EMO

TE C

ON

TRO

L TO

CO

NN

ECTO

R "

J8"

ON

MA

CH

INE.

K92

4-1

REM

OTE

CO

NTR

OL

(OP

TIO

NA

L) REM

OTE

CO

NTR

OL

PO

TEN

TIO

MET

ER B

OX

SW

ITC

H F

OR

LO

CA

L O

R

REM

OTE

CO

NTR

OL

SH

OW

N

IN L

OC

AL

PO

SIT

ION

.

#2 H

EA

VY

LE

AD

WIR

E FE

ED M

OD

ULE

(OP

TIO

NA

L)

WIR

E

FEE

D

MO

DU

LEN

EG.

PO

S.

OU

TPU

T TE

RM

INA

LSC

ON

NEC

T TO

PO

S.

& N

EG.

CO

NN

ECT

TO N

EG.

BR

US

H H

OLD

ER

608

609

#2 H

EAVY

LEA

D

#8

LEA

D

MA

CH

INE

MU

ST

NO

T B

E R

UN

NIN

GW

HE

N M

AK

ING

TH

ES

E C

ON

NE

CTI

ON

S.

*

ON

MA

CH

INE,

REM

OVE

PLU

G "

P10

" FR

OM

CO

NN

ECTO

R "

J5".

CO

NN

ECT

PLU

G "

P5"

ON

W.F

.M.

TO C

ON

NEC

TOR

"J5

" O

N M

AC

HIN

E.

250

AM

PTH

ER

MO

STA

TA

SS

EM

BLY

INLI

NE

CO

NN

ECTO

RS

W.F

.M.

CO

NTR

OL

PA

NEL

NEG

ATI

VE C

VO

UTP

UT

TER

MIN

AL

PA

NEL

PLU

G(P

5)Y

B

SEE BEL

OW

*W

G

B

*

P81 2 3 4 5 6

X

41 600

42 602

W

RB

ELO

WS

EE*

REM

OTE

CO

NTR

OL

REC

EPTA

CLE

& S

WIT

CH

XY

CO

NN

ECT

TO C

AS

E

K92

4-4

REM

OTE

CO

NTR

OL

(OP

TIO

NA

L)

REM

OTE

CO

NTR

OL

PO

TEN

TIO

MET

ER B

OX

SW

ITC

H F

OR

LO

CA

L O

R

REM

OTE

CO

NTR

OL

SH

OW

N

IN L

OC

AL

PO

SIT

ION

.

RES

ISTO

RS

1 2 3 4 5 6 7 8 9 10 11 12

P11 S

EEB

ELO

W**

**

PLU

G F

OR

REM

OTE

CO

NTR

OL

PO

TEN

TIO

MET

ER

WIT

H M

AC

HIN

E O

FF,

REM

OVE

PLU

G "

P9"

ON

MA

CH

INE

FRO

M C

ON

NEC

TOR

"J8

". T

HEN

CO

NN

ECT

PLU

G "

P8"

ON

REM

OTE

CO

NTR

OL

KIT

TO

CO

NN

ECTO

R "

J8"

ON

MA

CH

INE.

IF A

WIR

E FE

ED M

OD

ULE

IS IN

STA

LLED

, W

ITH

TH

E M

AC

HIN

E O

FF,

DIS

PO

SE

OF

THE

UN

CO

NN

ECTE

D

PLU

G "

P10

" (IF

ON

E IS

ON

TH

E M

AC

HIN

E).

FAS

TEN

TH

E N

EW P

LUG

"P

11"

NEA

RB

Y,

LEA

VIN

G IT

UN

CO

NN

ECTE

D.

IF N

O W

IRE

FEED

MO

DU

LE IS

INS

TALL

ED,

WIT

H T

HE

MA

CH

INE

OFF

, D

ISC

ON

NEC

T P

LUG

"P

10"

ON

TH

EM

AC

HIN

E FR

OM

CO

NN

ECTO

R "

J5".

CO

NN

ECT

PLU

G "

P11

" FR

OM

TH

E R

EMO

TE C

ON

TRO

L K

IT T

O C

ON

NEC

TOR

"J5"

ON

TH

E M

AC

HIN

E.

THE

RED

AN

D B

LAC

K L

EAD

S A

RE

US

ED O

N C

LAS

SIC

I M

AC

HIN

ES O

NLY

AN

D A

RE

NO

T C

ON

NEC

TED

ON

TH

ISM

AC

HIN

E.

DA

MA

GE

TO T

HE

REM

OTE

CO

NTR

OL

AN

D/O

R M

AC

HIN

E W

ILL

RES

ULT

IF T

HE

RED

AN

D B

LAC

KLE

AD

S A

RE

CO

NN

ECTE

D IN

TH

E C

LAS

SIC

II.

RED

AN

D B

LAC

K L

EAD

S N

OT

CO

NN

ECTE

D O

N T

HIS

MA

CH

INE.

CA

UT

ION

:P

LUG

INS

TALL

ED O

R A

WIR

E FE

ED M

OD

ULE

INS

TALL

ED.

DA

MA

GE

CA

N O

CC

UR

TO

TH

E R

EMO

TE C

ON

TRO

L S

WIT

CH

IF IT

IS U

SED

WIT

HO

UT

THE

"P11

"

NO

TE

: T

his

dia

gra

m is

fo

r re

fere

nce

onl

y.

It m

ay n

ot

be

accu

rate

fo

r al

l mac

hine

s co

vere

d b

y th

is m

anua

l. T

he s

pec

ific

dia

gra

m f

or

a p

artic

ular

co

de

is p

aste

d in

sid

eth

e m

achi

ne o

n o

ne o

f th

e en

clo

sure

pan

els.

If

the

dia

gra

m is

ille

gib

le, w

rite

to

the

Ser

vice

Dep

artm

ent

for

a re

pla

cem

ent.

Giv

e th

e eq

uip

men

t co

de

num

ber

..

WIRING DIAGRAM - CODE 10220 & 10220CVDIAGRAMS

F-4DIAGRAMSF-4

CLASSIC II DEUTZ

C

L11

863

CLA

SS

IC II

-

WIR

ING

DIA

GR

AM

LEA

D C

OLO

R C

OD

E

B-B

LAC

KG

-GR

EE

NN

-BR

OW

N

R-R

ED

U-B

LUE

W-W

HIT

EY

-YE

LLO

W

ELE

CTR

ICAL

SYM

BO

LSP

ER

E15

37C

ON

TRO

L P

AN

EL

CO

MP

ON

EN

TSS

HO

WN

AS

VIE

WE

D F

RO

M R

EA

R.

NE

UTR

AL

BO

ND

ED

TO

FR

AME

NE

UTR

E R

AC

CO

RD

E A

U B

ATI

’

700B

700A

+-

+ -

Y

R40

0D

B

10

WW

SLI

P R

ING

S

TO IR

ON

346

347

A

54

32

1

ALT

ER

NA

TOR

AU

XIL

IAR

YP

OW

ER

WIN

DIN

GS

CU

RR

ENT

TRA

NSF

OR

MER

CB

2

115

VO

LTR

ECE

PTA

CLE

230

VO

LTR

EC

EP

TAC

LE

Y

NEG

ATI

VE

SE

LEC

TOR

SW

ITC

H

WE

LDE

RLE

AD

BLO

CK

AC

AC

CR

2 R

EED

RE

LAY

42 602A

GN

D-E

U

CB

3

F

US

E15

A.

12

34

56

78

910

1112

1 2 3 4 5 6

600A41

GE

NER

ATO

R

N-W

+Y

48

GN

D-D

10

600B

610

610

602B

R

SW

ITC

HS

TAR

T

STA

RTI

NG

MO

TOR

+

EN

GIN

E

+

52

D+

D-

B+

W21

IDLE

RS

WIT

CH

+ A

FUE

LS

OLE

NO

ID

IDLE

RS

OLE

NO

ID

SE

NSO

R

7 83 4 56

ALT

ER

NA

TOR

AM

ME

TER

GA

UG

ESI G

ND

RE

CE

PTA

CLE

RO

TOR

SLI

P R

ING

NE

AR

ES

T

OIL

TE

MP

.

-

HO

UR

ME

TER

J5

P8

J8

PO

SIT

IVE

P10

+Y-W

NU

400D

400E

-

50A

50

51

51A

60

56

55

60B

RH

EOS

TAT

(CC

- )(C

C+)

& (C

V+ W

ITH

W.F

.M.)

60E

300B

650

GN

D-F

1 2 3 4

12

34

56

78

910

IDLE

R/E

NG

INE

PR

OTE

CTI

ON

P.C

. BO

ARD

53B 56

A57

60A

EN

GIN

EFA

ILU

RE

LAM

P

54B

59

58A

54

J1

J2

53

53A

61 60C

IGN

ITIO

N

109

J3P

3

EN

GIN

EC

ON

NE

CTO

R

OIL

PR

ES

SU

RE

S

EN

SO

R

62

W

G

B

XY

CO

NN

ECT

TO C

AS

E

K92

4-5

RE

MO

TE C

ON

TRO

L (O

PTI

ON

AL)

REM

OTE

CO

NTR

OL

PO

TEN

TIO

MET

ER

BO

X

RE

SIS

TOR

S

PLU

G F

OR

REM

OTE

CO

NTR

OL

PO

TEN

TIO

MET

ER

A

A

AA

15A

CB

4300A

400E

400A

CB

120

A20

A15

A

#2 H

EA

VY

LE

AD

WIR

E F

EE

D M

OD

ULE

(OP

TIO

NA

L)

WIR

E

FEE

D

MO

DU

LE

}

NEG

.P

OS

.O

UTP

UT

TER

MIN

ALS

CO

NN

EC

T TO

PO

S. &

NEG

. {C

ON

NE

CT

TO N

EG

.B

RU

SH H

OLD

ER

608

609

#2 H

EA

VY

LE

AD

#8 L

EA

D

MAC

HIN

E M

US

T N

OT

BE

RU

NN

ING

WH

EN M

AK

ING

TH

ES

E C

ON

NE

CTI

ON

S.

*

ON

MAC

HIN

E, R

EMO

VE

PLU

G "P

10" F

RO

M C

ON

NEC

TOR

"J5"

.C

ON

NE

CT

PLU

G "P

5" O

N W

.F.M

. TO

CO

NN

ECTO

R "J

5" O

N M

ACH

INE

.

250

AM

PTH

ER

MO

STA

TA

SS

EM

BLY

INLI

NE

CO

NN

EC

TOR

SW

.F.M

.C

ON

TRO

LP

AN

EL

NEG

ATI

VE

CV

OU

TPU

T TE

RM

INA

LP

AN

EL

PLU

G(P

5)

AY

600

4260

2

W

48

41W

R

400B

W

GR

EM

OTE

CO

NTR

OL

REM

OTE

CO

NTR

OL

SWIT

CH

SHO

WN

IN L

OC

AL P

OSI

TION

OIL

PR

ES

SUR

E

350

400C

NO

TE

: T

his

dia

gra

m is

fo

r re

fere

nce

onl

y.

It m

ay n

ot

be

accu

rate

fo

r al

l mac

hine

s co

vere

d b

y th

is m

anua

l. T

he s

pec

ific

dia

gra

m f

or

a p

artic

ular

co

de

is p

aste

d in

sid

eth

e m

achi

ne o

n o

ne o

f th

e en

clo

sure

pan

els.

If

the

dia

gra

m is

ille

gib

le, w

rite

to

the

Ser

vice

Dep

artm

ent

for

a re

pla

cem

ent.

Giv

e th

e eq

uip

men

t co

de

num

ber

..

WIRING DIAGRAM - CODE 10910

F-5

CLASSIC II DEUTZ

F-5

PAR

T N

O.

WEL

DER

AB

CD

EF

GH

AC

ON

TRO

L PA

NEL

F

G

B

H

D

EC

O HO

LE

O MO

UN

TIN

GH

OLE

N.A

.

N.B

.

NO

TES: O

IL A

ND

WAT

ER IN

EN

GIN

E,B

UT

NO

FU

EL.

N.A

. C

ENTE

R O

F G

RAV

ITY

WIT

H

O

S107

66-6

J

J

K

KL

DIM

EN

SIO

N P

RIN

T

S

1076

6

MET

RIC

cm

(EN

GLI

SH in

.)

150.

7(5

9.32

)4.

8(1

.90)

58.4

(23.

00)

79.2

(31.

19)

43.8

(17.

25)

105.

8(4

1.66

)19

.1(7

.51)

CLA

SSIC

II

106.

7(4

2.0)

16.5

(6.5

0)

N.B

.

1.5

4 (.5

6) T

RAI

LER

M

OU

NTI

NG

HO

LES.

94.3

(37.

12)

61.0

(24.

00)

104.

0(4

0.94

)

47.0

(18.

50)

52.4

(20.

62)

10.2

(4.0

0)10

.2(4

.00)

1.54

(.56

) SK

ID1.

54 (.

56)

SKID

MO

UN

TIN

G

.N.C

.. D

IME

NS

ION

TO

TO

P O

FE

XHAU

ST E

LBO

W O

RR

AIN

CAP

.

L

N.C

.

02/

26

/ 03

DIAGRAMS

NOTES

CLASSIC II DEUTZ

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabi

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• 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 •

Documents

IM553