Arco Sumergido Manual Cr10

CR-10
Roller - Idler Welder
Machinery LLC
W1222 Linden Road
Ixonia, Wisconsin 53036 USA
Phone: 800.248.8405 or 262.567.3993
Fax: 262.567.4307
www.wtcmachinery.com
Machinery, LLC CR-10 Idler/Roller Welder TABLE OF CONTENTS
TABLE OF CONTENTS
SECTION 1: INTRODUCTION .....................................................………………………………… 1
SECTION 2: CR-10 IDLER/ROLLER WELDER SPECIFICATIONS ........……………………..… 2-5

Specifications.....................……………………………………...….. 2
Control Identification ………………………............................….… 3 – 5
SECTION 3: INSTALLATION ............………………………………………………………………... 6-9

Setting Up Location ........................………………………………. 6
Setting Up the Pay-out Paks ………………......................….…... 7
Setting Up the Welding Power Supply Units ……………………… 8
Setting Up the Flux Pump .................................……….…………. 8
Connecting the Yoke Tilt Cable …...............................….………. 9
Installing the Upper Flux Hopper ………………………………….. 9
Connecting the Air Supply ………………............................…….. 9
Testing the Machine ......……………………………………………. 9
SECTION 4: USING THE WELDER ……........................................………………………………. 10 - 17

General Approaches to Idler and Roller Rebuilding ……………… 10
Required Tools …………...................………………………………. 11
Loading Wire ………………………………………………………….. 12
Loading Flux ………………………………………………………… 13
Setting the Beam Carriage Height …………………………………..13
Workpiece Preparation ………………………………………………. 13
Loading Disassembled Idlers and Rollers …………………………. 14
Loading Assembled Idlers ……………………………………………15
Loading Assembled Rollers …………………………………………. 16
Flux Dams …………………………………………………………….. 17
Preheating …………………………………………………………….. 17
Welding Set-up - Circumferential Welding ………………………… 18 - 21
Welding Set-up - Cross Welding …………………………………… 22
Workpiece Cool-down ………………………………………………. 23
Advanced Techniques ………………………………………………. 23
SECTION 5: PREVENTATIVE MAINTENANCE ……………………………………………………. 24 - 25
SECTION 6: TROUBLESHOOTING WELDER PROBLEMS .......................……………………. 26
SECTION 7: RECOMMENDED SPARE PARTS …………………………………………………… 27
SECTION 8: CONSUMABLE GUIDE ………………………………………………………………… 28
APPENDIX: ASSEMBLY AND PARTS DRAWINGS ……………………………………………… 29

Machinery, LLC CR-10 Idler/Roller Welder INTRODUCTION
SECTION 1 - INTRODUCTION
This Manual covers installing, using and maintaining the Model CR-10 Idler/Roller Welder.
Safety Statements
There are a number of safety statements throughout this manual, in three different categories -
DANGER! - Information about risks to life

WARNING! - Information about risks of injury
CAUTION! - Information about risks of damage to equipment.
It is in the interest of operator, but also of management and supervisors, to read and understand ways to
safely get the most from the CR-10 Idler/Roller Welder.
Cleanliness
Occasional cleaning is part of long term maintenance of the Idler/Roller Welder. A clean piece of equipment
is more pleasant to operate, safer and easier to maintain. Pay particular attention to removing flux dust,
which is an abrasive to mechanical parts, and traps heat in electrical parts, especially the Welding Power
Supplies
WARNING!
Altering any part of the CR-10 Idler/Roller Welder or its components, or using the Welder in a manner
other than intended is at the operator's own risk.
Such alterations or uses must necessarily void the warranty against the CR-10 Idler/Roller Welder.
WARNING!
The CR-10 Idler/Roller Welder contains dangerous moving parts and dangerous electrical voltages.
Never operate the CR-10 Idler/Roller Welder without all guards and covers in place and secured to the Welder.
1
Machinery, LLC CR-10 Idler/Roller Welder SPECIFICATIONS
SECTION 2 - CR-10 SPECIFICATIONS

MACHINE DIMENSIONS
Weight Width Height Length

Main Welder 5000 lbs (2270 kg) 90 in (2,3 m) 130 in (3,3 m) 80 in (2,0 m)
Power Supplies (X 2) 800 lbs (370 kg) each 24 in (0,7 m) 36 in (0,9 m) 42 in (1,1 m)
Flux Recovery Pump 200 lbs (90 kg) 19 in (0,5 m) 30 in (0,8 m) 37 in (1,0 m)
Water Cooling System 150 lbs (70 kg) 15 in (0,4 m) 27 in (0,7 m) 30 in (0,8 m)
(Optional)
Operating Temperature Range ….. 40° to 110° F (4° to 43° C)
WORKPIECE DIMENSIONS
Maximum Weight……………….. 2000 lbs (910 kg)
Maximum Diameter……………. 52 inches (1320 mm)
Maximum Width ……………….. 26 inches (660 mm)
MACHINE SUPPLY
Compressed Air Requirement - 80 to 120 p.s.i. (5,5 to 8,3 atm) 5.0 ft3/min (0,15 m3/min)
WELDING POWER SUPPLIES

Two Welding power supplies - Power Requirements - (43.0 kVA each)
Output Voltage Current
Maximum Current …..…600 Amperes 230 Volts 108 Amperes each
Maximum Voltage ……. 50 Volts 380 Volts 67 Amperes each
Duty Cycle…………….. 100% 460 Volts 54 Amperes each
Other voltages available
FLUX RECOVERY SYSTEM

Flux Pump Type…… 2-Lobe "Roots" Type Power Requirements - (1½ Hp 1.1 kW)
Voltage Current
Flux Hopper Capacity…… 4900 in3 (81 liters) 230 Volts 5.4 Amperes
380 Volts 3.0 Amperes
460 Volts 2.7 Amperes
Other voltages Available
WIRE PAY-OUT PAK
Two Pay-out Paks -
Capacity sized for all popular welding wire barrel containers
Maximum Wire Barrel Diameter ……….. 24 in (628 mm)
Minimum Wire Barrel Diameter ………… 6 in (152 mm)
Maximum Wire Barrel Weight ………….. 1200 lb (540 kg)
WATER COOLING SYSTEM (Optional)

Used in roller service, the Water Cooling System transfers heat from the roller currently being welded to next
roller to be welded. This eliminates bore shrinkage, and shortens pre-heat time. The included Adapter Kit
allows use with most undercarriage types.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
2
Control Identification
Upper Flux Hopper D1500 CR-10 Idler/Roller Rebuilder

Beam Flux Hopper
Movable Beam
Control Console
Left Stop
Handle
Left Torch
Right Torch
Cylinder
Lock Pin
Air Clamp Right
Control Stop
Handle
Cylinder
Clamp
Bottom Flux Yoke

Hopper Wire
Yoke Tilt Switch Pay-out
Drive Shaft Paks
Lock Screw
AIR CLAMP CONTROL - controls the air clamp to hold the idler or roller in place. Pressing down on the
control clamps the workpiece (idler or roller), pulling up releases the workpiece.
LEFT STOP HANDLE - sets the point at which the torches will stop traveling left, either in CIRC Mode step-
over, or in CROSS Mode travel
RIGHT STOP HANDLE - sets the point at which the torches will stop traveling right, either in CIRC Mode
step-over, or in CROSS Mode travel
YOKE TILT - tilts the yoke and workpiece clockwise or anti-clockwise.
3
Control Identification (Continued)
9 10 11 12 13
1) ARC STOP - Stops the welding cycle 8 14
AUTOMATIC DIRECTION SPEED MANUAL

MODE BEAM
2) ARC START - Starts the welding cycle

5
4 6 LIFT/LOWER
CIRC UP 3 7
7 OFF OFF
2
1 9
8
15
CROSS/FLANGE DOWN 0 10
WTC Machinery Corporation

AUTOMATIC MOVEUP 45 Capitol Drive, Oconomowoc, Wisconsin 53066 USA
16
6
3) LEFT VOLTAGE - Controls the voltage of the Left Torch WELD MODE
CROSS
OFF
Head CIRC 17
5 SPINDLE INDEX
LEFT ARC RIGHT ARC
VOLTAGE FEED RATE VOLTAGE FEED RATE
5 5 5 5
4 6 4 6 4 6 4 6
18
3 7 3 7 3 7 3 7
INCH
2 8 2 8 2 8 2 8
4 1 9 1 9 1 9 1 9
4) INCH - Manually moves the Left and Right welding wire 0 10

ELECTRODE 0
OFF
UP
10 0 10
ELECTRODE 0
OFF
UP
10
ARC START DOWN DOWN

19
SPINDLE
3 JOG FWD SPEED
FLUX REC.
ON
NOZZLE BEAM
MOVE SPEED
4
5
6
ARC STOP
5) SPINDLE INDEX - Lights at the Step-over point

3 7
OFF
2 8 20
REV 1 9
2 WTCMACHINERY CORPORATION OCONOMOWOC, WI. 53066

0 10
DWELL ELECTRODE
TIME INCH
1 21
6) WELD MODE - selects the welding mode : 25 24 23 22
CIRC (Circumferential or Stringer) Mode constantly 26 27

turns the idler or roller beneath the torch heads.
Once every revolution the torches
step to the left or right to overlap the
previous weld bead.
CROSS Mode moves the torch heads left and right over the roller or idler. At each end of the torch
travel, the idler or roller turns briefly, overlapping the previous weld bead.
7) LEFT VOLTMETER - Displays the voltage of the Left Torch Head
8) MOVEUP AUTOMATIC MODE - selects the Moveup mode

CIRC Mode raises the Beam and torch heads when the torches reach the right or left End-of -Travel
CROSS/FLANGE raises the Beam and torch heads at the Spindle Index Point
9) MOVEUP DIRECTION - selects the direction the Beam moves, or turns the Moveup off.
10) LEFT WIRE FEED METER - shows the speed of the wire feeding through the Left Torch Head. This is
directly related to the Amps of the Left Torch
11) LEFT FEED RATE - sets the speed of the Left welding wire once the welding arc is established. This is
directly related to the Amps at the Left Torch Head.
12) MOVEUP SPEED - sets the speed the torches move up and down. It also controls how far the torches
move in the Automatic Modes; a higher speed will mean a larger automatic moveup.
13) RIGHT VOLTMETER - Displays the voltage of the Right Torch Head
14) MANUAL BEAM LIFT/LOWER -This moves the torches close to or away from an idler or roller. Pulling
out on the pushbutton starts the torches moving. Pushing in on the pushbutton stops the torches.
15) RIGHT FEED RATE - sets the speed of the Right welding wire once the welding arc is established. This
is directly related to the Amps at the Right Torch Head.
16) RIGHT VOLTAGE - Controls the voltage of the Right Torch Head
4
Control Identification (Continued)
17) RIGHT FEED RATE - sets the speed of the Right welding wire once the welding arc is established. This
is directly related to the Amps at the Right Torch Head.
18) RIGHT ELECTRODE UP/OFF/DOWN - selects the direction of the right welding wire. Welding happens
in the DOWN position
19) NOZZLE BEAM SPEED - sets how fast the left and right troches move from side-to-side
20) NOZZLE BEAM MOVE - manually moves the left and right troches from side-to-side
21) FLUX RECOVERY ON/OFF - starts and stops the flux recovery system
22) LEFT ELECTRODE UP/OFF/DOWN - selects the direction of the left welding wire. Welding happens
in the DOWN position
23) SPINDLE SPEED - sets the speed the idler or roller rotates
24) SPINDLE FWD/REV - selects whether the idler rotates forward (top away from the front) or reverse (top
towards the front)
25) SPINDLE JOG - manually rotates the idler or roller
26) DWELL TIME (on the control console's right side) - sets how long a period the idler or roller rotates a
each end of CROSS Mode travel
27) ELECTRODE INCH - sets how fast the left and right welding wire travel before an arc is struck. This is
set to a meter reading of 30 for welding, but increased to allow faster loading of new wire.
5
Machinery, LLC CR-10 Idler/Roller Welder INSTALLATION
SECTION 3 - INSTALLATION -
A) SETTING UP THE LOCATION
Use care in locating the CR-10 Idler - Roller Welder. It should be sited near electrical and compressed air
supplies. (Cooling water and a waste-water drain are also needed if the Welder is equipped with the
optional Water System)
Provide room for walkways on all sides of the welder – this is safer and simplifies maintenance.
See the drawing (below) for a recommended floor plan.
If an existing floor is used, make sure it will support the Welder, that it is made from a non-flammable
material (concrete, for example) and that the floor does not include metal bars that conduct electricity.
Site the Main Machine. While not necessary, it is recommended that the Main Machine is anchored to the
floor using eight ¾" (19 mm) or smaller anchor bolts.
Unpack the Control Console, and position it as shown in the Floor Plan drawing, below.
CR-10 Idler Roller Welder

204 in
(5,18 m)
Workpiece Load
Unload Access
Control
)
,3 i n
m
Console
(0 14
55
89 1/2 in
Vertical Clearance
(2,27 m)
Required Over Machine:
130 in (3,30 m)
22 559
(0
,
in m)
Workpiece
Cooling
Area
Power Supplies
(2,03 m)
80 in
(2 Units Stacked)
(3,66 m)
144 in
Flux Pump
COMPRESSED AIR
CONNECTION
23 in
FLUX PUMP (0,58 m)
ELECTRICAL
CONNECTION
38 1/2 in
(0,98 m)
(1,02 m)
40 in
Wire Load Access
19 1/2 in
(0,50 m)
WELDER ELECTRICAL Wire Pay-Out Paks
CONNECTION (X 2)
134 in
(3,40 m)
6
B) SETTING UP THE PAY-OUT PAKS
Assemble the two Pay-out Paks, and locate them behind the Main Machine, as shown in the General Floor
Plan on page 5. Allow room between the Pay-out Paks and the Main Machine so the triangular Turntables
can move freely without hitting each other or any part of the Main Machine.
Focus on one of the Pay-out Paks. Loosen the bolts

holding the Turntable Pegs, and slide the Pegs away Pay-out Pak Assembly
from the center of the Turntable. Place a barrel of Wire Feed
Assembly
welding wire centered on the Turntable. Slide the three
Pegs in until they touch hthe wire barrel, and tighten the Wire Liner
Peg bolts.
Top Hat Wire Liner
Connect the Wire Liner from the nearer Wire Feed Wire Hold
Assemble to the Wire Hold Bracket, and tighten the bolt Bracket
to hold it in place. Top Hat Upright Wire Guide
Post (X 3) Pipe
Turntable
Loosen the bolt holding the Wire Guide on the Upright
Pipe, and move the Wire Guide so it is 1" -2" (25 - 50 TurnTable
Peg (X 3)
mm) above the top of the wire barrel, and the Wire Hold
Bracket is near the wire barrel. Re-tighten the bolt.
Loosen the nuts locking the Wire Hold Bracket to the Wire Guide, and adjust them so the Wire Hold Bracket
is 1" -2" (25 - 50 mm) away from the edge of the wire barrel. Tighten the nuts.
Loosen the bolts locking the Top Hat Posts to the Top Hat. Slide the Top Hat Posts so they are centered,
and just fit inside the cardboard liner at the center of the wire barrel. Re-tighten the bolts, and place the Top
Hat on the wire barrel.
Turn the Turntable, wire barrel and Top Hat to make sure they spin freely, and that they don't touch the Wire
Hold Bracket or any parts of the other Pay-out Pak or Main Machine.
Repeat the above steps with the other Pay-out Pak.
7
C) SETTING UP THE WELDING POWER SUPPLY UNITS
DANGER!
Electricity kills! All electrical work should be done by qualified personnel,
All electrical connections must be made in accordance with the U.S.A. National Electrical Codes.
Outside the U.S.A., local codes and ordinances must be followed and adhered to.
Position the two Welding Power Supply Units behind the Main Machine (see the Floor Plan drawing, page
5), facing the control end of the Units toward the Main Machine. The Power Supplies Units can be put side-
by-side, or stacked one atop the other. If placing the Units side-by-side, note that the right Unit is marked
with "R" tags ("R+", "R-" and "RC"), and the left Unit with "L" tags ("L+", "L-" and "LC") If stacking the Power
Supplies, make sure the bottom unit is level and firmly supported by the floor.
The electrical supply to the Welding Power Supply Units should have a lockable shutoff and over-current
protection. Two methods are a circuit breaker or a fused disconnect switch. Connect the electrical supply to
the end of the Power Supplies opposite the controls. Check the voltage connection instructions inside the
Power Supply to make sure the Power Supply is properly connected for the electrical supply voltage.
Unpack the Frame Ground cables ("L-" and "R-") and the Electrode Cables ("L+" and "R+") from the bottom
Flux Hopper to the back of the Main Machine. Route the cables to the Power Supply Units. Choose a path
to avoid the cables being tripped over, tangled in Pay-out Paks, run over or stepped on. Connect the cables
to the matching terminals on the Power Supply Units.
Unpack the Power Supply Control Cables ("LC" and "RC") from the Control Console. Again, route the
cables to the Power Supply Units choosing a path out of harm's way. Open the access covers at the front of
the Power Supply Units.
Loosen the cord grips to the right of the access covers, pass the ends of the Control Cables through the
cord grips, and then tighten the cord grips. Connect the Control Cable wires to the matching terminals on
the Power Supply Units.
D) SETTING UP THE FLUX PUMP
Locate the Flux Pump at the back of the Main Machine (see the Floor Plan drawing, page 5.) Face the Inlet
Connector towards the Main Machine.
As before, the electrical supply to the Flux Pump should have a lockable shutoff and over-current protection
(either a circuit breaker or a fused disconnect switch.) See the Section 2 – Specifications (page Connect the
electrical supply to the Starter at the side of the Flux Pump. Check the voltage of the electrical supply
against the voltage specified on the face of the Starter.
Unpack the Flux Pump Control Cable ("FP") from the Bottom Flux Hopper to the back of the Main Machine.
Choose a safe path to the Flux Pump. Pass the cable through the cord grip on the bottom of the starter, and
tighten the cord grip. Connect the cable leads to the matching wires in the Flux Pump Starter.
Unpack the 1½" (37 mm) diameter Flux Hose from the Bottom Flux Hopper to the back of the Main Machine.
Route it, via a safe path, to the Flux Pump. Locate the Flux Pump outlet - hold open the spring-loaded cover
and push the metal coupling at the end of the flux hose into the outlet.
8
E) CONNECTING THE YOKE-TILT CABLE
Unpack the Yoke-Tilt Power Cable ("115 VAC") from the Bottom Flux Hopper to the back of the Main
Machine. Route the cable safely, and connect it to the Left Welding Power Supply Unit ("LC") as follows -
Black wire to #32 Terminal
White wire to #31 Terminal
Green wire to GND Terminal
F) INSTALLING THE UPPER FLUX HOPPER
Unpack the Upper Flux Hopper. Remove one of the cotter pins from the Pivot Shaft, and remove the Pivot
Shaft from the Hopper.
Use a sturdy ladder or other stable platform to place the Upper Flux Hopper on top of the Beam Flux
Hopper, with the hose elbows on its top facing the back of the Main Machine.
Hose Clamps
Position the Upper Flux Hopper so the two metal angles
Flux Hoses Upper Flux Hopper
on its bottom are outside of the two metal angles on the
top of the Beam Flux Hopper. Pivot Shaft
Flux Limit Switch
Line up the holes at the back of the four angles, and Beam Flux Hopper
pass the Pivot Shaft through the holes, placing washers
in between the Upper Hopper angles and the Beam
Hopper angles. Re-install the cotter pin, and bend it so
it stays in place.
Install the Flux Limit Switch to the Upper Flux Hopper,

using the socket-head cap screws provided.
Bring the two 1½" (37 mm) flux hoses to the Upper Flux Hopper. Loosen the hose clamps at the ends of the
hoses, and push the hoses onto the elbows atop the Upper Flux Hopper. Re-tighten the hose clamps.
Re-position at the front of the Hopper. Remove the Die Spring and bolt from the under-side of the Upper
Flux Hopper. Place the Die Spring between the Beam Flux Hopper Frame and the Upper Flux Hopper.
Pass the bolt through the hole in the Beam Flux Hopper and the Die Spring, and tighten the bolt into the
threaded hole on the under-side of the Upper Hopper.
G) CONNECTING THE AIR SUPPLY Air Connection
Connect a compressed air supply line to the Air Supply Regulator/Filter at

the left back of the Main Machine. The supply pressure should be from
80 to 120 p.s.i. (5.5 to 8.3 atm) with a flow of 5.0 ft3/min (0,15 m3/min)
H) TESTING THE MACHINE
Focus on the Control Console. Make sure the "MODE" switch, the "LEFT ELECTRODE" switch, the
"RIGHT ELECTRODE" switch and the "FLUX RECOVERY" switch are all in the "OFF" position.
Start the right Welding Power Supply Unit. Position an assistant near the Flux Pump to watch the direction
the Pump Drive Belt turns. Turn the "FLUX RECOVERY" switch on for a second, and then off. If the Flux
Pump Drive Belt travels backwards, turn off power to the Flux Pump Starter, and swap two of the three
power leads to the flux pump. Turn power back on and check the belt travel direction again.
The CR-10 is now ready for operation.
9
Machinery, LLC CR-10 Idler/Roller Welder USING THE WELDER
SECTION 4 - USING THE WELDER
GENERAL APPROACHES TO IDLER AND ROLLER REBUILDING -
Techniques -
The goal in rebuilding idlers and rollers is returning the workpiece to its original dimensions while creating a
smooth, wear resistant surface. To do this, two techniques are used - "circumferential" (CIRC or "stringer")
welding, and "cross" welding. Stringer welding is easier to master and set-up and works on unevenly worn
tread surfaces and flanges. Cross welding is more difficult to master and only works level tread surfaces, but
can deposit metal faster.
Always consult the idler or roller manufacturer for guidance on the correct rebuild procedure.
Flange Face
Buildup Sequence - Flange Side Cupped Wear
No two idlers or rollers will be worn the same way. The operator Tread Surface
3rd Pass
must decide on the best sequence of beads to return the
2nd Pass
workpiece to its original dimensions.
1st Pass
Generally, rebuilding begins by leveling the tread surface. Use a

series of stringer beads to level cupped or sloping tread surfaces, 3rd Pass
working up from the lowest point of the tread surface. 2nd Pass
1st Pass
Once the tread is level, weld across the entire tread surface, either
with a series of stringer beads or using cross weld, until the tread Sloping Wear Flange
is built back to the original diameter.
Rebuild flange sides with a series of stringer weld beads, stepping up the face of the flange.
Checking the Dimensions -

Always consult the original manufacturer's specifications for idler and roller dimensions. Use a caliper to
measure the tread and flange diameters, and a wear gauge to check the shape of the tread and flange
surfaces, to make sure they will match the tractor rails.
It is important that both sides of the idler or roller are built up to the same diameter. If not, the larger side will
take more load and wear faster.
Step-over Correct
Step-over Distance -
The Step-over Distance sets the spacing between one weld bead and the next, and
affects the over-all smoothness of the welded surface. In circumferential, or
stringer, welding, the Step-over Distance is set by a combination of the Dwell Time Step-over Too Large
and the Nozzle Beam Speed. For cross welding, the Step-over Distance is set by a
combination of the Dwell Time and the Spindle Speed.
Step-over Too Small
A Step-over Distance set too large leaves gaps between weld beads. Too small a
Step-over distance cause the weld to "pile up" with the diameter getting larger as weld beads are added.
The correct step-over distance leaves a smooth, level surface.
10
GENERAL APPROACHES TO IDLER AND ROLLER REBUILDING - (CONTINUED)
Weld Quality and Bead Profile -

The easiest check on weld quality is the shape of the weld bead profile. Apart from the choice of welding
wire and flux, four things affect the bead profile - Voltage, Wire Speed, Lead Distance, and Travel Speed.
Voltage - is usually specified by the welding wire Welding Process -

General Arrangement Torch Pipe
manufacturer. Generally, the voltage is set from
Insulator Bushing
26 to 30 Volts for narrow weld beads, and 28 to 32
Welding Tip Adapter
Volts for wider weld beads.
Flux Hose
Welding Tip
Welding Flux
Wire Speed - is the rate at which the welding wire is feed Flux Nozzle
onto the workpiece. This is directly related to the
-out
Wire
Welding Wire
Stick
amperage of the weld. Flux and Slag
Flux Dam
The Wire Speed affects the width of the weld bead Lead
and the weld penetration (bonding of the weld CL WORKPIECE

bead with the surface.) Coordinate Wire Speed
with the Lead distance and Travel Speed to get the
proper weld bead.
Lead - is the horizontal distance between the welding wire and the vertical center-line of the idler or roller.
The correct lead will vary from ½" (12 mm) for a small roller to about 2½" (64 mm) a large idler.
Travel Speed - is the speed of the welding tip related to the workpiece. In circumferential or stringer
welding, this is the Spindle Speed (the speed that the idler or roller turns.) In cross welding, this is
the Nozzle Beam Speed (the speed that the torches move across the tread surface.)
A general guide is to set the travel speed at 30 inches per minute (760 mm/min) Faster or slower
speeds will give wider or narrower weld bead profiles.
Peaked Concave
Common bead profiles are the peaked and concave bead profiles, Bead Bead Flat
Bead
which are not wanted, and the flat bead, which is.
The peaked bead (cool weld) leaves an uneven surface, and

makes slag removal difficult. Causes are the Voltage or Wire
Speed set too low for the Travel Speed, or by a Lead Distance that Bead Profiles
is too small.
The concave bead (hot weld) also leaves an uneven surface. Often the weld bead is hot enough to flow
away from the weld bead, leaving rivulets and drops of weld metal on the surface. This is caused by the
Voltage or Wire Speed set too high for the Travel Speed, or a Lead Distance that is too large.
The flat bead has an oval cross-section. This is the correct balance of Voltage, Wire Speed and Travel
Speed. The flat bead allows the maximum build-up per pass and results in the best surface finish, with weld
beads flowing into each other to leave a smooth surface.
11
REQUIRED TOOLS -
The preferred tools for rebuilding idlers and rollers will vary between operators. At minimum, have:
- a chipping hammer to remove weld slag,
- a wire cutters to trim the welding wire,
- a large caliper and a tape measure or scale to check the diameter
- a wear gauge to check the profile of the idler or roller
- a set of inch (imperial) hex keys ("Allen wrenches") and open-end wrenches for machine
adjustments
LOADING WIRE -
The Model CR-10 Idler / Roller Welder uses welding wire (supplied in barrels, also known as “pay-out paks”
or POP’s) and shielding flux in the rebuilding process. Please see the “Consumable Guide” on page 28 for
details on recommended types of wire and flux.
Load wire barrels on the two Pay-out Paks (see page 6.) Focus
Clamp Spring
on one of the wire barrels, and find the end of the welding wire. Tube Adapter
Straighten the first 12" to 18" (300 to 450 mm) of the wire, and Clamp
remove any burrs from its end. Feed the welding wire through Bolt
Pressure Roll
the Wire Hold Bracket and lower Wire Liner until it touches the
Wire Feed Drive and Pressure Rolls. Latch Side
Drive Roll
Plate
Focus on the Wire Feed. Loosen the hex nut on the Clamp
Bolt, and move the Clamp Bolt and Clamp Spring out of the
way. Swing the Latch Side Plate open. Pull the welding wire
past the Drive Roll and feed it into the upper Tube Adapter.
Tube Adapter
Swing the Latch Side Plate back up until the Pressure Roll
touches the Drive Roll. If needed, turn the Pressure Roll so it
meshes with the Drive Roll. Push the Clamp Bolt and Clamp Spring back their original position. Tighten the
hex nut until it begins to compress the Clamp Spring, and then tighten it five more turns.
Move to the front of the welder, to the proper Torch Head (left or
right.) Loosen the Flux Nozzle hose clamp, and slide the Flux Nozzle
off of the Torch Pipe. Loosen and remove the Welding Tip and
Welding Tip Adapter together.
Turn the right-side Welding Power Supply On. Find the proper
Torch Pipe
"ELECTRODE" switch (left or right) and switch it to the DOWN
position. Press and hold the "INCH" push button.
Welding Tip and
Welding Tip Adapter
Occasionally, the wire will snag on the Spring Liner inside the Torch
Pipe. If this happens, push the Spring Liner back into the Torch Flux Nozzle
Pipe. When the welding wire extends 2" to 3" (50 to 75 mm) past the
end of the Torch Pipe, release the "INCH" push Button.
Re-install and tighten the Welding Tip, Welding Tip Adapter and Flux Nozzle, and then load the welding wire
on the other Torch Head.
12
LOADING FLUX -
Pour clean, dry welding flux into the Bottom Flux Hopper. With the right Welding Power Supply On, turn the
"FLUX RECOVERY" switch ON. The Flux Pump starts drawing flux to the Upper Flux Hopper.
Vibrator Flow Control
Move to the left back of the Main Machine and locate the
Vibrator Flow Control. Turning this clock-wise increases the
shaking of the Bottom Flux Hopper.
More shaking speeds the flux flow through the Bottom Flux
Hopper screen, but increases the noise and compressed air
use. Generally, choose the lowest setting that allows flux to
pass easily through the flux screen.
SETTING THE BEAM CARRIAGE HEIGHT -
To make sure there is enough clearance for the workpiece,

measure the vertical clearance - the vertical distance from Beam Carriage
the center of the Spindle Shaft to the bottom of the Flux
Nozzle.
This distance should be larger than the distance from the

center of the workpiece to its edge. If not, raise the Beam Vertical
Carriage. Clearance
To raise the Beam Carriage, set the "MOVEUP DIRECTION"

switch to UP, and turn the "MOVEUP SPEED" control fully
clock-wise to the "10" setting. Pull out on the "MANUAL
BEAM LIFT/LOWER" push button. When the Beam
carriage reaches the proper height, push in on the "MANUAL
BEAM LIFT/LOWER" push button.
To lower the Beam Carriage, set the "MOVEUP DIRECTION" switch to DOWN, and turn the "MOVEUP
SPEED" control fully clock-wise to the "10" setting. Pull out on the "MANUAL BEAM LIFT/LOWER" push
button. When the Beam carriage reaches the proper height, push in on the "MANUAL BEAM
LIFT/LOWER" push button.
WORKPIECE PREPARATION -
Thoroughly clean the idler or rollers. Remove all dirt, grease and rust by steam cleaning, washing and wire
brushing. A power wire brush is very helpful for the removal of rust, but take extreme care not to mix the dirt
or rust with the flux in the Bottom Flux Hopper. Dirt or rust mixed with the flux will cause porosity in the
welds.
13
LOADING DISASSEMBLED IDLERS AND ROLLERS -
WARNING!
Solid (drum style) idlers have an inside cavity which can contain moisture.
Heating these idlers creates steam, which can rupture the idler, destroying the idler and creating dangerous flying debris.
Always vent these idlers with a drill or cutting torch before rebuilding.
Disassembled idlers and rollers have the axle shaft removed - this common for idlers.
The first step in setting up is to measure the center bore diameter and bore length of the workpiece.
Choose and install the proper cones, based on the bore diameter. The smaller cones (B2712 Cylinder Cone
and B2713 Spindle Cone) are used on bores smaller than 7" (175 mm), generally small idlers and rollers.
The large cones (D1521 Cylinder Cone and D1522 Spindle Cone) are used on large idlers.
Retract the Air Cylinder, by pulling up on Disassembled Idler and Roller Clamping
D1521 Large Cylinder Cone
the Air Clamp Control. Adjust the Air D1522 Large Spindle Cone
Air Cylinder Clamp
Cylinder and the Spindle Shaft so the
Air Clamp Control
distance between the cones is slightly
Cylinder Spindle Shaft
larger than the bore length of the Lock Pin Lock Screw
workpiece and centered on the yoke.
Spindle Shaft
B2713 Cylinder Cone B2712 Spindle Cone
Adjust the Air Cylinder by removing the
Cylinder Lock Pin, sliding the Cylinder to
line up with a hole in the Yoke, and
reinstalling the Cylinder Lock Pin.
Adjust the Spindle Shaft by loosening the

Spindle Shaft Lock Screw, sliding the Spindle Shaft, and re-tightening the Lock Screw.
Lift the workpiece, using a safe lifting device (Locking Lifting Tongs, part number 532-
239A, are available from WTC Machinery Corporation) and a crane or forklift with Lifting Tongs
(WTC Part No. 532-239A)
enough lifting capacity for the weight of the idler or roller.
Place the workpiece between the cones, so the right side of bore touches the Spindle
Cone. Push down on the Air Clamp Control to clamp the workpiece. Slowly lower the
crane or forklift, while checking that the workpiece is tightly clamped.
If not, raise the crane or forklift to support the idler or roller again. Pull up on the Air
Clamp Control, and remove the Cylinder Lock Pin. Shift the Air Cylinder closer and re-
install the Lock Pin. Push down on the Air Clamp Control to again clamp the workpiece.
Once the workpiece is tightly clamped, loosen the bolt on the Air Cylinder Clamp, and slide the Clamp to the
left as far as possible. Tighten the Clamp bolt again.
The workpiece is ready to pre-heat.
14
LOADING ASSEMBLED IDLERS -
WARNING!
Solid (drum style) idlers have a sealed cavity, which can contain moisture.
Heating these idlers creates steam, which can rupture the idler, destroying the idler and creating dangerous flying debris.
Always vent these idlers with a drill or cutting torch before rebuilding.
The first step in setting up assembled idlers is to measure the length of the idler axle shaft. The CR-10
Idler/Roller Welder can hold axles up to 26" (660 mm) long.
Loosen the Axle Lock Screw on the Air Cylinder. If a cone is mounted on the Air Cylinder, remove it and the
A2361 Center Shaft, and install the A2360 Axle Center onto the Air Cylinder. Tighten the Axle Lock Screw
until it just touches the Axle Center, and then loosen it ¼ turn. Tighten the Axle Lock Screw's lock nut.
If a cone is installed on the Spindle Shaft,

loosen the locking set screw, and remove Assembled Idler Clamping
A1947 Weld-on Tab
A2360 Axle Center
the cone. A1389 Connector Arm
Air Cylinder Clamp A1926 Turning Arm
Air Clamp Control C0701 Drive Bar
Assemble the Drive Bar, Turning Arm, A1927 Bushing (X 2)
Cylinder Spindle Shaft
Connector Arm and Weld-on Tab as Lock Pin Lock Screw
shown in the Appendix.
Spindle Shaft
Install these parts onto the Spindle Shaft. Axle Lock Screw
Retract the Air Cylinder, by pulling up on

the Air Clamp Control. Adjust the Air
Cylinder and the Spindle Shaft so the
distance between the Axle Center and
the end of the Spindle Shaft is slightly
larger than the length of the idler axle.
Lift the idler, using a safe lifting device (Locking Lifting Tongs, part number 532-239B, are available from
WTC Machinery Corporation) and a crane or forklift with enough lifting capacity for the idler's weight.
Place the idler between the Axle Center and the Spindle Shaft, touching the Spindle Shaft. Push down on
the Air Clamp Control to clamp the idler. Slowly lower the crane or forklift, checking that the idler is
supported. If not, raise the idler, unclamp the idler, adjust the Air Cylinder, clamp again.
Once the idler is supported, loosen the Air Cylinder Clamp, slide the Clamp to the left and tighten the Clamp
bolt again.
Adjust the Turning Arm and Connector Arm so the Weld-on Tab touches the side of the idler. Weld the
Weld-on Tab to the idler with a minimum 1/4" (6 mm) weld bead. Tighten the bolts holding the Weld-on Tab,
Connector Arm, Turning Arm and Drive Bar together.
The idler is ready to pre-heat.
15
LOADING ASSEMBLED ROLLERS -
Always use the Water Cooling System (WTC Machinery part number D1099) when welding assembled
rollers. Without water cooling, rollers heat beyond safe levels, warping the roller and damaging the roller's
bearings and seals.
The first step in setting up assembled rollers is to install the water cooling components (probe tip, adapter
and probe base) into the roller shaft. See the Water Cooling System manual for part numbers and details.
Measure the length of the roller axle shaft, including the probe base and adapter. The CR-10 Idler/Roller
Welder can hold axles up to 26" (660 mm) long.
Loosen the Axle Lock Screw on the Air Cylinder. If a cone is mounted on the Air Cylinder, remove it along
with the A2361 Center Shaft.
Assembled Roller Clamping
A1780 Drive Rod (X 2)
A2360 Axle Center
Install the A2360 Axle Center onto the Air 56-0114 Spring (X 2)
Air Cylinder Clamp A1725 Bushing (X 2)
Cylinder. Tighten the Axle Lock Screw until it
Air Clamp Control C0701 Drive Bar
just touches the Axle Center, and then loosen it
Cylinder
¼ turn. Tighten the Axle Lock Screw's lock nut. Lock Pin
Spindle Shaft
Lock Screw
If a cone is installed on the Spindle Shaft, Spindle Shaft
loosen the locking set screw, and remove the Axle Lock Screw
cone.
890110 Probe Base
Assemble the Drive Bar, Bushings, Springs and

Drive Rods as shown in the Appendix. Install
these parts onto the Spindle Shaft.
Pull up on the Air Clamp Control to retract the Air Cylinder. Adjust the Air Cylinder and the Spindle Shaft so
the distance between the Axle Center and the end of the Spindle Shaft is slightly larger than the length of
the roller axle and water adapter.
Lift the roller, using a safe lifting device (Locking Lifting Tongs, part number 532-239A, are available from
WTC Machinery Corporation) and a crane or forklift with enough lifting capacity.
Place the roller between the Axle Center and the Spindle Shaft, touching the Spindle Shaft. Push down on
the Air Clamp Control to clamp the idler. Slowly lower the crane or forklift, while checking that the idler is
tightly clamped.
If not, raise the crane or forklift to support the idler, unclamp the roller, adjust the Air Cylinder, clamp again.
Once the roller is tightly clamped, loosen the bolt on the Air Cylinder Clamp, and slide the Clamp to the left
as far as possible. Tighten the Clamp bolt again.
Adjust the Bushings so the two Drive Rods are even with the sides of the roller. Turn the hex nuts on the
Drive Rods until the Springs start to compress, and then turn the hex nuts to put tension on the Drive Rods
(generally 4 full turns for small rollers, and 6 turns for large rollers.)
The roller is ready to pre-heat.
16
FLUX DAMS -
Flux dams contain the flux around the welding wire. This makes sure that the weld is shielded, and keeps
the use of the Flux Recovery system to a minimum. The placement of flux dams depends on the size,
shape and wear pattern of the workpiece.
In general:
All Rollers and small idlers need flux dams in Dam Dam
front of the welding wire to keep the flux Dam
Dam
from spilling down the tread surface
Dam
Single-flange rollers need flux dams on the

unflanged side of the tread surfaces to Front Dam
Single-Flange
keep the flux from spilling off of the edge Roller Dams
Idler Dams
of the tread.
All Idlers - need flux dams on the sides of the

idler to keep flux from spilling off of the Position Flux Dams
edge of the tread surface.
Assemble the Flux Dam Mount, adjust the height

of the Cross Bar to clear the idler or roller, and
clamp the flux dams in position – against the Adjust Height
outside of the tread surface on idlers, or against
the inside of the tread surface on single-flange
rollers. Once the position is correct, tighten all of
the bolts to lock the Flux Dam Mount.
PREHEATING -
Pre-heating the workpiece is necessary for good quality welding. It removes moisture from the workpiece,
and prevents cracking from too-rapid heating of welding on cold metal.
As a general rule, small disassembled rollers should be heated from 90° to 120°F (30° to 50°C) and large
rollers to 200°F (95°C) Idlers should be thoroughly to pre-heated to 300°F (150°C), starting at the hub and
working out to the rim. Always consult the manufacturer for pre-heating recommendations.
The most effective way to evenly pre-heat is to use large fuel-oxygen torches ("rosebuds") pointed at the
front of the workpiece, while the workpiece is turning.
To set the workpiece turning, make sure the "LEFT ELECTRODE" and "RIGHT ELECTRODE" switches are
in the OFF position. Move the "SPINDLE DIRECTION" switch up, press the "ARC START" push button, and
adjust the SPINDLE SPEED control to get a satisfactory speed.
When pre-heating is done, press the "ARC STOP" button.
17
WELDING SET-UP - CIRCUMFERENTIAL WELDING
Before welding on an idler or roller, plan the sequence of beads, starting at the lowest (smallest diameter)
Setting the Width of the Weld Area-

Once every complete turn of idler or roller, the two torch heads will step-over (move sideways.)
When the right Torch Carriage reaches the left and right Limit Stops, it changes step-over direction, to keep
the torches from traveling past the weld area in step-over.
The Limit Stops are set to keep the Torch Heads confined within the part of the workpiece that needs
welding. With unevenly worn workpieces, the 1st series of weld beads are narrower than the 2nd series of
weld beads. The weld process can be stopped after the 1st series of welds to re-adjust the Limit Stops.
With practice and experience, the adjustment can be made while the welding continues.
Briefly using CROSS mode is the easiest way to set the Limit Stops.
Use the Beam Lift controls, or the Left and Torch Head Adjustments
Right Vertical Adjustments to raise the torch
heads clear of the highest part of the
workpiece. Left Limit Stop
Adjustment
Make sure the make sure both the "LEFT

ELECTRODE" and "RIGHT ELECTRODE" Left Side
Adjustment
switches are in the OFF position. Turn the
Left Vertical
right Welding Power Supply ON. Put the Adjustment
"WELD MODE" switch is in the CROSS Right Limit Stop
Left Lead Adjustment
position. Press the "ARC START" push Adjustment
Right Side
button to start the torch carriages moving side Adjustment
to side. Turn the "NOZZLE BEAM SPEED" Right Lead Right Vertical
control clockwise to increase the travel speed Adjustment Adjustment
of the torch carriages.
Watch the right Torch Head relative to the weld area on the workpiece. Turn the Right Limit Switch
Adjustment to change where the torch stops at the right end of its travel, and the Left Limit Switch
Adjustment to change the left.
When the right Torch is set, move to the left Torch Head over its weld area using the Left Side Adjustment.
Press the "ARC STOP" push button to stop the Torch Heads moving.
18
WELDING SET-UP - CIRCUMFERENTIAL WELDING (CONTINUED)
Setting the Step-over Distance -

The correct step-over distance depends on the width of the weld. A step-over from ½ to ¾ the width of the
weld bead usually gives a flat weld surface with good blending between weld beads.
A good general step-over setting is ¼" (6 mm.)
To set the step-over distance, make sure both the "LEFT ELECTRODE" and "RIGHT ELECTRODE"
switches are in the OFF position, and the right Welding Power Supply is ON. Turn the "WELD MODE"
switch to the CIRC position. Press the "ARC START" push button to start the workpiece turning. Turn the
"SPINDLE SPEED" control clockwise to shorten the time between step-overs.
The step-over happens once every revolution, shown by the "SPINDLE INDEX" light. The step-over is also
advertised by machined flat on the Spindle Shaft - the step-over happens when the flat is facing up.
Two controls change the step-over distance -

The "DWELL TIME" control (on the right side of the Control Console) sets the length of time
for the step-over. This is usually left at a time setting of about one second.
The "NOZZLE BEAM SPEED" control sets how fast the Torch Heads move during the step-
over. Turning this clock-wise increases the step-over speed and the distance.
When the step-over distance is set, press the "ARC STOP" push button to stop the workpiece.
Setting the Spindle Speed -
To set the spindle speed, make sure both the "LEFT ELECTRODE" and "RIGHT ELECTRODE" switches
are in the OFF position. Turn the right Welding Power Supply ON, and set the "WELD MODE" switch to the
CIRC position. Press the "ARC START" push button to start the workpiece turning.
The correct spindle speed setting depends on the size of the workpiece, and the size of the weld wanted.
A good general guide is to set the spindle speed so the weld surface moves at 30 inches/minute
(760 mm/min) or 10" (255 mm) in 20 seconds.
To adjust the Spindle Speed, turn the "SPINDLE SPEED" control (clock-wise to move faster, anti-clock-wise
to move slower) until the idler or roller turns at the correct speed.
Once the Spindle Speed is set, press the "ARC STOP" push button to stop the workpiece turning.
19
Setting the Voltages -

The correct welding voltage depends on the type of welding wire, and on the size of weld bead wanted.
Generally, use a voltage between 26 and 30 Volts for narrower weld beads, and between 28 and 32 Volts
for wider weld beads.
To set the voltage, make sure the welding wires of both the left and right Torch Heads are well away from
the workpiece. Focus on the "ELECTRODE INCH" control on the right side of the Control Console. Use a
flat screwdriver to turn the control fully anti-clock-wise (this prevents the welding arc from striking.)
Turn both the left and right Welding Power Supplies ON, and both the "LEFT ELECTRODE" and "RIGHT
ELECTRODE" switches to DOWN. Press the "ARC START" push button.
Adjust the "LEFT VOLTAGE" control to get the correct voltage (shown on the "LEFT VOLTMETER"), and
adjust the "RIGHT VOLTAGE" control to for the correct voltage (shown on the "RIGHT VOLTMETER".)
Press the "ARC STOP" push button to shut off the process. Turn both the "LEFT ELECTRODE" and "RIGHT
ELECTRODE" switches to OFF. Press the "INCH" push button, and adjust the "ELECTRODE INCH" control
so a wire speed of 30 shows on the "LEFT WIRE FEED SPEED" and RIGHT WIRE FEED SPEED" meters.
Setting the Lead and Height Distances of the Torch Heads -

Experience is the best guide in setting the lead distance. Rollers usually need a lead distance of 1/2" to 1"
(12 to 25 mm) and idlers a lead distance of 1" to 2-1/2" (25 to 63 mm.) Turn the left and right Lead
Adjustment knob to change the lead distance.
The height is usually set so there is ½" to ¾" (12 to 19 mm) between the bottom of the Flux Nozzles and the
weld surface. The Welding Tip should recessed ¾" to 1" (19 to 25 mm) inside the Flux Nozzle. The total
wire stick-out is 1¼" to 1¾" (32 to 45 mm) Turn the left and right Vertical Adjustment knob to set the Torch
Head height.
Setting the Wire Feed Speeds -

Wire feed speed sets the amperage of the welding arc, and also the weld’s size and penetration.
Use the left and right "WIRE FEED SPEED" controls to change the wire feed speeds as needed.
Generally, a control setting of "6" is a good initial setting, but operator experience and the shape and
appearance of the weld bead are the best guides.
Starting the Welding Arc -

With the weld area width, step-over distance, voltage, stick-out, lead distance and wire feed speeds set,
welding can start.
Press and hold the "SPINDLE JOG" push button until the workpiece comes to the step-over point (and the
"INDEX" light comes on.) Turn both the left and right Welding Power Supplies ON, and "WELD MODE"
switch to the CIRC position. Turn both the "LEFT ELECTRODE" and "RIGHT ELECTRODE" switches to
DOWN.
Open the left and right Flux Valves to cover the weld area with flux, and press the "ARC START" push
button to start welding.
20
While Welding -
After the welding arc starts, the operator needs to do a number of things:
- Remove slag (solidified flux) from the weld bead, leaving clean metal for the next weld.
- Watch the weld bead shape and appearance, and adjusting the Voltage, Wire Feed Speed and
Lead Distance as need.
- Watch the step-over distance, and adjust the Nozzle Beam Speed as needed.
- On unevenly worn idlers and rollers, change the Limit Switch Stop positions as a wider weld
area is needed.
- Check the current diameter of the workpiece against the finished diameter.
- Occasionally, turn on the Flux Recovery, making sure enough flux is in the Beam Flux Hopper.
Experience is the best guide to how and when to do these. With practice, more of these can be done
without stopping the welding process.
Stopping the Welding Process -

To stop the welding process, press the "ARC STOP" button, and close the left and right Flux Valves.
As the welding arc stops, flux will coat the end of the welding wire. If left on, this coating prevents the
welding arc from starting again, so it is a good practice to trim ¼ " to ½" (6 to 12 mm) off of the end of the
electrode whenever welding ends.
Flange Face Welding (Idlers) -

Once the tread surfaces are rebuilt to their original diameters, a wear gauge will show any wear on the
flange face (or center rib) of idlers. The process for rebuilding the flange face is identical to the tread
surface, except that usually only one torch head can be used. Turn the "ELECTRODE" switch for the
unused Torch Head OFF.
Flange Side Welding -

Flange side wear is usually left to last in rebuilding. At this point, with
the tread surfaces restored to their original diameter, so a wear
gauge accurately shows how much rebuilding weld the flanges need.
Beam Carriage
Since welding is much easier on a horizontal surface, the Yoke and Watch For
workpiece are almost always tilted to rebuild flange sides. Clearance
Yoke Tilt
Watch For Switch
To tilt the Yoke anti-clock-wise, lift up on the switch. To tilt the Yoke Clearance
clock-wise push down on the switch. Watch that the Yoke and idler
or roller does not collide with the Torch Heads or the Beam Carriage.
If they get close, raise the Beam Carriage using the Beam Lift
Controls.
Welding begins at the tread face and works along the flange side. Weld set-up is similar to tread surface
welding, except that the only one Torch Head is used and the that a smaller step-over distance is probably
needed. If the Flange side is not completely horizontal, the Torch Head needs to move up slightly along with
the step-over each revolution.
21
WELDING SET-UP - CROSS WELDING
Cross welding is used to more rapidly build level tread

Circumferential
surfaces. Setting the width of the weld area width, the lead (Stringer) Welding Cross Welding
distance and stick-out are the same as for circumferential
welding. Step-over
Point
Setting the voltage and wire feed speed are also the same,
but cross welding beads are usually thicker and wider, with
higher settings for voltage and wire feed speed.
The difference in circumferential welding is that the travel

now happens across the tread surface (by moving the Torch
Heads), while the step-over between weld passes is created by rotating the workpiece.
Setting the Travel Speed -

The cross travel speed (along with Wire Feed Speed and Voltage) determines the width of the weld bead.
Generally, travel speeds of 25 to 30 inches per minute (635 to 760 mm/min) produce good results.
To set the travel speed, make sure both the "LEFT ELECTRODE" and "RIGHT ELECTRODE" switches are
in the OFF position. Turn the right Welding Power Supply ON, and set the "WELD MODE" switch to the
CROSS position. Press the "ARC START" push button to start the cross mode pattern. Turn the "NOZZLE
BEAM SPEED" control to set the required travel speed.
Setting the Step-over Distance -

The step-over distance, again, is distance between weld passes. The best step-over distance allows weld
beads to blend smoothly with one another, while keeping a flat surface. A good average value for cross-
mode step-over distance is ½" (12 mm.)
To set the step-over distance, make sure both the "LEFT ELECTRODE" and "RIGHT ELECTRODE"
switches are in the OFF position, the right Welding Power Supply is ON, and set the "WELD MODE" switch
to the CROSS position. Press the "ARC START" push button to start the workpiece moving in the cross
welding pattern. Turn the "SPINDLE SPEED" control to set the step-over distance.
Welding -
Starting the welding arc, welding and stopping are all the same for cross welding as for circumferential
welding.
22
WORKPIECE COOL-DOWN -
Slow cool-down after welding is important to avoid cracks and spalling in the weld surface. This is true both
when the rebuild is complete, and when welding is interrupted for more than a few minutes.
The best ways to slow cooling are to cover the idler or roller with a high-temperature blanket, or to bury it in
flux, sand or other high-temperature material. Avoid putting the idler or roller directly on a cool surface such
as a concrete floor.
ADVANCED TECHNIQUES -
Some "tricks of the trade” that make rebuilding faster and easier -
- Uneven wear on idler and roller treads can be leveled somewhat by changing the step-over
distance. Use a normal step-over setting on the high portions of the tread. Decrease the step-
over setting over the lower parts of the tread surface, increasing the build-up in these areas.
- Place one or more circumferential "Dam" beads near the outer edge of idler treads. This keeps
weld and flux from spilling off of the edge of the idler, especially when using the cross welding
technique.
- When welding flange sides which are not completely horizontal, use the "MOVEUP
AUTOMATIC" control to raise the torch every turn of the workpiece. Set this at the same time
as the step-over distance - put the "MOVEUP AUTOMATIC MODE" switch to the FLANGE
position, the "MOVEUP DIRECTION" switch to UP, and set the "MOVEUP SPEED" control to
get the correct amount of raise.
- For narrow flanges, it is sometimes faster to control the Torch Head position manually. Turn the
"NOZZLE BEAM SPEED" control full anti-clock-wise, and the "MOVEUP AUTOMATIC MODE"
OFF to stop automatic step-over. At the step-over point, (when the "INDEX" light come on) turn
the Vertical Adjustment Side Adjustment knobs to move the Torch head to the correct position
for the next weld bead.
- Standing upright, idler treads usually can not be welded to the edge, because the weld spills off
of the tread face. To "square off" the tread face, wait until the idler is still tilted to weld the flange
side, and then place a weld bead in the corner of the tread surface and the idler side.
23
Machinery, LLC CR-10 Idler/Roller Welder MAINTENANCE
SECTION 5 - PREVENTATIVE MAINTENANCE

General-
Remember the importance of keeping the CR-10 Idler/Roller Welder clean. Flux dust is very
abrasive, and can cause serious (and expensive) wear to Welder parts.
Except for the places listed below, never grease parts of the Welder. Dry lubricants can be used
sparingly, but some of these (like graphite powder) are electrical conductors - keep them away from
the electrical insulators on the Welder Torch Heads and Wire Feed Assemblies.
Torch Heads -
Inspect the Torch Heads for burnt or worn components.
Especially important are the copper Welding Tips.
Torch Head
Worn Welding Tips allow the welding wire to move sideways, Replacement Parts
leading to a "wandering" weld bead. Badly worn Weld Tips
loose contact with the welding wire, stopping the weld.
A2514 Insulator Bushing
A0569 Welding Tip Adaptor
A0777-008 Welding Tip
D1511-007 Flux Nozzle
Grease Fittings -
The CR-10 has the seven grease points, shown to the right. Regularly top these off with good
quality carriage grease.
Grease Points
Use high temperature grease (750°F or
400°C) for the Air Cylinder Axle.
Wipe off any excess grease. Sprocket Shaft Yoke Shaft

Spindle Shaft (X 2)
Air Cylinder
Axle
Pay-out Pak
Turntable Axle
(X 2)
Gear Boxes -
Regularly inspect the oil level of the three gearboxes - the Yoke Tilt Gearbox, the Spindle
Drive Gearbox and the Spindle Drive Transmission.
See the attached gearbox manufacturer's manuals for recommended methods and oils.
Flux Hoses -
At least once every month, inspect the rubber flux hoses (connecting the Beam Flux Hopper to the
Flux Nozzles) Look for leaks, kinks, burnt spots or cracks. Replace damaged hoses.
Occasionally inspect the 1½" (37 mm) diameter hoses from the Bottom Flux Hopper to the Upper
Flux Hopper, and from the Upper Flux Hopper to the Flux Pump. Replace damaged hoses.
24
Machinery, LLC CR-10 Idler/Roller Welder MAINTENANCE
RECOMMENDED MAINTENANCE SCHEDULE

Every Day -
Use a hand brush to clean the Torch Carriage slide, the Torch adjuster tubes and the Air Cylinder Shaft
Every Week -
Use compressed air to clean the Welder, especially the Wire drive motors and gears and the wire liners
Every Month -
Check grease levels NOTE: Wipe excess grease off all exposed surfaces.
(If desired) Lubricate the Torch adjuster tubes lightly with a dry graphite or molybendium lubricant only
Every Two Months -

Clean out Flux Pump filter elements and change oil in the flux pump oil breather (use SAE 30-45 W oil)
Check Wire Feed Drive Rollers and Pinch Rollers for wear and misalignment
Check the tension of the Yoke Tilt chain, the Spindle drive chains and the Beam drive chain
Every Six Months -

Check the gearbox oil levels - top off with recommended lubricant.
Thoroughly clean the Welding Power Supplies with low-pressure compressed air
Check the condition of the Spring Liners inside the Torch Pipe, and replace if needed.
Check the condition of the Ball Screw Assembly at

the back of the CR10’s main frame.
Inspect the area around the Top and Bottom Bellows

for ball bearings or other parts of the Ball Screw
Assembly, and then use low-pressure compressed
air or a vacuum to remove any dust and dirt around
the Bellows.
Remove the middle boot clip, raise the Top Bellows

and lower the Bottom Bellows to get access to the
Ball Screw.
Inspect the threads along the length of the Ball

Screw. In good condition, the threads have circular
grooves with a 0.125” (3,18 mm) diameter. Worn
threads have an oval groove that can cause sudden
failure.
NOTE: Never grease the Ball Screw Assembly! Grease attracts abrasive dust, and will cause the Ball
Screw to fail.
Replace the Ball Screw assembly (WTC Part number D1508-001) if the Ball Screw threads are worn, or if
parts of the Ball Screw Assembly are found.
As needed (to be determined by the operator) -

Replace the Welding Tips, Wire Liners, Flux Cones, Insulator Bushings and Air Cylinder Bellows.
25
Machinery, LLC CR-10 Idler / Roller Welder TROUBLE SHOOTING
SECTION 6 - TROUBLE SHOOTING WELDER PROBLEMS

SYMPTOM PROBABLE CAUSE REMEDY
Primary disconnect
Check disconnect switch, turn on.
switch off.
Primary Fuses blown. Test fuses, replace if needed.
Right Welding Power Check the Welding Power Supply overload, reset if tripped. Check for
Welder Won't Start Supply Control overload causes of the overload - shorts on the wiring or blocked air flow
tripped. through the welder.
Broken control cable
between the right Inspect the control cable for cuts, breaks, burns or signs of crushing.
Welding Power Supply Replace suspicious looking cable.
and the Control Console
Check the Turntable for free rotation.
Grease the Turntable Axle.

Binding of or blocking of
Pay-out Pak Turntable Inspect the Thrust bearing under the Turntable, replace if frozen.
Relocate the Pay-off Pak if the Turntable hits the Main Machine, the
other Pay-out Pak or any other object..
Inspect the Wire Liners for kinks or crushes, and replace if damaged.
Blockage or kinks in the
Wire Liners Remove the Liner, and blow through with compressed air. Replace
blocked Wire Liners.
Welding Wire does Check the alignment between the Wire Feed Drive Roll and Pressure
not Feed, or Feeds Roll, and adjust if necessary.
Unevenly Worn, misaligned or
Reset the tension of the Pressure Roll - loosen the Clamp Bolt hex
improperly tensioned nut. Re-tighten until the Clamp Spring begins to compress, and then
Wire Feed Rolls turn the hex nut five full turns.
Replace worn Drive Rolls and Pressure Rolls.

Blockage in the Welding Check for blockage, especially caused by a worn spring liner, Welding
Torch Tip Adapter or Welding Tip.
Flux insulating the Cut off the end of the Welding Wire
Welding Wire
Worn Welding Tips Inspect the Welding Tips, replace if necessary.
Difficulty Starting Dirt, rust or welding slag Inspect the workpiece, clean if necessary.
Arc Welding - on the workpiece
Intermittent Welding surface
Poor ground connection Inspect the cone faces, clean if necessary.
between Spindle Shaft
and workpiece
Electrode Cables or Inspect the welding cables, clean or replace if needed.
Ground Cables loose or
corroded
Blocked Flux Pump
Clean or replace Flux Pump filters.
filters
Poor Flux Recovery Leaks in Flux Hoses, Inspect for leaks on Flux Recovery System components. Tighten or
replace leaking components.
fittings or Upper Flux
Hopper
Workpiece Slips, Low clamping force. Check the air pressure. If below 100 p.s.i. (6.9 atm) increase the
Causing uneven pressure.
Step-over Check for leaks in air cylinder or its supply line. Repair or replace
leaking components.
26
Machinery, LLC CR-10 Idler/Roller Welder RECOMMENDED SPARE PARTS
SECTION 7 - RECOMMENDED SPARE PARTS
The following is a list of factory recommended spare parts for the CR-10 Idler/Roller Welder.
Part Number Qty. Description Used On

A0777-008 12 Welding Tip D1511 Torch Head
A0569 2 Welding Tip Adapter D1511 Torch Head
A2514 4 Insulator Bushing D1511 Torch Head
D1511-003 2 Torch Spring Liner D1511 Torch Head
D1511-007 2 Flux Nozzle D1511 Torch Head
34-0299 12 feet Flux Hose D1511 Torch Head
A0137-008 2 Drive Roll D1512 Wire Feed
A2958-008 2 Pressure Roll D1512 Wire Feed
49-0294 1 Air Cylinder Bellows D1505 Yoke Assembly 2/4
A5240 2 Flux Dam B3656 Flux Dam
05-0134 3 Fuse – 2.8 Amp D1519 Electrical Schematic (F5, 6, 7)
05-0153 1 Fuse – 1.0 Amp D1519 Electrical Schematic (F2)
05-0342 1 Fuse – 8.0 Amp D1519 Electrical Schematic (F4)
05-0347 1 Fuse – 12 Amp D1519 Electrical Schematic (F3)
27
Machinery, LLC CR-10 Idler/Roller Welder CONSUMABLE GUIDE
SECTION 8 – CONSUMABLE GUIDE

The Model CR-10 Idler / Roller Rebuilder uses a submerged-arc (or sub-arc) welding process to
build up worn idlers and rollers to their original dimensions. Submerged-arc welding uses a flux-
cored welding wire (or tubular electrode), covered with a layer of granular flux. This gives a rapid
deposit of high-quality weld, free from impurities, while protecting the operator from arc flash.
Welding wire (or electrode) -

The Model CR-10 Idler / Roller Welder uses 1/8” (3.2 mm) diameter flux-cored (or tubular)
welding wire, in drum (or barrel) packaging. The CR-10 can hold drums up to 1000 pounds (454
kg), with a diameter up to 24 inches (610 mm) and a height up to 36 inches (915 mm.)
The recommended wire is suitable for hard-facing parts with metal-to-metal wear. Below are
hard-facing wire brands to use as a guide.
HARD-FACING WIRES
Maker Product Name Part Number Package Size
Thermadyne/Stoody 105B 11040100 500 lb (230 kg) Drum
Thermadyne/Stoody 105B 11902600 750 lb (340 kg) Drum
Lincoln Electric Lincore 40-S ED015945 300 lb (135 kg) Drum
NOTE: hard-facing wires are limited to four passes (about ½ inch or 13 mm) of build-up
thickness. Badly worn idlers and rollers require the initial welding to be done in a low-alloy
welding wire and the final few welding passes done with hard-facing wire. Below are initial-pass
brands to use as a guide.
INITIAL PASS WIRES

Thermadyne/Stoody 104 11001500 500 lb (230 kg) Drum
Thermadyne/Stoody 104 11902800 750 lb (340 kg) Drum
Granular Flux –
The recommended flux is a neutral flux with a slow chill time and a maximum grain size of 0.08”
(2.0 mm) or 10 Sieve Mesh. Below are granular flux brands to use as a guide.
GRANULAR FLUX
Thermadyne/Stoody Roll-Rite 11257000 50 lb (23 kg) Bag
Lincoln Electric Lincolnweld 801 ED019588 50 lb (23 kg) Bag
28
AMERICAN VACUUM COMPANY
OPERATION AND MAINTENANCE

MANUAL FOR ARCO WAND
FLUX RECOVERY UNITS
Model # 7MH
7301 N. Monticello Avenue

Skokie, Illinois 60076
800/ 321-2849
ARCO WAND FLUX RECOVERY UNITS
MH AND DMH SERIES
OPERATING INSTRUCTIONS
INSTALLATION. THE ARCO WAND STATIONARY FLUX RECOVERY UNITS ARE MADE IN SINGLE
SEPARATOR MODELS (MH SERIES) AND DOUBLE SEPARATOR MODELS (DMH SERIES). IN THE
SINGLE (MH) SEPARATOR TYPE THE ENTIRE UNIT IS USUALLY MOUNTED OVERHEAD, WHILE IN
THE DOUBLE (DMH) SEPARATOR TYPE JUST THE, FIRST (PRIMARY) SEPARATOR IS OVERHEAD
AND THE POWER UNIT WITH SECOND SEPARATOR ATTACHED IS PLACED ON THE FLOOR. IN
EITHER CASE THE HOPPER BUCKET WITH DUMP VALVE SHOULD BE LOCATED OVER THE WELDER
SO THAT A VERTICAL FEEDOUT HOUSE CAN BE USED. THE FEED OUT ROSE SHOULD BE AS
LONG AND AS CLOSE TO VERTICAL AS POSSIBLE. IT SHOULD BE AT LEAST 4' LONG ON 1
1/2 H.P., 5' ON 2 H.P. AND 6' ON 3 H.P. AND LARGER MACHINES. IT SHOULD HAVE AT
LEAST A 2" I.D. AND NEVER BE MORE THAN 30" OFF VERTICAL.
LUBRICATION: WARNING: UNITS ARE SHIPPED WITHOUT LUBRICATING OIL. DO NOT ATTEMPT
TO OPERATE WITHOUT LUBRICATING AS BLOWER MAY BE DAMAGED AND GUARANTEE VOIDED.
FILL GEAR CASE BY REMOVING SQUARE HEAD OIL FILL PLUG AND ADD OIL UNTIL OIL DRIPS
OUT PET COCK. DO NOT OVER LUBRICATE. TOO MUCH OIL IN GEAR HOUSING WILL CAUSE
FLOODING AND EXCESS HEATING. USE NO. 40 SAE OIL. BEARINGS AT DRIVE END ARE
PACKED WITH GREASE BEFORE SHIPMENT BUT GREASE SHOULD BE ADDED AS OFTEN AS
NECESSARY. USE SPECIAL HIGH TEMPERATURE BALL BEARING GREASE. CHECK LUBRICATION
EVERY 250 WORKING HOURS.
MOTOR: MOTOR SHOULD BE LUBRICATED IN ACCORDANCE WITH MANUFACTURER'S

INSTRUCTIONS. IT IS VERY IMPORTANT TO SEE THAT THE MOTOR IS RUNNING IN THE
DIRECTION INDICATED BY ARROW.
AIR CLEANER: THE UNIT IS EQUIPPED WITH A VORTOX AIR CLEANER TO PREVENT DAMAGE TO
THE VACUUM PRODUCER IN THE EVENT OF SCREEN FAILURE. SEE INSTRUCTION CARD
ATTACHED TO AIR CLEANER FOR CARE AND OPERATION. BOTTOM CUP MUST BE FILLED WITH
OIL BEFORE USE. CHECK OIL CUP AND SMALL PRE-FILTER AT BOTTOM OF AIR CLEANER
FREQUENTLY AND CLEAN AS OFTEN AS NECESSARY. A RAPID CLOGGING OF THIS AIR CLEANER
MEANS SEPARATOR SCREENS (DUST BAGS) IN LARGE SEPARATOR SHOULD BE CHECKED.
PRIMARY TANK: ON TWO TANK (DMH) MODELS THE PRIMARY TANK IS EQUIPPED WITH A
BAFFLE INSIDE TOP OF TANK TO AGITATE FINES OF FLUX FLOUR WHICH IS CARRIED OVER
BY SUCTION TO SECONDARY TANK WHERE THEY CAN BE QUICKLY DISPOSED OF BY EMPTYING
THE FLAT BOTTOM BUCKET ON THIS TANK.
SECONDARY TANK: SECONDARY TANK ON POWER UNIT IS EQUIPPED WITH SEPARATOR SCREENS
(DUST BAGS) WHICH SEPARATE THE FINES FROM THE AIR, ALLOWING NOTHING BUT PURE AIR
TO PASS THROUGHT THE VACUUM PRODUCER. THESE BAGS SHOULD BE CLEANED FREQUENTLY TO
MAINTAIN HIGH EFFICIENCY AND LONG BAG LIFE.
PARTS LIST
MODEL NO. 7MH
ITEM# PART# DESCRIPTION REQ'D

1 AW-1004 Inlet Valve 1
2 AW-1005 Slip Joint Nipple 1
3 AW-2325 Separator Cover 1
4 AW-1006 K-49 Gasket 1
5 AW-1007 Dust Bag Clamp - Top 1
6 AW-0026 Separator Shell 1
7 AW-4249 Dust Bag Support Cage & Funnel 1
8 AW-5080 Dust Bag(s) 1
9 AW-GS55 Vortox Air Cleaner 1
10 AW-GS551 Vortox Pre-Filter 1
11 AW-GS552 Vortox Gasket 1
12 AW-GS553 Vortox Cup 1
13 AW-1008 Dust Bag Clamp - Bottom 1
14 AW-1006 K-49 Gasket 1
15 AW-1685 Slag Screen 1
16 AW-1818 Hopper Bucket 1
17 AW-1302 Breather Tube 1
18 AW-5000 Dump Valve 1
19 AW-1521 Motor Mount 1
20 AW-10015 Motor Unit 1
21 AW-1009 Check Valve 1
22 AW-10047 Pump 1
23 AW-1000 Muffler 1
24 AW-1512 Top Tray 1
25 AW-1015 Pump Pulley 1
26 AW-1560 Belt Guard 1
27 AW-1020 V-Beit 1
28 AW-1014 Motor Pulley 1
29 AW-1035 Relief Valve 1
PLEASE SPECIFY MODEL & SERIAL NUMBERS WHEN ORDERING PARTS

7301 N. MONTICELLO AVE., SKOKIE, IL 60076 PHONE 800-321-2849
TO CLEAN SEPARATOR SCREENS (DUST BAGS): INLET ON TOP OF SEPARATOR TANK MUST BE
CLOSED TIGHT. TURN ON MACHINE. HOLD DOWN STEM ON BRASS RELIEF VALVE MOUNTED
ALONG SIDE SEPARATOR TANK UNTIL MOTOR BEGINS TO LABOR (SLOW DOWN). STOP MACHINE
STILL HOLDING DOWN ON RELIEF VALVE STEM. WHEN MACHINE STOPS, QUICKLY PRESS
UPWARD ON STEM. REPEAT FOUR OF FIVE TIMES. CLEAN BAGS FREQUENTLY. CLEAN BAGS
MEAN EFFICIENT OPERATION.
RELIEF VALVE: RELIEF VALVE ON THE MACHINE IS SET AT THE FACTORY FOR THE MAXIUM
VACUUM THE MOTOR CAN CREATE WITHOUT OVER-LOADING AND THE ADJUSTMENTS ON THIS
VALVE SHOULD NOT BE CHANGED.
SLAG SCREEN: A WIRE SCREEN SEPARATING THE FUSED (SLAG) PIECES FROM THE USEABLE
FLUX IS LOCATED IN THE TOP OF THE OVERHEAD (PRIMARY) SEPARATOR. THIS SHOULD BE
REMOVED AS OFTEN AS NECESSARY AND THE FUSED FLUX DISPOSED OF SO THERE WILL NOT
BE AN ACCUMULATION AT THIS POINT WHICH COULD PREVENT THE USEABLE FLUX FROM
FLOWING INTO THE BOTTOM OF THE HOPPER. IT IS MOST ADVISABLE TO LOCATE THE PICK
UP TOOL IN A POSITION WHICH WILL PREVENT PICKING UP ANY QUANTITY OF THIS SLAG.
WHERE PICKUP IS MADE FROM A PAN OR TROUGH UNDER THE WELDING ARC THIS CONTAINER
SHOULD BE COVERED WITH A 1/8" TO 1/4" MESH SCREEN. THIS ALLOWS A VERY EASY AND
CONVENIENT REMOVAL OF SLAG FROM THE SYSTEM.
PICK UP HOSE: PICKUP HOSE SHOULD BE AS SHORT AS POSSIBLE TO AVOID ANY LOOPS OR
TRAPS IN THE HOSE THAT MIGHT TEND TO CREATE A POCKET. THE FLUX IS VERY HEAVY AND
WILL CLOG EASILY IN A POCKET.
BELT: BELT SHOULD BE REASONABLY TIGHT. NOT TOO TIGHT. TO ADJUST BELT TENSION,
LOOSEN LOCKING NUTS ON PLATFORM ADJUSTING STUDS. THEN LOOSEN MOTOR PLATFORM
BOLTS. TURN BOTH STUDS MOVING MOTOR PLATFORM AWAY FROM VACUUM PRODUCER UNTIL
PROPER BELT TENSION IS OBTAINED. MAKE CERTAIN BOTH SHEAVES REMAIN IN ALIGNMENT.
TIGHTEN LOCKING NUTS ON ADJUSTING STUDS.

7301 N. MONTICELLO AVE., SKOKIE, IL 60076 PHONE 800-321-2849
FLEX-A-LINE SPEED REDUCERS
Installation,
Lubrication
and
Maintenance
Instructions
CONGRATULATIONS!
Your decision to purchase an American Crafted Speed Reducer from Grove Gear
will provide you with many years of trouble free service if the following
installation and maintenance instructions are adhered to.
Instruction Manual
Selection Information
Read ALL instructions prior to operating reducer. Injury to personnel or reducer failure may be caused by improper installation,
maintenance or operation.
Written authorization from Grove Gear is required to operate or use reducers in man lift or people moving devices.
Check to make certain application does not exceed the allowable load capacities published in the current catalog.
Buyer shall be solely responsible for determining the adequacy of the product for any and all uses to which Buyer shall apply the
product. The application by Buyer shall not be subject to any implied warranty of fitness for a particular purpose.
Safety Alert
WARNING • For safety, Buyer or User should provide protective guards over all shaft extensions and any moving
apparatus mounted thereon. The User is responsible for checking all applicable safety codes in his area
and providing suitable guards. Failure to do so may result in bodily injury and/or damage to equipment.
• Hot oil and reducers can cause severe burns. Use extreme care when removing lubrication plugs and vents.
• Make certain that the power supply is disconnected before attempting to service or remove any
components. Lock out the power supply and tag it to prevent unexpected application of power.
• Reducers are not to be considered fail safe or self-locking devices. If these features are required, a
properly sized, independent holding device should be utilized. Reducers should not be used as a brake.
• Any brakes that are used in conjunction with a reducer must be sized or positioned in such a way so as to
not subject the reducer to loads beyond the catalog rating.
• Lifting supports including eyebolts are to be used for vertically lifting the gearbox only and no other
associated attachments or motors.
• Use of an oil with an EP additive on units with backstops may prevent proper operation of the backstop.
Injury to personnel, damage to the reducer or other equipment may result.
• Overhung loads subject shaft bearings and shafts to stress which may cause premature bearing failure
and/or shaft breakage from bending fatigue, if not sized properly.
CAUTION • Test run unit to verify operation. If the unit tested is a prototype, that unit must be of current production.
• If the speed reducer cannot be located in a clear and dry area with access to adequate cooling air supply,
then precautions must be taken to avoid the ingestion of contaminants such as water and the reduction in
cooling ability due to exterior contaminants.
• Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for
proper operation.
Important Information
In the event of the resale of any of the goods, in whatever form, Resellers/Buyers will include the following language in a
conspicuous place and in a conspicuous manner in a written agreement covering such sale:
The manufacturer makes no warranties or representations, express or implied, by operation of law or otherwise,
as to the merchantability or fitness for a particular purpose of the goods sold hereunder. Buyer acknowledges
that it alone has determined that the goods purchased hereunder will suitably meet the requirements of their
intended use. In no event will the manufacturer be liable for consequential, incidental or other damages. Even
if the repair or replacement remedy shall be deemed to have failed of its essential purpose under Section
2-719 of the Uniform Commercial Code, the manufacturer shall have no liability to Buyer for consequential
damages.
Resellers/Buyers agree to also include this entire document including the warnings above in a conspicuous place and in a
conspicuous manner in writing to instruct users on the safe usage of the product.
This instructions manual should be read together with all other printed information such as catalogs, supplied by Grove Gear.
Phone: (262) 878-1221 2 Fax: (262) 878-1968

Instruction Manual
General Operation
1. Run the motor which drives the reducer and check the direction of reducer output rotation. Consult motor nameplate for
instructions to reverse the direction of rotation.
2. Attaching the load: On direct coupled installations, check shaft and coupling alignment between speed reducer and loading
mechanism. On chain/sprocket and belt/pulley installation, locate the sprocket or pulley as close to the oil seal as possible to
minimize overhung load. Check to verify that the overhung load does not exceed specifications published in the catalog.
3. High momentum loads: If coasting to a stop is undesirable, a braking mechanism should be provided to the speed reducer output
or the driven mechanism.
CAUTION The system of connected rotating parts must be free from critical speed, torsional or other type vibration,
no matter how induced. The responsibility for this system analysis lies with the purchaser of the speed
reducer.
Installation
1. Mount the unit to a rigid flat surface using grade 5 or higher fasteners. The mounting fasteners should be the largest standard size
that will fit in the base mounting hole. Shim as required under flange or base feet which do not lie flat against the mounting surface.
2. For shipment, pipe plugs are installed in the unit and a vent plug is packed separately. After mounting the unit in position, remove
the appropriate pipe plug and install the vent plug in the location shown on page 5. On double reduction units both the primary
and the secondary must be vented. Failure to vent the unit can cause premature seal wear or loss of seal and oil. These conditions
are not covered by warranty. Check for correct oil level. Contact the factory for level and vent recommendations on non-standard
mounting positions. Grove Gold units with optional internal pressure compensating system do not use vents. See (internal pressure
compensating system) under Lubrication for further information.
3. Grove Gold units include synthetic oil and an internal pressure compensation system pre-installed at the factory. It is not necessary
to vent these units, and they can be used as supplied from the factory. Do not loosen the nut holding the stem of the pressure
compensator, and do not block the hole in the stem. Do not blow pressurized air into the hole, and avoid spraying washdown
chemicals directly into the hole.
4. Connect motor to speed reducer.
WARNING Depending upon gear geometry and operating conditions worm gear reducers may or may not backdrive.
Special consideration should be given to high inertia loads connected to the output shaft. Consult the
factory for further details.
CAUTION DO NOT CHANGE MOUNTING POSITIONS WITHOUT CONTACTING FACTORY.
Altering the mounting position may require special lubrication provisions which must be factory installed.
CAUTION Do not operate the reducer without making sure it contains the correct amount of oil. Do not overfill or
underfill with oil, or injury to personnel, reducer or other equipment may result. Grove Gold units are
lubed and sealed for life, so in most applications it will not be necessary to drain or re-fill the unit.
CAUTION A unit cannot be used as an integral part of a machine superstructure which would impose additional
loads on the unit other than those imposed by the torque being transmitted either through a shaft-
mounted arrangement, and any shaft mounted power transmitting device. (e.g., sprockets, pulleys,
couplings)
CAUTION For safe operation and to maintain the unit warranty, when changing a factory installed fastener for any
reason, it becomes the responsibility of the person making the change to properly account for fastener
grade, thread engagement, load, tightening torque and the means of torque retention.
Lubrication - Standard Units

With the exception of unit sizes 2700, 2800 and 21000 which are shipped dry, all standard reducers ordered from the factory are filled
with lubricant to operate within a 30° to100° F ambient temperature range. Double and triple reduction units have separate oil sumps
and must be filled/checked independently. Prior to startup, verify that the oil is at the level shown on the drawings on page 5. If the
ambient temperature will be outside the range for the lubricant installed at the factory, drain and refill the reducer with the proper
viscosity lubricant prior to use. Consult the chart on page 4 or the factory for alternate lubricants.
Change Intervals: Standard compounded lubricants should be changed every six months or 2500 operating hours, whichever comes first.
Factory installed synthetic lubricants should be changed every two years or 6000 hours, whichever comes first.
Internal pressure compensating system: Grove Gold and stainless steel reducers come standard with an internal pressure
compensating system and synthetic oil pre-installed at the factory. It is not necessary to vent these reducers, and they can be used as
supplied from the factory.
Phone: (262) 878-1221 3 Fax: (262) 878-1968

Instruction Manual
CAUTION Oil should be changed more often if reducer is used in a severe environment. (i.e. dusty, humid)
CAUTION In the Food and Drug Industry (including animal food), consult the lubrication supplier for
recommendation of lubricants which are acceptable to the Food and Drug Administration and/or other
authoritative bodies having jurisdiction. Factory supplied oil is not suitable for these applications or this
industry.
CAUTION Do not mix different oils in the reducer. Oils should be compatible with Viton® seal material.
Special Lubrication Requirements - Sizes 218 & Larger

Units shipped from the factory are assembled to properly lubricate all internal components based on a specific assumed
mounting orientation. The factory assumed mounting orientations are given below. If a size 218 or larger unit will be mounted in a
different orientation than listed below, or run with sustained input speeds less than 900 RPM, it should be specified with the order. The
unit can then be modified to assure proper lubrication.
Factory Assumed Mounting Orientation Applicable Unit Styles*

Worm Over B, T, F, H, FH, C, Single Reduction
D, DT, DF, DH, DFH Double Reduction Worm-Worm
DX, DXT, DXH, DXFH, Double Reduction Helical-Worm
TT Triple Reduction Worm-Worm-Worm
Worm Under U Single Reduction

DU Double Reduction Worm-Worm
Vertical Output VL/VH, FE Single Reduction

DVL/DVH, DFE Double Reduction Worm-Worm
DXVL/DXVH, DXFE Double Reduction Helical-Worm
Vertical Input J Single Reduction

DJ Double Reduction Worm-Worm
DXJ Double Reduction Helical-Worm
* Includes "M" and "MQ" versions of all styles listed
The precision-made gears and bearings in Grove Gear Speed Reducers require high-grade lubricants of the proper viscosity to maintain
trouble-free performance. For best results, use lubricants on the following chart for worm gear reducers:
30° to 100° F Ambient Temperature 50° to 125° F Ambient Temperature

Manufacturer AGMA Compounded No. 7 AGMA Compounded No. 8
Amoco Oil Co. Worm Gear Oil Cylinder Oil #680
Chevron USA, Inc. Cylinder Oil #460X Cylinder Oil #680X
Exxon Co. USA Cylesstic TK-460 Cylesstic TK-680
Gulf Oil Co. Senate 460 Senate 680D
Mobile Oil Corp. 600 W Super Cylinder Extra Hecla Super
Shell Oil Co. Valvata Oil J460 Valvata Oil J680
Sun Oil Co. Gear Oil 7C Gear Oil 8C
Texaco Honor Cylinder Oil 650T Cylinder Oil
Union Oil Co. of CA Steaval A Worm Gear Lube 140
Standard factory-installed lubricant, shipped with 6.00” C.D. and smaller units.
Some gear lubricants contain E.P. additives that can be corrosive to gear bronze. Avoid lubricants that are compounded with sulfur and/or chlorine.
For temperature ranges not shown, contact factory.
For lubrication requirements of Grove Gold or helical reducers (primaries of helical/worm reducers, ratio multipliers, and styles BAMCQ,
BAMC, and BA), contact factory.
Phone: (262) 878-1221 4 Fax: (262) 878-1968

Instruction Manual
Oil Capacities (pints) - Standard Units
Mounting UNIT SIZE
Position 213 215 217 220 224 226 230 232 242 252 2600 2700* 2800* 21000*
Worm Over 1/2 3/4 1 1 1/2 1 3/4 3 3 3/4 5 8 1/4 12 1/2 19 1/2 35 48 72
Worm Under 1/2 3/4 1 1 1/2 1 3/4 3 3 3/4 5 1/2 8 13 1/2 20 1/2 32 3/4 51 1/4 80
Vertical Output 1/2 3/4 1 1 1/2 1 3/4 3 3 3/4 5 8 13 1/2 20 20 3/4 28 3/4 40
Vertical Input 1/2 3/4 1 1 1/2 1 3/4 3 3 3/4 5 8 13 1/2 20 1/3 36 1/2 50 75
Extended Bearing N/A N/A N/A N/A N/A N/A N/A 8 12 17 27 40 63 102
Worm over on Secondary Unit of Double Reduction N/A N/A N/A N/A 12 19 1/4 20 30 1/3 50 1/3 71 1/2 107 1/4
*Shipped Dry
16 oz. = 1 pint
2 pints = 1 quart
4 quarts = 1 gallon
1 gallon = 128 oz. = 231 cu. in.
CAUTION Always check for proper oil level after filling. Capacities vary somewhat with model and mounting position.
Oil should rise to bottom edge of level hole. Do not overfill.
Synthetic Lubricants
Synthetic lubricants provide the potential for numerous benefits including wider temperature range and increased interval between
changes. Use of synthetics can cause problems if they are not compatible with the seals or the conventional lubricants they replace. For
continuous duty at normal ambient temperatures (-10°F to 105°F) we recommend the use of Mobil SHC 634 which is compatible with the
standard compounded oil shipped in our product and the Viton® seal material used through size 252. For other temperatures, or for
intermittent operation below 20° F, contact the factory for a recommendation.
For synthetic lubrication to be used in helical reducers (primaries of helical/worm reducers, ratio multipliers, and styles BAMCQ, BAMC,
and BA), contact factory.
Lubrication - Grove Gold

All Grove Gold reducers are shipped from the factory filled with synthetic lubricant suitable for continuous operation within a -10° F to
105° F ambient environment. If ambient temperature will be outside the above range, or if operation will be intermittent at temperatures
below 20° F, consult the factory for lubrication recommendations. The unit is factory filled with the correct amount of oil for most
mounting positions. If the unit will operate at input speeds below 900 RPM, or if a 230 or larger unit is to operate with one of its shafts
in a vertical position, consult the factory for special lubrication considerations.
CAUTION In the Food and Drug Industry (including animal food), consult the lubrication supplier for recommenda-
tion of lubricants which are acceptable to the Food and Drug Administration and/or other authoritative
bodies having jurisdiction. Factory supplied oil is not suitable for these applications or this industry.
Standard Speed Reducer Mounting Positions & Vent Plug, Level and Drain Locations
VENT VENT VENT VENT VENT
DIPSTICK**
LEVEL*
LEVEL LEVEL
LEVEL
LEVEL
DRAIN
DRAIN
DRAIN
VENT VENT DRAIN
(All primary units have
LEVEL their own oil level.)
LEVEL DRAIN
DRAIN *For 4 1/4” through 6” center distance units (far side plug).
DRAIN
**For 7” center distance & larger units.
Note: High oil level applies to all 4 1/4” center distance & larger secondary & tertiary units
regardless of primary unit type.
Maintenance - Standard Units

Your Grove Gear reducer has been tested and adjusted at the factory. Dismantling or replacement of components must be done by Grove
Gear to maintain the warranty.
Frequently check the oil level of the reducer. If oil level is low, (refer to reducer vent and level position chart) add proper lubrication
through the filler plug until it comes out the oil level plug.
Inspect vent plug often to insure it is clean and operating.
Phone: (262) 878-1221 5 Fax: (262) 878-1968

Instruction Manual
CAUTION Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation.
Seals: The Grove Gear line of speed reducers utilize premium quality seals which are the state-of-the-art in sealing technology. Seals are,
however, a wear item and eventually need to be replaced. Replacement can be easily accomplished by following the steps below:
1. Remove the worn seal without damaging the shaft surface or the seal bore. This can be done by drilling a .062
diameter hole in the seal casing (being careful not to drill into the bearing behind the seal). Screw a #10 sheet metal
screw into the hole and pry out the seal.
2. Clean the seal bore of sealant.
3. Before installing the new seal, use electrical tape to cover any keyways on the shaft to prevent seal lip damage.
4. Grease the seal lips with bearing grease and apply a sealant to the seal bore.
5. Slide the seal into the shaft being careful not to fold the inner lip over on any shaft steps.
6. Press the seal into its bore with a sleeve that presses on the seal casing, being careful to keep the seal square in its
bore.
Maintenance - Grove Gold

Your Grove Gold reducer has been tested and adjusted at the factory. Dismantling or replacement of components must be done by Grove
Gear to maintain the warranty.
Inspect the stem of the pressure compensating system often to ensure it is clean and operating properly.
CAUTION Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation.
Seals: The Grove Gold line of speed reducers utilize premium quality seals which are state-of-the-art in sealing technology. Seals are,
however, a wear item and eventually need to be replaced. Replacement can easily be accomplished by following the procedure given
under Maintenance - Standard Units above.
If seal leakage has resulted in the loss of a significant amount of oil, it may be necessary to add more lubricant. For normal
ambient temperature conditions, Grove Gear recommends Mobil SHC 634 synthetic gear oil for worm drives, and Mobil SHC 150 for
helical drives. For all worm drives, fill the gearbox to the level indicated in the diagram below.
Standard Oil Level for Grove Gold Reducers

LEVEL LEVEL
~22°
CAUTION Always check for proper oil level after filling. Do not overfill or underfill with oil, or injury to personnel, reducer, or
other equipment may result.
CAUTION Do not mix different oils in the reducer.
Class of Service
All capacity ratings are based on American Gear Manufacturers Association (AGMA) Standards. Load conditions must be within cataloged
ratings published in the current Grove Gear Catalog (available upon request).
Warranty From Grove Gear - See catalog pages 192-195 for warranty terms and conditions.
A Division of REGAL-BELOIT
1524 15th Avenue • Union Grove, WI 53182
Phone: 262-878-1221 • Fax: 262-878-1968 • www.grovegear.com 6-02/BH
RETURN TO MAIN INDEX
IM642-B
DC-600 May, 2004
For use with machines having Code Numbers: 10558 to 10701,11071, 11072,11129,
11130, 11131, 11132, 11133 and 11140
Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR 4
5 6
REPAIR THIS EQUIPMENT 3

8
WITHOUT READING THIS

2
9
1
10
MANUAL AND THE SAFETY

PRECAUTIONS CONTAINED DC-600
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S MANUAL
Copyright © 2004 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 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY 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 you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar ‘95
DC-600
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
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
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
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
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or FUMES AND GASES
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and 5.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace coming from degreasing, cleaning or spraying operations.
damaged insulation. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
3.g. Never dip the electrode in water for cooling. products.
3.h. Never simultaneously touch electrically “hot” parts of 5.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage especially in confined areas, to insure breathing air is safe.
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
3.i. When working above floor level, use a safety belt to protect equipment and the consumables to be used, including the
yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
3.j. Also see Items 6.c. and 8. your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘ 95
DC-600
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 7.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact • A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
DC-600
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique: 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
a. Les circuits à l’électrode et à la piéce sont sous tension la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains. des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on câbles jusqu’à ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans 9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse. galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement. 10. Ne pas souder en présence de vapeurs de chlore provenant
d. Ne jamais plonger le porte-électrode dans l’eau pour le d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir. chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder ou autres produits irritants.
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,
f. Si on utilise la machine à souder comme une source de voir le code “Code for safety in welding and cutting” CSA
courant pour soudage semi-automatique, ces precautions Standard W 117.2-1974.
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
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié 1. Relier à la terre le chassis du poste conformement au code de
ainsi qu’un verre blanc afin de se protéger les yeux du ray- l’électricité et aux recommendations du fabricant. Le dispositif
onnement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de 2. Autant que possible, I’installation et l’entretien du poste seront
l‘arc. 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 4. Garder tous les couvercles et dispositifs de sûreté à leur
de l’huile, tels que les gants en cuir, chemise épaisse, pan- place.
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les Mar. ‘93
zones où l’on pique le laitier.
DC-600
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. 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.
TABLE OF CONTENTS vi
Page
Installation .......................................................................................................Section A
Technical Specifications ............................................................................................. A-1
Safety Precautions ..................................................................................................... A-2
Select Proper Location.................................................................................................A-2
Limit on Stacking ...................................................................................................A-2
Stacking .................................................................................................................A-2
Tilting .....................................................................................................................A-2
Electrical Input Connections ....................................................................................... A-3
Fuses and Wire Sizes............................................................................................A-3
Ground Connection .............................................................................................. A-3
Input Power Supply Connections...........................................................................A-3
Reconnect Procedure ................................................................................................ A-4
Output Connections ................................................................................................... A-7
Electrode, Work and #21 Lead ..............................................................................A-7
Auxiliary Power and Control Connections .............................................................A-8
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions ............................................................................................... B-1
General Description ............................................................................................. B-2
Recommended Processes and Equipment ...........................................................B-2
Design Features and Advantages ........................................................................B-2
Welding Capability ............................................................................................... B-3
Meaning of Graphical Symbols on Case Front ......................................................B-3
Meaning of Graphical Symbols on Rating Plate ....................................................B-4
Meaning of Graphical Symbol for Ground Connection ..........................................B-4
Controls and Settings ....................................................................................B-4, B-5
Auxiliary Power in MS - Receptacle.......................................................................B-6
Overload, Overcurrent and Fault Protection ..........................................................B-6
Operating Steps ................................................................................................... B-7
Remote Control of Machine Operation ..................................................................B-7
Welding Procedure Recommendations ............................................................... B-7
Semi-Automatic and Automatic Wire Feeding
with a DC-600 and Wire Feeders ..........................................................................B-8
NA-3 Automatic Wire Feeder ..........................................................................B-8
NA-5 Automatic Wire Feeder ........................................................................B-10
LN-8 Semi-Automatic Wire Feeder ...............................................................B-10
LN-7 & LN-9 Semi-Automatic Wire Feeders .................................................B-10
________________________________________________________________________
Accessories .....................................................................................................Section C
Wire Feeders and Tractors....................................................................................C-1
Field Installed Options ...........................................................................................C-1
Remote Output Control (K775 or K857)..........................................................C-1
Remote Control Adapter Cable (K864) ...........................................................C-1
Undercarriages (K817P, K842).......................................................................C-1
Paralleling Kit (K1611-1) .................................................................................C-1
TIG Module (K930-2) ......................................................................................C-1
Factory or Field Installed Options..........................................................................C-1
Multi-Process Switch (K804-1)........................................................................C-1
Connections for Semi-Automatic or Automatic Wire Feeder Control ....................C-3
________________________________________________________________________
vii TABLE OF CONTENTS
Page
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine and Periodic Maintenance........................................................................D-2
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Wiring Diagrams, Connection Diagrams and Dimension Prints.................Section F
Parts List ......................................................................................................P349 Series

A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS – DC-600
INPUT - THREE PHASE ONLY
Standard Input Current at Rated Output
Volatge 100% Duty Cycle 60% Duty Cycle 50% Duty Cycle
230/460/60 108/54 122/61 134/67

230/460/575/60 108/54/43 122/61/49 134/67/54
460/60 54 61 67
575/60 43 49 54
220/380/440/50/60 116/67/58 128/74/64 138/80/69
380/500/50/60 67/51 74/56 80/61
440/50/60 58 64 69
200/400/50/60 128/64 140/70 152/76
415/50/60 61 68 73
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
100% Duty Cycle 600 44
OUTPUT
Output Range Maximum Open Circuit Voltage Auxiliary Power
70A/13V-780A/44V (CV) 72V for 60 HZ models See the OPERATION section
90A/24V-780A/44V (CC) 69V for 50/60 HZ models for Auxiliary Power
information by model
RECOMMENDED INPUT WIRE AND FUSE SIZES
INPUT HERTZ INPUT AMPERE TYPE 75°C TYPE 75°C TYPE 75°C
VOLTAGE / RATING ON COPPER WIRE GROUND WIRE (SUPER LAG)
FREQUENCY NAMEPLATE IN CONDUIT IN CONDUIT OR BREAKER
AWG(IEC-MM2) SIZES AWG(IEC-MM2) SIZES SIZE (AMPS)1
30°C (86°F) Ambient
230 60 108 2 (34) 6 (14) 175 Amp
460 60 54 6 (14) 8 (8.4) 90 Amp
575 60 43 8 (8.4) 8 (8.4) 70 Amp
200 50/60 128 1 (43) 6 (14) 175 Amp
220 50/60 116 2 (34) 6 (14) 175 Amp
380 50/60 67 6 (14) 8 (8.4) 100 Amp
400 50/60 64 6 (14) 8 (8.4) 100 Amp
415 50/60 61 6 (14) 8 (8.4) 100 Amp
440 50/60 58 6 (14) 8 (8.4) 90 Amp
500 50/60 51 8 (8.4) 8 (8.4) 80 Amp
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
30.75 in 22.25 in 39.0 in 522 lbs.
781 mm 567 mm 988 mm 237 kg.
1Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases.
DC-600
SAFETY PRECAUTIONS STACKING
Read entire Installation Section before installing Three DC-600 machines can be stacked.
the DC-600.
DO NOT stack more than three machines in one
grouping.
ELECTRIC SHOCK CAN KILL.
DO NOT stack the DC-600 on another type of
WARNING machine.
• Only qualified personnel should Follow these guidelines when stacking:

install this machine.
1. Select a firm, level surface capable of sup-
• Turn the input power OFF at the porting the total weight of up to three
disconnect switch or fuse box machines (1570 pounds/712 kilograms).
before
working on the equipment. 2. Set the bottom machine in place.
• Do not touch electrically hot parts. 3. Stack the second machine on top of it by
aligning the two holes in the base rails of the
• Always connect the IDEALARC second machine with the two pins on top front
DC-600 grounding terminal to a good electrical of the bottom machine.
earth ground.
4. Repeat process for third machine.
• Set the DC-600 Power ON/OFF PUSH BUTTON to
the OFF position when connecting power cord to NOTE: The machines must be stacked with the Case
input power. Front of each machine flush with each other. See
Figure A.1.
__________________
SELECT PROPER LOCATION
STACKING HOLE
Place the welder where clean cooling air can freely
circulate in through the front louvers and out through
the rear louvers. Dirt, dust or any foreign material that
can be drawn into the welder should be kept at a mini-
mum. Failure to observe these precautions can result
in excessive operating temperatures and nuisance
shut-downs.
LIMIT ON STACKING STACKING PINS

WARNING
• Lift only with equipment of ade-
quate lifting capacity.
• Be sure machine is stable when
lifting. FIGURE A.1 - Stacking DC-600 machines
• Do not lift this machine using lift
bail if it is equipped with a heavy
accessory such as trailer or gas
cylinder.
FALLING • Do not lift machine if lift bail is TILTING
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bail. The DC-600 must be placed on a stable, level surface
• Do not stack more than three high. so it will not topple over.
• Do not stack the DC-600 on top of any other machine.
------------------------------------------------------------------------
DC-600
ELECTRICAL INPUT CONNECTIONS INPUT POWER SUPPLYCONNECTIONS
Before installing the machine check that the input sup- A qualified electrician should connect the input power
ply voltage, phase, and frequency are the same as the supply leads.
voltage, phase, and frequency as specified on the
welder Rating Plate located on the Case Back 1. Follow all national and local electrical codes.
Assembly. Input power supply entry is through the
hole in the Case Back Assembly. See Figure A.2 for 2. Use a three-phase line.
the location of the machine’s input cable entry open-
ing, Input Contactor (CR1), and reconnect panel 3. Remove Input Access Door at upper rear of
assembly for dual voltage machines. machine.
INPUT SUPPLY 4. Follow Input Supply Connection Diagram located

CABLE ENTRY on the inside of the door.
INPUT
OPENING
CONTACTOR (CR1) 5. Connect the three-phase AC power supply leads
L1, L2, and L3 to the input contactor
RECONNECT terminals in the Input Box Assembly by passing
PANEL ASSEMBLY them thru the three aligned .50” diameter holes in
the baffle and tighten them in the terminal connec-
tors. Be sure to close the baffle by inserting the
tab into the slot in the baffle. See Figure A.3.
FIGURE A.2 - Rear Panel
FUSE AND WIRE SIZES
Protect the input circuit with the super lag fuses or

delay type circuit breakers listed on the Technical
Specifications page of this manual for the machine
being used. They are also called inverse time or ther-
mal/magnetic circuit breakers. INPUT
CONTACTOR (CR1)
DO NOT use fuses or circuit breakers with a lower
amp rating than recommended. This can result in “nui- INPUT POWER SUPPLY
sance” tripping caused by inrush current even when CABLE WITH BUSHING
RECONNECT
machine is not being used for welding at high output OR BOX CONNECTOR
PANEL ASSEMBLY
currents.
Use input and grounding wire sizes that meet local

electrical codes or see the Technical Specifications
page in this manual.
GROUND CONNECTION
Ground the frame of the machine. A ground

terminal marked with the symbol ( ) is located inside
the Case Back of the machine near the input contac-
FIGURE A.3 - Input Power Supply
tor. Access to the Input Box Assembly is at the upper Connections
rear of the machine. See your local and national elec-
trical codes for proper grounding methods.
DC-600
RECONNECT PROCEDURE To reconnect a multiple voltage machine to a different

voltage, remove input power and change the position
Multiple voltage machines are shipped connected to of the reconnect board on the Reconnect Panel.
the highest input voltage listed on the machine’s rating Follow The Input Connection Diagram located on the
plate. Before installing the machine, check that the inside of Case Back Input Access Door. These con-
Reconnect Panel in the Input Box Assembly is connection diagrams for the following codes are listed
nected for the proper voltage. below.
1. For Dual Voltage except 380/500-460/575, see

Figure A.4. (M15009)
CAUTION 2. For 220/380/460, see Figure A.5. (M15010)
Failure to follow these instructions can cause 3. For 380/500-460/575, see Figure A.6. (M15011)
immediate failure of components within the
machine. 4. For 460 and 440 Single Voltage, see Figure A.7.
(S17894)
When powering welder from a generator be sure
to turn off welder first, before generator is shut 5. For 230/460/575, see Figure A.8. (M15666)
down, in order to prevent damage to the welder
6. For Voltages not listed, see the Input Connection
------------------------------ Diagram pasted on the inside of the Case
Back Input Access Door.
CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

LINK 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
L3 W CRI 2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LINES L2 V LEAST 600 VOLT INSULATION.
INPUT L1
CONTACTOR
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF
U THE CRI CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
GND H1 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS,
H3 H2 DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE. SECURE THE
PILOT
TRANSF. REMAINING HEX NUTS IN PLACE.
CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

LINK
L3 W CRI 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
LINES L2 2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT
V LEAST 600 VOLT INSULATION.
INPUT L1 CTOR
U 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF
THE CRI CONTACTOR AS SHOWN.
GND H1 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
H2 H3 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
PILOT
TRANSF.
FIGURE A.4-Reconnect Panel Board Positions for Dual Voltage Machines
DC-600
CONNECTION FOR 440 VOLTS 50 OR 60 HZ. (460V 60HZ)

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
L3 W CRI 2. DISCONNECT AND INSULATE THE H2 & H3 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
INPUT L1
CONTACTOR
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H4 CONTROL TRANSFORMER LEADS TO THE
U INPUT SIDE OF THE CRI CONTRACTOR AS SHOWN.
H3 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.
GND H4 H1 H2 5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE OR TRIPLE STACK THE LINKS IN THREE
POSITIONS. CONNECT THE FLEX LEAD AS SHOWN: POSITIONING THE LUGS TO MAINTAIN MAXIMUM
PILOT
CLEARANCE TO THE LINKS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
LINKS TRANSF.
CONNECTION FOR 380 VOLTS, 50 OR 60 HZ.

L3 W CRI 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
LINES L2 V 2. DISCONNECT AND INSULATE THE H2 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
CONTACTOR LEAST 600 VOLT INSULATION.
INPUT L1 U 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
H4
GND H3 H1 H2
5. MOUNT THE LINKS IN THE POSITIONS SHOWN: DOUBLE UP THE LINKS IN TWO OF THE POSITIONS,
PILOT
LOOP THE POSITIONS. INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
LINKS TRANSF.
CONNECTION FOR 220 VOLTS, 50 OR 60 HZ.

W CRI 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
L3 2. DISCONNECT AND INSULATE THE H3 & H4 LEAD TERMINALS SEPARATELY WITH TAPE TO PROVIDE AT
CONTACTOR
INPUT L1 U 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 CONTROL TRANSFORMER LEADS TO THE
INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
H4
GND H2 H1 H3
5. MOUNT THE LINKS IN THE POSITIONS SHOWN. LOOP THE FLEX LEAD IN THE POSITION SHOWN.
PILOT INSTALL AND TIGHTEN ALL OF THE HEX NUTS.
LINKS TRANSF.
FIGURE A.5-Reconnect Panel Board Positions for 220/380/440 VAC Machines
CONNECTION FOR 380/460 VOLTAGES CONNECTION FOR 500/575 VOLTAGES

H2 H3
L3 W CRI L3 W CRI
LINES LINES
INPUT L2
V
INPUT L2
V CONTACTOR
CONTACTOR
L1 U L1 U
GND H1 GND H1
H3 LINK H2 LINK
TAPE TAPE
1. DISCONNECT AND INSULATE THE H3 LEAD TERMINA WITH TAPE TO PROVIDE AT 1. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LEAST 600 VOLT INSULATION. LEAST 600 VOLT INSULATION.
2. CONNECT H2 LEAD TO CONTACTOR. 2. CONNECT H3 LEAD TO CONTACTOR..
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES TO THE INPUT SIDE OF THE CRI CONTACTOR
AS SHOWN. AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES. 4. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN. REPLACE AND TIGHTEN 5. REMOVE THE HEX NUTS AND POSITION LINKS AS SHOWN, REPLACE AND TIGHTEN
ALL HEX NUTS ALL HEX NUTS
FIGURE A.6-Reconnect Panel Board Positions for 380/500, 460/575 VAC Machines
DC-600
SEE MACHINE RATING PLATE FOR REQUIRED INPUT SUPPLY VOLTAGE

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX
L3 W CRI
2. CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRIC CODES.
LINES
INPUT L2
V 3. CONNECT THE L1, L2, & L3 INPUT SUPPLY LINES TO INPUT SIDE OF THE CRI CONTACTOR AS SHOWN.
CONTACTOR
L1 U
GND
FIGURE A.7-Reconnect Panel Board Positions for Single Voltage Machines
FIGURE A.8-Reconnect Panel Board Positions for 230/460/575 VAC Machines
DC-600
OUTPUT CONNECTIONS
See Table A.1 for recommended DC-600 cable sizes for combined lengths of electrode and work cables.
TABLE A.1
DC-600 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable
at 100% Duty Cycle
ELECTRODE, WORK AND #21 LEAD
Cable Length Parallel Cables Cable Size
Lengths up to 150 ft. (46m) 2 1/0 (53mm2)
150 ft.(46m) to 200 ft (61m) 2 2/0 (67mm2)
200 ft.(61m) to 250 ft.(76m) 2 3/0 (85mm2)
CONNECTIONS
A. Connect Electrode and Work Leads to

Output Terminals.
1. Set the ON/OFF toggle switch to OFF.
2. Locate the retractable strain relief loops directly

below the output terminals in the lower right and
lower left corners of the Case Front Assembly.
See Figure A.9.
3. Pull out the retractable strain relief loops.
4. Insert the electrode lead through the loop directly

below the desired polarity (positive or negative).
Pull through enough cable to reach the output
terminals.
5. Connect electrode lead to the desired terminal FIGURE A.9 - Output Terminals.
(positive/negative).
B. Connect #21 Work Sense Lead to Proper
6. Tighten the output terminal nut with a wrench. Terminal
7. Connect the work lead to the other output There are two work sense lead connection points (+21
terminal following steps 4-6. and -21) on terminal strip (T.S.2) located behind the
hinged access panel on the right side of the case
front. See 14 Pin MS Type Receptacle section or
Terminal Strip Section for connection procedure.
DC-600
AUXILIARY POWER AND PIN LEAD NO. FUNCTION
CONTROL CONNECTIONS
A 32 115 VAC
Located at the left side of the front of the welder B GND Chassis Connection
behind a hinged cover is a 115VAC duplex receptacle C 2 Trigger Circuit
for auxiliary power (60 Hertz Models only). On the right D 4 Trigger Circuit
side of the case front is a 14 Pin MS type receptacle E 77 Output Control
for connection of auxiliary equipment such as wire F 76 Output Control
feeders. Also, terminal strips with 115VAC and con- G 75 Output Control
nections for auxiliary equipment are located behind the 2
H 21 Work Sense Connection
hinged access panel on the right side of the case front.
I 41 42 VAC
(see Auxiliary Power Table for details) 1.
J 31 115 VAC
K 42 42 VAC
AUXILIARY POWER TABLE
Voltage and Circuit Breaker Ratings at Auxiliary Power
L --- ---
Connections for Various Models M --- ---
Auxiliary 60 Hz 50/60 Hz N --- ---
Power Models Models
Connections TERMINAL STRIPS
At Duplex 115V 15A No Duplex

Receptacle
Terminal strips are available behind the cover on the
case front to connect wire feeder control cables that
Terminal strip 115V 15A 115V 15A do not have a 14 Pin MS-type connector. These termi-
terminals 31 & 32
nals supply the connections as shown in the following
MS-Receptacle 115V 15A 115V 15A Terminal Strip charts. NOTE: There are two work
pins A & J
sense lead connection points on the terminal strip.
MS-Receptacle 42V 10A 42V 10A Connect both the work sense lead #21 from the 14 pin
pins I & K
connector and #21 lead of the control cable to “-21”
when welding positive polarity or to “+21” when weld-
115VAC DUPLEX RECEPTACLE (60 HERTZ ing negative polarity.
MODELS ONLY)
The 115VAC duplex receptacle is protected by a circuit TERMINAL STRIP 1 (T.S.1)

breaker located on the nameplate. The receptacle is a Lead No. Function
NEMA 5-15R.
14 PIN MS TYPE RECEPTACLE 75 Output Control
(For MS3106A-20-27PX Plug. L.E.C. Part #S12020-32) 76 Output Control
77 Output Control
Refer to the figure A.10 for the available circuits in the
14 pin receptacle. TERMINAL STRIP 2 (T.S.2)
Lead No. Function
42 VAC is available at receptacle pins I and K.
A 10 amp circuit breaker protects this circuit.
+21 Work Connection (Electrode Negative)
-21 Work Connection (Electrode Positive)2
115 VAC is available at receptacle pins A and J (All
41 42 VAC
Models). A 15 amp circuit breaker protects this circuit.
4 Trigger Circuit
Note that the 42 VAC and 115 VAC circuits are electri-
2 Trigger Circuit
cally isolated from each other.
31 115 VAC1
FIGURE A.10 FRONT VIEW OF 14-PIN 32 115 VAC1
CONNECTOR RECEPTACLE 1.
115VAC circuit is on all models.
K=42
A=32 J=31
2.
As shipped from the factory Lead #21 from the 14 Pin connector is
B=GND I=41
connected to “-21” on the terminal strip (T.S.2). This is the config-
L N uration for positive welding. If welding negative polarity, connect
lead #21 to the “+21” connection point on the terminal strip
C=2 (T.S.2).
H=21
D=4
G=75
E=77 F=76
M
DC-600
B-1 OPERATION B-1
SAFETY PRECAUTIONS
Read this entire section of operating instructions
before operating the machine.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
or electrodes with your skin or wet
clothing.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
• Do not use AC welder if your cloth-
ing, gloves or work area is damp or
if working on, under or inside work-
piece.
Use the following equipment:
-Semiautomatic DC constant voltage
(wire) welder.
-DC manual (stick) welder.
-AC welder with reduced voltage
control.
• Do not operate with panels removed.
• Disconnect input power before ser-
vicing.
-------------------------------------------------------------
READ THIS WARNING, PROTECT YOURSELF &
OTHERS.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust at the arc,
or both,to keep fumes and gases
from your breathing zone and gener-
al area.
WELDING, CUTTING and GOUG-
ING SPARKS can cause fire or
explosion.
• Do not weld near flammable material.
• Do not weld, cut or gouge on contain-
ers which have held flammable materi-
al.
ARC RAYS can burn.

• Wear eye, ear, and body protection.
Observe additional Safety Guidelines detailed in

the beginning of this manual.
DC-600
B-2 OPERATION B-2
GENERAL DESCRIPTION DESIGN FEATURES AND
ADVANTAGES
The DC-600 is an SCR controlled three phase welding
and cutting power source. It uses a single range
• Excellent arc characteristics for optimum constant
potentiometer to control:
voltage submerged arc and Innershield welding
performance.
• Submerged Arc Semi-Automatic or Automatic
• A control circuit designed to provide good starting
Welding
for a large variety of processes and procedures.
• Open Arc Semi-Automatic or Automatic Welding
• Output Control Potentiometer that provides easy
• Stick Welding
single range continuous control.
• Air/Carbon Arc Cutting (Carbon Rod Sizes up to
• Output Control Switch that provides simple switch-
3/8” Diameter)
ing from local to remote control.
• Output Terminals Switch to energize output termi-
nals either local or remote.
The DC-600 has a three-position Welding Mode
• White neon pilot light to confirm that the Input
Switch to enable the user to operate in one of three
Contactor is energized.
modes:
• DC Ammeter and Voltmeter
• 42VAC 10 Amp auxiliary power available for the
• Constant Current (CC) Stick (also used for AAC)
wire feeder, circuit breaker protected.
• Constant Voltage (CV) Submerged Arc
• Single MS-type (14 pin) connector for wire feeder.
• Constant Voltage (CV) Innershield (also used for
• 115VAC 15 Amp auxiliary power available for the
FCAW/GMAW)
wire feeder, circuit breaker protected.
• 115VAC 15 Amp duplex plug receptacle available
Three models are available:
on 60 Hertz models, circuit breaker protected.
• Multi-functional terminal strip for easy connection
• Domestic - all 60 Hertz models except
of wire feeding control cables.
230/460/575V.
• Recessed output terminals to avoid any person or
• Canadian-230/460/575V 60 Hertz models
object from accidentally coming into contact with
• Export-50/60 Hertz models
the output terminals and labeled " + " and " - " for
easy identification.
The optional Multi-Process Switch allows the user to
• Thermostatically protected power source.
switch between semi-automatic or automatic welding
• Electronic protection circuit to protect power
and stick welding or air/carbon arc cutting without dis-
source against overloads.
connecting the wire feeder equipment control, elec-
• Input line voltage compensation to provide an
trode,and work leads.
essentially constant output.
• SCR electronically controlled welder output pro-
RECOMMENDED PROCESSES AND vides extra long life, especially for highly repetitive
EQUIPMENT welding applications.
• Solid state 2 and 4 circuit for extra long life.
The DC-600 is designed for GMAW (MIG), FCAW, • Two circuit solid state control system provides
and submerged arc (SAW) within the capacity of the maximum performance and circuit protection.
machine. It can also be used for stick welding • Low profile case provides maximum use of space.
(SMAW) and for air carbon arc (AAC) cutting with car- • Convenient access to all controls.
bon rods up to 3/8" diameter. • Output lead strain relief loops to prevent terminal
and cable damage.
The DC-600 is provided with a three position mode • Easily removed case side, even when stacked.
switch that selects CV Innershield, CV Submerged • Outdoor operation because enclosure is designed
Arc, or CC Stick. with air intake louvers that keep dripping water
from entering the unit. Transformer, SCR bridge,
The DC-600 can be easily connected to wire feeding and choke have special corrosion resistant paint
equipment, including: for added protection.
• Semi-automatic wire feeders LN-7, LN-7 GMA,

LN-742, LN-8, LN-9, LN-9 GMA, LN- 10, LN-15
LN-23P, LN-25, and DH-10.
• Automatic wire feeders NA-3, NA-5, and NA-5R.
• Tractors LT-56 and LT-7
DC-600
B-3 OPERATION B-3
WELDING CAPABILITY
The DC-600 has the following Output and Duty Cycle
based on operation for a 10 minute period:
600 Amps, 44 Volts at 100%

MEANINGS OF GRAPHICAL SYMBOLS ON CASE FRONT

Input POWER ON/OFF Switch LOCAL/REMOTE Switch
SYMBOL MEANING SYMBOL MEANING
Control Of Output Voltage and

ON Current is Via DC-600's Control Dial
Remote Control of Output Voltage

OFF and Current
MODE Switch
INPUT POWER CC STICK: Shielded Metal Arc
Welding (SMAW), this switch
position is also used for Air
Carbon Arc Cutting (AAC)
Pilot Light
CV SUBMERGED ARC:
Input power on when light is illuminated Constant Voltage Submerged
(except for abnormal conditions). Arc Welding (SAW)
Always indicates POWER ON/OFF
switch is in ON position.
CV INNERSHIELD: Flux Cored
Arc Welding (FCAW), this switch
position is also used for Gas
OUTPUT CONTROL Metal Arc Welding (GMAW).
OUTPUT VOLTAGE Output Terminal Connections

AND CURRENT
Positive Output Terminal
Clockwise Increase of Output

Voltage and Current Negative Output Terminal
WARNING Identification
TERMINALS ON/REMOTE Switch
Warning Identification
OUTPUT TERMINALS
ENERGIZED
Circuit Breaker
Remote Control of Output Terminals Circuit Breaker (two breakers: 15A
(Energized or Non-Energized) for 115V circuit and 10A for 42V
circuit)
DC-600
B-4 OPERATION B-4
MEANING OF GRAPHICAL MEANING OF GRAPHICAL

SYMBOLS ON RATING PLATE SYMBOL FOR GROUND CON-
(LOCATED ON CASE BACK) NECTION
Designates welder complies with
Signifies the equipment connection
National Electrical Manufacturers
point for the protective earth ground
NEMA EW 1 (100%) Association requirements EW 1
Class I with 100% duty cycle at
600Amps output. CONTROLS AND SETTINGS
All operator controls and adjustments are located on
Three Phase Input Power the Case Front Assembly of the DC-600. See Figure
B.1 for the location of each control.
3 Phase transformer with rectified

DC output 3 8
5 6 9 4
Line Connection
5
1
7
6
4
7
Gas Metal Arc Welding (GMAW)

3
8
2
9
1
10
DC-600
2
Flux Cored Arc Welding (FCAW) 11
10
Shielded Metal Arc Welding (SMAW)
12
13
Submerged Arc Welding (SAW)
FIGURE B.1 - CONTROL PANEL KEYS
1. Input POWER ON/OFF Switch
Designates welder complies with This toggle switch turns the machine on or off.
R
both Underwriters Laboratories (UL) Putting the switch in the ON “ ” position ener-
standards and Canadian Standards gizes the machine’s input contactor applying input
NRTL/C power to the machine. Switching the switch to the
Association (CSA) standards. (60
OFF “ ” position de-energizes the input con-
Hertz Models) tactor.
2. POWER Light
When the POWER switch is in the ON position the
machine’s white POWER light will illuminate. If the
input contactor de-energizes the machine in an
abnormal situation the pilot light will still illuminate.
In this situation it may be necessary to reset the
machine by switching the POWER switch to the
OFF and then to the ON position. (See Overload,
Overcurrent, and Fault Protection Section)
DC-600
B-5 OPERATION B-5
3. OUTPUT CONTROL 11.Terminal Strip Cover Panel
This control provides continuous control of the Rotate this panel to gain access to the circuits
machine’s output voltage and current from mini- made available at the two terminal strips (T.S.1
mum to maximum (typical full pot range between and T.S.2). These terminal strips contains the
15 to 44 volts and 90 to 750 amps) as it is rotated same circuits as the 14 pin MS-receptacle. There
clock-wise. Voltage or current control is deter- is a box connector adjacent to this cover for routing
mined by setting of Mode Switch (CV or CC). leads to the terminal strips.
4. OUTPUT TERMINALS ON/REMOTE Switch 12.Negative Output Terminal

When this switch is in the REMOTE “ ” posi- This output terminal is for connecting a welding
tion, the DC-600’s output terminals will be electri- cable. To change welding polarity and for proper
cally “cold” until a remote device such as a wire welding cable size refer to Electrode and Work
feeder closes the #2 and #4 circuit in the MS- Cables in the Installation Section.
receptacle or terminal strip (T.S.2). When this
switch is in the ON “ ” position the machine’s 13.Positive Output Terminal
output terminals will be electrically energized all This output terminal is for connecting a welding
the time. cable. To change welding polarity and for proper
welding cable size refer to Electrode and Work
5. LOCAL/REMOTE Switch Cables in the Installation Section.
When this switch is set to the LOCAL “ “ posi-
tion, control of the output voltage and current is via AUXILIARY POWER IN MS-RECEPTACLE
the OUTPUT CONTROL on the DC-600’s control
panel. When this switch is set to the REMOTE
42 volt AC auxiliary power, as required for some wire
“ ” position, control is through a remote source
feeders, is available through the wire feeder MS-
such as a wire feeder via the #75, #76, and #77
receptacle. A 10 amp circuit breaker protects the 42
leads in the MS-receptacle or terminal strip (T.S.1).
volt circuit from overloads.
6. Mode Switch
DC-600 machines can also supply 115 volt AC auxil-
This switch allows for selecting the welding
iary power through the wire feeder receptacle. A 15
process to be used:
amp circuit breaker protects the 115 volt circuit from
CC STICK-for SMAW and AAC
overloads.
CV SUBMERGED ARC- for SAW
CV INNERSHIELD- for FCAW and GMAW
OVERLOAD, OVERCURRENT, AND
7. 115VAC Duplex Receptacle (60 Hertz Models) FAULT PROTECTION
This receptacle provides up to 15 amps of 115
VAC auxiliary power. This welder has thermostatic protection from exces-
sive duty cycles, overloads, loss of cooling, and high
8. 115VAC 15 Amp Circuit Breaker ambient temperatures. When the welder is subjected
This breaker protects the 115 VAC auxiliary cir- to an overload or loss of cooling, a thermostat will
cuits located in the duplex receptacle, terminal open. The input contactor will open and remain open
strip (T.S.2) and MS-receptacle. until the machine cools; the white POWER light stays
illuminated. No welding is possible during this cool
9. 42VAC 10 Amp Circuit Breaker down period. The machine will reset automatically
This breaker protects the 42VAC auxiliary circuits when the thermostat cools.
located in the terminal strip (T.S.2) and MS-recep-
tacle. The power source is also protected against overcur-
rents in the SCR bridge assembly through an elec-
10.14 Pin MS-Receptacle tronic protection circuit. This circuit senses currents
This connector provides easy connection for a wire over 780 amps on the power source and opens the
feeder control cable. It provides connections for input contactor should the overcurrent remain for a
auxiliary power, output switching, remote output predetermined time (the white POWER light stays illu-
control, wire feeder voltmeter sense lead and minated). The predetermined time varies with the
ground. Refer to 14 Pin MS Type Receptacle in the amount of overcurrent; the greater the overcurrent,
Installation Section for information about the cir- the shorter the time. The input contactor will remain
cuits made available at this receptacle. open until the power source is manually started by
resetting the POWER ON/OFF toggle switch.
DC-600
B-6 OPERATION B-6
The power source circuitry is protected from faults on REMOTE CONTROL OF MACHINE
leads 75, 76, or 77. If any of these leads are connect-
ed to either the positive or negative output leads, the OPERATION
DC-600 will either shut down completely (input con-
tactor opens and white POWER light stays illuminat- The toggle switch on the control panel labeled
ed), or will operate at minimum output thus preventing “Remote - Panel” gives the operator the option of con-
any damage to the DC-600. If DC-600 shuts down, it trolling the machine output from a remote location. If
must be manually started by resetting the POWER in the Remote position a wire feeder with remote con-
ON/OFF toggle switch. trol capabilities or a remote control device such as a
K775 must be connected to terminals 75, 76, and 77.
Refer to Accessories Section for wire feeder remote
OPERATING STEPS information.
The following procedures are for using the DC-600 in
the local control mode of operation. For remote con- WELDING PROCEDURE
trol of the machine, see the Remote Control of RECOMMENDATIONS
Machine Operation section.
Select Welding Mode Switch position based on type of
Before operating the machine, make sure you have all welding to be done.
materials needed to complete the job. Be sure you
are familiar with and have taken all possible safety 1. Innershield Welding (FCAW)/MIG (GMAW)
precautions before starting work. It is important that Welding: Use the CV INNERSHIELD mode.
you follow these operating steps each time you use
the machine. 2. Submerged Arc Welding (SAW): Use the CV
SUBMERGED ARC mode. If performing high
1. Turn on the main AC power supply to the speed welding, switch between the CV
machine. Submerged Arc and the CV Innershield mode and
use the mode that produces the best welding
2. Connect the #21 work lead to either + or - on ter- results.
minal strip (T.S.2).
3. Air/Carbon Arc Cutting (AAC) / Stick Welding
3. Set the Welding Mode switch to welding process (SMAW) / High Current, Large Puddle Submerged
being used: Arc Welding (SAW): Use the CC STICK mode.
When the DC-600 is used for Air/Carbon Arc cut-
• CC STICK (for SMAW and AAC) ting, the OUTPUT CONTROL potentiometer
should be set to "9" initially. Based on the size of
• CV SUBMERGED ARC (for SAW) the carbon being used or the process, turn the
potentiometer to a lower setting as required by the
• CV INNERSHIELD (for FCAW and GMAW) process. You can use carbon rods up to 3/8" in
diameter at currents as high as 750 amps with
4. Turn the POWER ON/OFF Toggle Switch to the excellent arc control. The welder protection circuit
“ON” position protects the machine from extremely high short
circuiting pulses.
• The white pilot light glows.
• The fan starts.

SEMI-AUTOMATIC AND
AUTOMATIC WIRE FEEDING WITH
5. Set OUTPUT CONTROL Potentiometer to desired THE DC-600 AND WIRE FEEDERS
voltage or current.
When using the DC-600 with semi-automatic or auto-
6. Set the OUTPUT TERMINALS switch to either matic wire feeding equipment and for stick welding or
“ON” ( output terminals energized) or “REMOTE” air/carbon arc cutting, it is recommended that the
(output terminals energized when #2 and #4 optional MULTI-PROCESS SWITCH be used. This
closed by remote device such as wire feeder) switch permits you to easily change the polarity of the
connected wire feeding equipment or switch to stick
7. Make the weld. welding or air/carbon arc cutting.
DC-600
B-7 OPERATION B-7
NA-3 AUTOMATIC WIRE FEEDER • To adjust the Open Circuit Voltage Control to get
the best starting performance, make repeated
1. Set the DC-600 LOCAL/REMOTE Switch to starts observing the NA-3 voltmeter.
REMOTE. Set the OUTPUT TERMINALS switch
to REMOTE. NOTE: Later model NA-3 automatic When the voltmeter pointer swings smoothly up to
wire feeders are capable of cold starts when the the desired arc voltage, without undershooting or
NA-3 Mode switch is in the CV or CC mode posi- overshooting the desired arc voltage, the Open
tion. Some earlier models are capable of cold Circuit Voltage Control is set properly.
starting only in the CC mode position. Cold start-
ing enables you to inch the wire down to the work, If the voltmeter pointer overshoots the desired
automatically stop, and automatically energize the voltage and then returns back to the desired volt-
flux hopper valve. age, the Open Circuit Voltage Control is set too
high. This can result in a bad start where the wire
2. Set the DC-600 welding mode switch for the tends to "Blast off."
desired process: CV SUBMERGED ARC, CV
INNERSHIELD mode or CC STICK mode. If the voltmeter pointer hesitates before coming up
to the desired voltage, the Open Circuit Voltage
3. Set the NA-3 mode Switch Position to either CV or Control is set too low.This can cause the elec-
CC to match the DC-600 mode selected in step 2. trode to stub.
4. Refer to the NA-3 operators manual for instruc- 4. Start and make the weld.
tions on how to use the NA-3 in conjunction with
the DC-600. • Cold starts. For cold starts, be sure the work
piece is clean and the electrode makes posi t i v e
5. Follow the following guidelines for good arc strik- contact with the work piece.
ing detailed below for each welding mode.
• Hot "On the Fly" starts. For hot starts, travel
GOOD ARC STRIKING GUIDELINES FOR THE NA- should begin before the wire contacts the work
3 WITH THE DC-600 IN THE CV INNERSHIELD, CV piece.
SUBMERGED ARC OR CC STICK WELDING
MODES. ARC STRIKING WITH DC-600 AND THE NA-3
START BOARD
Following are some basic arc striking techniques that
apply to all wire feed processes. Using these proce- When electrical strikeouts exceed 1 3/4” (44.4mm) an
dures should provide trouble-free starting. \These pro- NA-3 Start Board may be required to improve arc
cedures apply to single, solid wires and Innershield striking.
wires.
When the NA-3 Start Board is used to improve arc
1. Cut the electrode to a sharp point. striking, use the following procedures:
2. Set the NA-3 Open Circuit Voltage Control to the 1. Set start time at 0.
same dial setting as the Arc Voltage Control. If
this is a new welding procedure, a good starting 2. Set NA-3 start current and start voltage at mid-
point is to set the Open Circuit Voltage Control to # 6. range.
NOTE: The open circuit voltage of the 3. Set the NA-3 output current and voltage to the
DC-600 varies from approximately 16 volts to 56 proper settings for the welding procedure to be
volts in the CV INNERSHIELD or CV used.
SUBMERGED ARC modes. The open circuit volt-
age is constant in the CC STICK mode. 4. Turn the Start Board Timer to maximum.
3. Run a test weld. Set proper current, voltage, and 5. Set Start Board current and voltage control.
travel speed.
• Set the Start Board current control to 1 1/2 dial
• For the best starting performance, the NA-3 Open numbers below that set on the NA-3 current control.
Circuit Voltage Control and Voltage Control set-
ting should be the same. Set the Inch Speed • Set the Start Board voltage control equal with the
Control for the slowest inch speed possible. NA-3 voltage control setting.
DC-600
B-8 OPERATION B-8
NOTE: These Start Board current and voltage set- DC-600 POWER SOURCE SETTING WHEN
tings result in a start up current that is lower than CONNECTED TO NA-5 WIRE FEEDER
the NA-3 current setting and approximately equal
with the NA-3 voltage setting for the desired weld- When using the DC-600 with the NA-5 wire feeder, set
ing procedure. the controls on the DC-600 as follows for the best per-
formance:
6. Establish the correct arc striking procedure with
the NA-3 Start Board timer set at maximum. 1. Turn OFF main AC input power supply to the DC-
600.
• For the best starting performance, the NA-3 Open
Circuit Voltage Control and Voltage Control set- 2. Connect the electrode cables to terminal polarity
ting should be the same. Set the Inch Speed to be used.
Control for the slowest inch speed possible.
3. Connect the #21 work lead (on T.S.2) to the
• To adjust the Open Circuit Voltage Control to get
the best starting performance, make repeated
same polarity as the work cable connection.
starts observing the NA-3 voltmeter.
4. Set the DC-600 LOCAL/REMOTE Switch to
When the voltmeter pointer swings smoothly up to REMOTE.
the desired arc voltage, without undershooting or
overshooting the desired arc voltage, the Open 5. Set the DC-600 OUTPUT TERMINALS switch to
Circuit Voltage Control is set properly. REMOTE.
If the voltmeter pointer overshoots the desired 6. Set the DC-600 WELDING MODE SWITCH to the
voltage and then returns back to the desired volt- position that matches the welding process being
age, the Open Circuit Voltage Control is set too used.
high. This can result in a bad start where the wire
tends to "Blast off." • For submerged arc welding, set WELDING MODE
SWITCH to CV SUBMERGED ARC position.
If the voltmeter pointer hesitates before coming up
to the desired voltage, the Open Circuit Voltage • For all open arc welding processes set WELDING
Control is set too low. This can cause the elec- MODE SWITCH to CV INNERSHIELD position.
trode to stub.
• Set NA-3 Start Board current and voltage as

close to the welding procedure current and volt-
age as possible.
NOTE: The Start Board current and voltage

should be as close as possible to the welding pro-
cedure current and voltage, while still getting sat-
isfactory starts.
• Set the start time to as low a time as possible

while still getting satisfactory starts.
7. Start and make the weld.
DC-600
C-1 ACCESSORIES C-1
WIRE FEEDERS AND TRACTORS Undercarriages (K817P, K842)
The DC-600 can be used to power any of the follow- For easy moving of the machine, optional undercar-
ing Lincoln Wire Feeders and Tractors: riages are available with polyolefin wheels (K817P) or
a platform undercarriage (K842) with mountings for
Semi-Automatic Wire Feeders: two gas cylinders at rear of welder.
DH-10 LN-9
LN-7 LN-9 GMA Paralleling Kit (K1611-1)
LN-7 GMA LN-23P
LN-742 LN-25 Permits paralleling of two DC-600's for welding cur-
LN-8 LN-10 rents of up to 1200 amps, 100% duty cycle.
Automatic Wire Feeders: Tig Module (K930-2)

NA-3 NA-5R
NA-5 Portable high frequency generator for AC/DC TIG
welding.
Tractors:
LT-7 LT-56
FACTORY OR FIELD INSTALLED
OPTIONS
FIELD INSTALLED OPTIONS
Multi-Process Switch (K804-1)
Remote Output Control (K775 or K857
with K864 Adapter) The MULTI-PROCESS SWITCH gives you the ability
to:
An optional “remote out control” is available. The • Switch between "stick welding or air/carbon arc
K775 is the same remote control that is used on other cutting" and using a semi-automatic or automatic
Lincoln power sources. The K775 consist of a control wire feeder.
box with 28 feet (8.5mm) of four conductor cable. This
connects to terminals 75,76, and 77 on the terminal • Change the polarity of a semi-automatic or auto-
strip (T.S.1) and the case grounding screw so marked matic wire feeder without changing any electrical
with the symbol “ ” on the machine. These termi- cable connections.
nals are located behind the hinged cover on the case
front. This control will give the same control as the See Figure C.1
output control on the machine.
The K857 is similar to the K775, except the K857 has

a 6-pin MS-style connector. The K857 requires a
K864 adapter cable which connects to the 14-pin con-
nector on the case front.
+
Remote Control Adapter Cable (K864) -
STICK OR
AIR
CARBON
ARC
STRAIGHT PLUG (14 PIN) CABLE RECEPTACLE (6 SOCKET)
TO POWER SOURCE
TO: K857 REMOTE CONTROL
CABLE RECEPTACLE (14 SOCKET)
TO: LN-7 WIRE FEEDERS

– +
A "V" cable 12" (.30 m) long to connect a K857
WIRE STICK OR
Remote Control (6-pin connector) with an LN-7 wire-
FEEDER AIR/CARBON
feeder (14-pin connector) and the machine (14-pin
CABLES ARC CABLES
connector). If a remote control is used alone the wire-
feeder connection is then not used.
FIGURE C.1 - MULTI-PROCESS SWITCH
DC-600
C-2 ACCESSORIES C-2
The MULTI-PROCESS SWITCH has two sets of out-
put terminals. You connect the wire feeder unit cables
TERMINAL
to the set of terminals on the left side of the box and STRIP COVER
the stick or air/carbon arc cables to the set of termi- BOX
nals on the right side (facing the front of the machine) CONNECTOR
as shown in Figure C.1. The output terminals are pro-

tected against accidental contact by hinged covers.
21+ 21- 41 4 2 31 32 75 76 77
When the MULTI-PROCESS SWITCH is in the "Stick
CONTROL
or Air/Carbon Arc" position, only those LEADS
terminals are energized. The wire feeder nozzle or
gun and electrode are not electrically "hot" when in NEGATIVE (–)
OUTPUT – +
POSITIVE (+)
OUTPUT
this mode. STUD STUD
Follow these steps to install the MULTI-PROCESS ELECTRODE ELECTRODE

CABLE CABLE
SWITCH:
WORK +
WIRE STICK AIR/CARBON
FEEDER ARC WELDING
1. Confirm that the DC-600 POWER ON/OFF switch ELECTRODES
EQUIPMENT
is in the OFF position.

WORK WORK
CABLE JUMPER (IF NEEDED CABLE
2. Disconnect main AC input power to the DC- SEE INSTRUCTIONS)
600.
FIGURE C.4 - MULTI-PROCESS SWITCH
3. Open the terminal strip hinged cover located on CABLE CONNECTIONS.
the Case Front Assembly.
8. Connect the left cable from the MULTI-PROCESS
4. The MULTI-PROCESS SWITCH is mounted to SWITCH (facing the front of the machine) to the
the case front with four 1/4” self-tapping screws. DC-600 negative (-) output terminal. See Figure
The screw holes are 13.8” apart side to side and C.2.
4.5” apart top to bottom, Run one of the 1/4”
screws part way in and out of the screw holes to 9. Connect the wire feeder electrode and work
open them up. Make sure that the two sleeved cables. See Figure C.2.
control leads do not get pinched when hanging
the switch; route them out the side to the right of • Insert the wire feeder electrode and work cables
the switch. Support the switch in position and start through the strain relief loop on the left side of the
the four screws, then tighten them. DC-600 (facing the front of the machine).
5. Route the MULTI-PROCESS SWITCH control • Connect the wire feeder electrode and work
leads through the strain-relief box connectors and cables to the electrode and work
into the terminal strip. Connect wire feeder control terminals on the left side of the MULTI-PROCESS
cable as specified in specific connection diagram SWITCH.
and make other terminal strip connections as
specified on the connection diagram for the 10. Connect wire feeder control cable and make other
Lincoln wire feeder being used. terminal strip connections as specified on the
connection diagram for the Lincoln wire feeder
6. Connect the control leads from the MULTI- being used.
PROCESS SWITCH to terminals #2 and #4 on
the DC-600's terminal strip. 11. Set the DC-600 OUTPUT TERMINALS switch to
REMOTE.
7. Connect the right cable from the MULTI-
PROCESS SWITCH (facing the front of the
machine) to the DC-600 positive (+) output termi-
nal. See Figure C.2.
DC-600
C-3 ACCESSORIES C-3
12. Connect stick or air/carbon arc electrode and work CONNECTIONS FOR SEMI-AUTO-
cable. See Figure C.2.
MATIC OR AUTOMATIC WIRE FEED-
ER CONTROL
• Insert the electrode and work cables through the
strain relief loop on the right side (facing the front
of the machine) of the DC-600. 1. Set the DC-600 ON/OFF switch to OFF.
• Connect the electrode cable to the "Positive" ter- 2. Set the DC-600 LOCAL/REMOTE switch to
minal on the right side of the MULTI-PROCESS REMOTE.
SWITCH.
3. Set the DC-600 OUTPUT TERMINALS switch to
• Connect the work cable to the "Negative" terminal REMOTE.
on the right side of the MULTI-PROCESS
SWITCH. 4. Set the DC-600 MODE switch to the welding
process being used.
NOTE: The instructions above are for connecting
the stick polarity positive. To change the polarity, 5. Refer to the proper connection diagram in the DIA-
turn the DC-600 OFF, and reverse the cables. GRAMS section for more information.
NOTE: When it is not necessary to have separate

ground cables for stick and semi-automatic or
automatic welding, connect a jumper from the
MULTI-PROCESS SWITCH "Work" terminal to
the MULTI-PROCESS SWITCH "negative" termi-
nal. See Figure C.2.
To operate the MULTI-PROCESS SWITCH, refer to

the operating instructions on the switch nameplate.
DC-600
D-1 MAINTENANCE D-1
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN
KILL.
Only qualified personnel should
perform this maintenance.
Turn the input power OFF at the disconnect

switch or fuse box before working on this equip-
ment.
Do not touch electrically hot parts.
ROUTINE AND PERIODIC

MAINTENANCE
1. Disconnect input AC power supply lines to the
machine before performing periodic maintenance,
tightening, cleaning, or replacing parts.
Perform the following daily:
1. Check that no combustible materials are in the

welding or cutting area or around the machine.
2. Remove any debris, dust, dirt, or materials that

could block the air flow to the machine for cooling.
3. Inspect the electrode cables for any slits or

punctures in the cable jacket, or any condition that
would affect the proper operation of the machine.
Perform Periodically:
Clean the inside of the machine with low pressure air

stream. Clean the following parts.
• Main transformer and choke.
• Electrode and work cable connections.
• SCR rectifier bridge and heat sink fins.
• Control board.
• Firing board.
• Fan Assembly.
NOTE: The fan motor has sealed bearings which
require no maintenance.
DC-600
E-1 TROUBLESHOOTING E-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
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 and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
DC-600
PC BOARD TROUBLESHOOTING PROCEDURES

WARNING • If the P.C. Board uses protective shorting jumpers,
don’t remove them until installation is complete.
ELECTRIC SHOCK can kill.
Have an electrician install and ser- • If you return a P.C. Board to The Lincoln Electric
vice this equipment. Turn the input Company for credit, it must be in the static-shield-
power OFF at the fuse box before ing bag. This will prevent further damage and
working on equipment. Do not touch allow proper failure analysis.
electrically hot parts.
4. Test the machine to determine if the failure symp-
tom has been corrected by the replacement PC
CAUTION: Sometimes machine failures appear to be board.
due to PC board failures. These problems can some-
times be traced to poor electrical connections. To NOTE: It is desirable to have a spare (known good)
avoid problems when troubleshooting and replacing PC board available for PC board troubleshooting.
PC boards, please use the following procedure:
NOTE: Allow the machine to heat up so that all electri-
1. Determine to the best of your technical ability that cal components can reach their operating tem-
the PC board is the most likely component causing perature.
the failure symptom.
5. Remove the replacement PC board and substitute it
2. Check for loose connections at the PC board to with the original PC board to recreate the original
assure that the PC board is properly connected. problem.
3. If the problem persists, replace the suspect PC • If the original problem does not reappear by substi-
board using standard practices to avoid static elec- tuting the original board, then the PC board was not
trical damage and electrical shock. Read the warn- the problem. Continue to look for bad connections
ing inside the static resistant bag and perform the in the control wiring harness, junction blocks, and
following procedures: terminal strips.
P.C. Board can be damaged by static electricity.
• If the original problem is recreated by the substitu-
• Remove your body’s static tion of the original board, then the PC board was
charge before opening the static- the problem. Reinstall the replacement PC board
shielding bag. Wear an anti-static and test the machine.
wrist strap. For safety, use a 1
Meg ohm resistive cord connect- 6. Always indicate that this procedure was followed
ATTENTION ed to a grounded part of the when warranty reports are to be submitted.
Static-Sensitive equipment frame.
Devices NOTE: Following this procedure and writing on the
Handle only at • If you don’t have a wrist strap,
warranty report, “INSTALLED AND SWITCHED PC
Static-Safe touch an unpainted, grounded,
BOARDS TO VERIFY PROBLEM,” will help avoid
Workstations part of the equipment frame.
denial of legitimate PC board warranty claims.
Keep touching the frame to pre-
Reusable vent static build-up. Be sure not
Container to touch any electrically live parts
Do Not Destroy at the same time.
• Tools which come in contact with the P.C. Board

must be either conductive, anti-static or static-dis-
sipative.
• Remove the P.C. Board from the static-shielding

bag and place it directly into the equipment. Don’t
set the P.C. Board on or near paper, plastic or
cloth which could have a static charge. If the P.C.
Board can’t be installed immediately, put it back in
the static-shielding bag.
DC-600
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major Physical or Electrical Contact the Lincoln Electric Service
Damage is Evident Dept. (216) 383-2531 or 1-800-
833-9353 (WELD)
The Machine is dead- The Input 1. Check for blown or missing

contactor does not operate. fuses in input lines.
2. Check the three- phase input

line voltage at the machine.
The input voltage must match
the rating plate and reconnect
panel.
3. Power ON/OFF switch may be

defective If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
CAUTION
DC-600

OUTPUT PROBLEMS
Input contactor (CR1) chatters. 1. The input line voltage may be
low. Check all three phases.
2. Make sure input line voltage

matches machine rating and
the reconnect panel is connect-
ed correctly for the line voltage.
Variable or sluggish welding arc. 1. Poor electrode or work lead con-

nection
2. Welding cables too small.
3. Welding current or voltage too

low.
If all recommended possible areas

Output Control Pot. not functioning 1. LOCAL/REMOTE Switch (S3) of misadjustment have been
in “LOCAL” control. faulty or in wrong position. checked and the problem persists,
2. Faulty OUTPUT CONTROL Pot. Authorized Field Service Facility.
No output control in “REMOTE” 1. LOCAL/REMOTE Switch (S3)

control. faulty or in wrong position.
2. Faulty Remote Control Unit.
115VAC duplex receptacle not 1. 115VAC Circuit Breaker tripped.

working. (60HZ machines only)
CAUTION
DC-600

OUTPUT PROBLEMS
Machine input contactor operates 1. Place OUTPUT TERMINAL
but machine has no weld Switch to “ON”, or install a
output.Fan runs and pilot light jumper from #2 to #4 on
glows. machine terminal strip. If
machine weld output is
restored the problem is in the
wire feeder or control cable.
2. If remote control is not being

used make certain the
LOCAL/REMOTE SWITCH
(SW3) is in the "Local" position.
3. Check 42V Circuit Breaker in

the front panel.Reset if neces-
sary.
4. Check for loose or faulty weld

cable connections. If all recommended possible areas
5. Trigger circuit not working. checked and the problem persists,
CAUTION
DC-600

OUTPUT PROBLEMS
Machine has maximum weld out- 1. LOCAL/REMOTE Switch (S3)
put and no control. in wrong position.
2. LOCAL/REMOTE Switch (S3)

is faulty, or an open lead going
to the LOCAL/REMOTE Switch
(S3).

CAUTION
DC-600

OUTPUT PROBLEMS
Machine has minimum output and 1. If a remote control unit is NOT
no control. connected to the terminal strip
#75, #76, and #77 terminals, or
is not connected to the 14 pin
MS receptacle the
LOCAL/REMOTE SWITCH
must be in the "Local" position.
2. If a remote control cable is con-

nected to terminals #75, #76
and #77 or is connected to the
14 pin MS receptacle the leads
may be "shorted" to the posi-
tive weld output.
3. Make certain the Three Phase

input voltage is correct and
matches the machine rating
and the reconnect panel. If all recommended possible areas
The machine does not have maxi- Contact your local Lincoln
mum weld output. Authorized Field Service Facility.
1. Check all Three-Phase input
lines at the DC600. Make
sure input voltages match
machine rating and recon-
nect panel.
2. Put LOCAL/REMOTE
SWITCH (SW3) in "LOCAL"
position. If problem is
solved then check remote
control unit or wire feeder.
3. Check for loose welding

cable connections.
CAUTION
DC-600

OUTPUT PROBLEMS
Machine shuts off (input contactor 1. Remove all welding cables and
drops out) when the welder output control cables from the DC
terminals are made electrically 600. Jumper #2 to #4 at the
"hot". terminal strip or set OUTPUT
(#2 to #4 closure at terminal strip.) TERMINALS switch to ON
or OUTPUT TERMINALS switch position. If the machine does
is in ON position. NOT shut off and normal open
circuit voltage is present at the
welder output terminals the
problem is external to the
DC600. Either the remote
leads #75, #76 or #77 are
grounded to the negative out-
put cable or there is a short on
the welding output terminals.
2. If the machine still shuts off

when all control and welding
cables are removed then the
problem is internal to the DC- If all recommended possible areas
600. of misadjustment have been
The DC600 will NOT shut off when 1. Contact your local Lincoln
the Power Switch is turned to Authorized Field Service
OFF. Facility.
CAUTION
DC-600

OUTPUT PROBLEMS
The weld output terminals are 1. Remove any external leads
always electrically "hot". hooked to #2 and #4 on the ter-
minal strip or any connections
to the 14 pin MS connector. If all recommended possible areas
Set OUTPUT TERMINALS of misadjustment have been
switch to the OFF position. If checked and the problem persists,
the problem disappears the Contact your local Lincoln
fault is in the control cable or Authorized Field Service Facility.
wire feeder.
2. If some open circuit voltage is

present (over 3VDC.) after per-
forming Step #1. then the prob-
lem is within the DC-600.
CAUTION
DC-600

WELDING PROBLEMS
Poor arc starting when the DC600 1. Make sure the proper welding
is in the CV Sub-Arc or CV procedures are being used.
Innershield Modes. (wire feed speed , arc voltage
and wire size)
2. Check weld cables for loose or

faulty connections.
Machine has output but trips off 1. Remove output cables from
immediately when wire feed unit DC-600. If problem is resolved
trigger is activated check for external short
between weldiong cables. Also
check control cable (#75, #76,
& #77) for grounds or shorts.

CAUTION
DC-600

WELDING PROBLEMS
Poor arc characteristics in all 1. Check for the correct input volt-
processes. ages on the three- phase input
lines at the DC-600.
2. Make sure the proper welding

procedures are being used. (wire
feed speed, arc voltage and wire
size).
3. Check the welding cables for

loose or faulty connections.

CAUTION
DC-600
PC BOARD TROUBLESHOOTING GUIDE Voltage across leads 255 and 256 should be
approximately 115VAC. Check voltage across sec-
FIRING P.C. BOARD ondary winding of the control transformer (T2) which
supplies leads 255 and 256. Measure +16VDC from
1. All 10 LED’s must be ON when the POWER TEST POINTS “A” to “C” and -10VDC from TEST
SOURCE is turned “ON” and the trigger circuit* is POINTS “A” to “J” on Control board.
closed.
2. LED 2 indicates welder output voltage is being sup-
2. LED’s 7, 8, and 9 indicate AC power being supplied plied to the control circuit. LED 2 will be “ON”
to the P.C. board from auxiliary windings on the brightly in CC STICK mode with trigger circuit*
main transformer (T1). If a LED is not “ON”, turn the closed and no load. (LED 2 diminishes in bright-
machine off and unplug P5 from the firing board. ness as output voltage is reduced). If LED 2 is not
Turn the machine back on and check the following “ON”, look for open connection in lead 222 circuit.
voltages:
LED that Check AC voltage between pins specified, 3. LED 3 indicates power is being applied to FAULT
was off it should be approximately 32VAC . PROTECTION RELAY (CR2). LED 3 will be “ON”
7 P5 pins 15 & 16 (wires 203,204) when machine POWER is “ON”. LED 3 goes “OUT”
8 P5 pins 7 & 8 (wires 205,206) when CR2 drops out which turns off the INPUT
9 P5 pins 5 & 6 (wires 207,208) CONTACTOR (CR1). When LED 3 goes out, LED 4
comes “ON”. See step 3.
3. If all voltages are present, turn power off, and plug
P5 back into J5. Turn power back on. If LED’s are 4. LED 4 indicates an overload or fault condition; LED
still “OUT”, replace Firing PCB. should not be on. If this LED comes “ON”, the
INPUT CONTACTOR (CR1) will turn off and the red
4. If voltages were not present then check the wiring POWER light stays illuminated. This was do to
back to the auxiliary windings for a possible open. either a short across output, or a current draw in
excess of 780A, or leads 75, 76, or 77 grounded to
5. LED 10 senses when trigger circuit* is closed. negative output lead. Remove short or reduce out-
Close trigger circuit, LED10 should be on be “ON”. put current or eliminate ground. Welder must be
Open trigger circuit, LED 10 should be “OFF”. If reset by turning POWER ON/OFF switch to “OFF”
LED does not come “ON”, check to make sure and then back to “ON”. If no short or loads above
leads 2,4, or 41 are not broken. 780A exists or no ground, replace Control PCB.
6. LED’s 1 through 6 indicate gate signals are being 5. LED 5 indicates DC control voltage (which supplies
sent to the main SCR’s 1 through 6 respectively. If Firing board) is present. LED 5 will be “ON” in CV
LED 5 (located on Control Board) is “ON”, along INNERSHIELD mode with trigger circuit* closed,
with LED’s 7, 8, and 9 (on Firing PCB), and LED’s 1 CONTROL POT at minimum, and no load. (LED 5
through 6 are “OFF”, check to make sure lead 231 diminishes in brightness as output voltage is
between Control board and Firing board is not bro- increased). Replace P.C. board if LED 5 did not go
ken “ON”.
7. If any one of LED’s 1 through 6 are “OFF” and 6. LED 6 indicates trigger circuit* condition. LED 6
LED’s 7, 8, and 9 are “ON”, replace the Firing PCB. “ON” indicates trigger circuit is closed. LED 6 “OFF”
indicates trigger circuit is open. If LED 6 does not
PC BOARD TROUBLESHOOTING GUIDE come “ON”, when trigger circuit closed, look for
CONTROL P.C. BOARD open connections in the 2 & 4 circuit and in leads
290 and 291.
1. LED 1 indicates AC input voltage necessary to gen-
erate the DC supply voltages is present. These volt- TRIGGER CIRCUIT is closed by any of the following:
ages power the Control board circuitry. If LED 1 is • Wire feeder’s trigger is closed.
not “ON” when machine POWER is “ON”, check • A jumper is placed across 2 & 4 on terminal strip
leads 255, 256, X1, and X2 for broken connection. T.S.2. or across pins C & D in 14 pin connector.
• OUTPUT TERMINAL switch is in the “ON” position.
CAUTION
DC-600
CHECKING POWER ON/OFF SWITCH (S1) CONNECTING REMOTE OUTPUT

CONTROL RHEOSTAT TO THE MACHINE
1. Turn off the machine input power (" o "position). Extreme caution must be observed when installing or
SW1 has 115 volts across it when the input power extending the wiring of a remote control. Improper
is connected. connection of this unit can lead to loss of control
and/or poor welding. Only the green lead can and
2. Isolate the switch to be tested by removing all co- should be grounded to the machine case. When
nnecting leads. extending the standard remote control, make sure the
leads are the same and the splice is waterproof. Be
3. Check to make sure the switch is making open and very careful not to ground the cable when in use and
closed connections with a V.O.M. meter. Put ohm don't let the lugs touch against the case.
meter on X1 scale. The meter should read zero
resistance with switch " I " and infinite with switch
" o" CHECKING REMOTE OUTPUT CONTROL
4. Put the ohmmeter on X1K scale and measure the RHEOSTAT
resistance between the terminal and the case of the
machine (touch a self-tapping screw). Reading Disconnect the remote output control and connect an
should be infinite. ohmmeter across 75 and 76 and rotate the rheostat in
the remote control. The resistance reading should go
5. If either step (3) or step (4) fails, replace the switch. from zero to 10K ohms. Repeat with ohmmeter across
77 and 76 with same results. Connect ohmmeter
across 75 and 77. The reading should be 10K "10%
CHECKING OUTPUT CONTROL RHEO- ohms. A lower reading will indicate a shorted or par-
tially shorted rheostat. A very high reading will indicate
STAT ON MACHINE (R1) an open rheostat. In either of the last two cases,
replace rheostat. Check cable for any physical dam-
1. Turn machine off (" o " position). age.
2. Remove the screws from the hinged control panel
and open the panel.
3. Turn the LOCAL/REMOTE CONTROL switch to

"REMOTE".
4. With an ohmmeter on X1K, connect it to lead 236

and 237 on R1.
5. Exercise caution to avoid damaging rheostat tabs.
6. Rotate the OUTPUT voltage control rheostat. The

resistance reading should be from around zero to
10K ohms. Check the resistance reading between
the two outer tabs on the rheostat (leads 236 and
75). The reading must be 10K "10% ohms. No
reading will indicate an open rheostat and a low
reading will indicate a shorted or partially shorted
rheostat; in either case, replace.
CAUTION
DC-600
F-1
WIRING DIAGRAM FOR CODES 10588, 10701, 11129, 11130, 11131, 11140
SINGLE VOLTAGE OVER 345 V.
H3 TO (EXCEPT 440 & 460V.) DUPLEX (ON 60 HZ MACHINES ONLY)
SUPPLY 32 42 31
H1 GND
LINES
272
TO GROUND 41 CIRCUIT
15A OUTPUT
PER NATIONAL A J 31 BREAKER
3 9 6 32 TERM.
ELECTRICAL I
B 32A T.S.2 WELDING MODE
L3 CODE SWITCH
2 8 5 K 32 236 SWITCH S4
2 21 S2
L2 R1 (SHOWN IN CC
1 7 C L N H 31
4 RECONNECT
4 75 STICK POSITION)
L1 PANEL 10K 2W
M R.F.
CR1 4 D G OUTPUT 237
TO PRIMARY COILS
CHOKE 42 2
271 INPUT E F CONTROL
CONTACTOR N.C. AS’BLY 2 2
42
DUAL EXCEPT 380/500V AND 14 PIN 77 76 75 81
TO 4 4
H2
SINGLE VOLTAGE UNDER 346V. RECEPT. LOCAL/
H1 SUPPLY 76
(SHOWN CONNECTED FOR LOW VOLTAGE) 41 77
LINES (FRONT 41 REMOTE 80
272 41 226 SWITCH 232
VIEW) -
222 21 S3
9 TO GROUND
3 6 - 222
PER NATIONAL
+
L3
VM 210 21
ELECTRICAL H1 H2 H3
+
2 8 5 210
CODE CONTROL 237 236 280 215
L2
1 7 4 T2 TRANSFORMER
RECONNECT 229 224
L1 238
PANEL
X1
CR1
TO PRIMARY COILS 255 X2
271 INPUT FAULT
S1
CONTACTOR
INPUT PROTECTION R.F.
255 75 76 77
380/500V. & 460/575V.
POWER CHOKE
RELAY
SWITCH CR2
(SHOWN CONNECTED AS’BLY
FOR LOW VOLTAGE) 7 5
H2 TO T.S.1
271 255
H1 SUPPLY
LINES
272
A B
TO GROUND PILOT
W 235
PER NATIONAL LIGHT
15 3 CIRCUIT 233 1 1 229
ELECTRICAL
L3 CODE 10A BREAKER 233 256 2 2 75
14 2 256
T1 MAIN TRANSFORMER 42 3 3 232
L2
13 1 RECONNECT 4 4 80
L1 PANEL
PRIMARY 256
231 5 J2 5 226
272 THERMOSTAT
CR1 255 6 81
TO PRIMARY COILS 6
271 INPUT 273 J1
1 S 2 42A 3 32A 290 7 7
CONTACTOR
S SEC. LEAD 291
31 S 8 8 280
H2 220/380/440 VOLT N.A. THERMOSTAT
TO 13 AUX.2 14 F 41 15 F 31 TWISTED 238 9 9
H1 F
SUPPLY TOGETHER 10 10
PRI. 235 215
272 LINES 207
TO GROUND F F F R.F. 11 224
203 205 210 1
PER NATIONAL LEADS 4 6 CHOKE J3
4 S 5 S S 12 222
11 3 9 6 ELECTRICAL FAN 215 2
THRU 9 TO AS’BLY
L3 CODE AUX. 1 MOTOR
10 2 RECONNECT 204 206
8 5 208 32A CONTROL
L2 RECONNECT PANEL 7 8 9 R.F.
12 1 7 4 PANEL (SHOWN P.C. BOARD CHOKE
L1 CONNECTED
FOR 380V.)
PRI. N.B. AS’BLY
CR1
N.B.
271 TO PRIMARY COILS
INPUT
11 12 R2 214
CONTACTOR 10
222 222 30 100W G1 1 1 41
SINGLE VOLTAGE 440V & 460V 222
H3 G2 2 2
H1
G3 3 3
J4
3 G4 4 4 2
L3 TO (-)
SEC. G5 5 5 208
2 SUPPLY
222
L2 G6 6 6 207
LINES
J5
1 7 206
L1
A 1 8 205
CR1 TO GROUND
DC-600
.05 B 2 9 4
271 PER NATIONAL
INPUT mFd
ELECTRICAL 3 10 290
CONTACTOR
CODE SEC.
272 B’ 4 11 291
OUTPUT .05 J7
mFd C 5 12 215
CHOKE
OUTPUT
NOTES: C’ 6 13 231
C7
N.A. LEADS 4 THRU 9 ARE NOT PRESENT ON 7 14 214
460V., 380/500V. & 460/575V. MACHINES. N.D. A’ 8
DIAGRAMS
15 203
N.B. THERE IS NO 10, 11 AND 12 CONNECTION 16 204
210
ON 220/380/440 VOLT MACHINES. P22
N.C. LOCATION OF THIS LEAD ON T.S.2 TERMINAL STRIP
AM J6 1 261 1
MAY VARY. SEE IM MANUAL FOR LOCATION. 210 (+)
+ - 2 262 2
G1 G3 G5 SCR
N.D. WELDING CABLE MUST BE OF THE PROPER A A A FIRING CIRCUIT 3 263 3
SNUBBERS 4 4
CAPACITY FOR THE CURRENT AND DUTY CYCLE P.C. BOARD 342
215 210
OF IMMEDIATE AND FUTURE APPLICATIONS. 2
SCR SCR SCR + - J23
N.E. THIS DIAGRAM SHOWS THE "STICK" POLARITY 1 3 5 FOR OPTIONAL
320V 4
"POSITIVE". TO CHANGE THE POLARITY, TURN PARALLELING
210 160J
THE DC-600 OFF, AND REVERSE THE LEADS AT TP1 KIT
OUTPUT SHUNT 215
THE MULTI-PROCESS SWITCH. (50MV @800 AMPS)
C1
N.F. USING A WIRE FEEDER, K-317 OR K-318 C C C
.05mFd
CONNECTION DIAGRAM, CONNECT ELECTRODE
OUTPUT 600 V
AND WORK LEADS TO THESE TERMINALS
SNUBBER C C C 215
INSTEAD OF THE POWER SOURCE
OUTPUT TERMINALS.
THESE NOTES APPLY ONLY TO DC-600 WITH A

MULTI-PROCESS SWITCH INSTALLED. TO STICK ELECTRODE HOLDER OR
SCR SCR SCR WORK +
2 4 6 AIR-CARBON ARC TORCH
J3 J6 J4 J7
N.D. N.E.
1 1 2 1 3 1 4 N.D., N.F.
ELECTRODE
A A A G6 TO "WORK" USED WITH STICK
G2 G4
3 4 6
- OR AIR-CARBON ARC
2 4 5 8
J2 J1 J5 OUTPUT RECTIFIER
1 5 1 7 1 8 ASSEMBLY OPTIONAL USER SUPPLIED JUMPER FOR
STICK WORK LEAD NOT
THOSE SITUATIONS WHERE IT IS NOT
OPTIONAL USED WHEN JUMPER IS
NECESSARY TO HAVE SEPARATE GROUND
6 10 8 8 16 MULTI-PROCESS USED.
14
CABLES FOR STICK AND SEMI-AUTOMATIC
SWITCH WELDING.
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
ELECTRICAL SYMBOLS PER E1537

8-2000J
ENHANCED DIAGRAM
G3506
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-1
F-2
WIRING DIAGRAM FOR CODES 11071, 10702, 11073, 111073, 11132, 11133
H4 230/460/575V DUPLEX (ON 60 HZ MACHINES ONLY)
N.G. H3 (SHOWN CONNECTED 32 42 31
H2 TO FOR LOW VOLTAGE) GND FOR MACHINES WITH A GFCI
H1 SUPPLY
LINES 41 RECEPTACLE, LEAD 31 CONNECTS CIRCUIT
272 15A BREAKER OUTPUT
A J TO THE WHITE LINE TERMINAL; LEAD 32 31 32 TERM.
TO GROUND B I CONNECTS TO THE HOT LINE TERMINAL. 32A T.S.2 WELDING MODE
9 K 32 SWITCH 236
3 PER NATIONAL 2 21 S2 SWITCH S4
L3 6 ELECTRICAL
8 C L N H 31 R1 (SHOWN IN CC
5
(SILVER)
2 CODE 4 75 STICK POSITION)
L2 4 10K 2W
7 M R.F.
L1
A
1 RECONNECT 4 D G CHOKE OUTPUT 237
PANEL E F 42 2
CR1 N.C. AS’BLY 2 2 CONTROL
271 INPUT TO PRIMARY COILS 42
14 PIN 77 76 75 4 81
CONTACTOR 4
RECEPT. LOCAL/
41 76 77
18,17,16 15,14,13 (FRONT 41 41 REMOTE 80
226 SWITCH 232
VIEW) 222 21-
N.G. N.G. S3
- 222 +
H1 H3 VM 210 21
H2
+
210
CONTROL 237 236 280 215
T2 TRANSFORMER
229 224
X1 238
255 X2
S1 FAULT
INPUT PROTECTION
255 POWER 75 76 77
R.F.
SWITCH CR2 RELAY CHOKE
7 5 T.S.1 AS’BLY
271 255
A B
W PILOT 235
LIGHT 233
CIRCUIT 1 1 229
10A BREAKER 233 256 2 2 75
256
T1 MAIN TRANSFORMER 42 3 3 232
PRIMARY 4 4 80
256
THERMOSTAT 231 5 J2 5 226
272 255 6 6 81
17 273 290 J1
16 S 42A 18 32A 7 7
31 S SEC. LEAD 291
S 8 8 280
N.G. 1 AUX.2 2 F 41 3 F 31 THERMOSTAT TWISTED 238 9 9
F TOGETHER 235 10 10 215
PRI. 207
F 203 F 205 F R.F. 210 1 11 224
ALL PRIMARY 4 S 5 S 6 S CHOKE J3 12 222
LEADS TO FAN 215 2
AUX. 1 MOTOR AS’BLY
RECONNECT 13 204 206 15
208 32A CONTROL
PANEL 14 R.F.
7 8 9 P.C. BOARD CHOKE
AS’BLY
PRI.
R2 214
222 222 30 100W 41
G1 1 1
222
G2 2 2
G3 3 J4 3
G4 4 4 2
SEC. (-) G5 5 5 208
222
G6 6 6 207
J5 7 206
A 1 8 205
DC-600
.05 B 2 9 4
mFd 3 10 290
SEC. B’ 4 11 291
OUTPUT .05 J7
mFd C 5 12 215
CHOKE
OUTPUT
C7 C’ 6 13 231
NOTES:
7 14 214
N.C. LOCATION OF THIS LEAD ON T.S.2 TERMINAL STRIP
DIAGRAMS
N.D. A’ 8 15 203
MAY VARY. SEE IM MANUAL FOR LOCATION. 16 204
210
N.D. WELDING CABLE MUST BE OF THE PROPER P22
CAPACITY FOR THE CURRENT AND DUTY CYCLE 1 1
AM J6 261
OF IMMEDIATE AND FUTURE APPLICATIONS. 210 (+) 2 2
G1 + - 262
N.E. THIS DIAGRAM SHOWS THE "STICK" POLARITY A A G3 A G5 SCR 263
FIRING CIRCUIT 3 3
SNUBBERS 4 342 4
"POSITIVE". TO CHANGE THE POLARITY, TURN 215 210 P.C. BOARD
THE DC-600 OFF, AND REVERSE THE LEADS AT SCR SCR SCR - 2 J23
THE MULTI-PROCESS SWITCH.
+
1 3 5 FOR OPTIONAL
320V 4
N.F. USING A WIRE FEEDER, K-317 OR K-318 PARALLELING
210 160J TP1
CONNECTION DIAGRAM, CONNECT ELECTRODE KIT
215
AND WORK LEADS TO THESE TE RMINALS OUTPUT SHUNT
C C (50MV @800 AMPS) C1
INSTEAD OF THE POWER SOURCE C
OUTPUT TERMINALS. .05mFD
OUTPUT 600 V
N.G. TAPE UP SEPARATELY TO PROVIDE AT SNUBBER C C C
LEAST 600V INSULATION. 215
THESE NOTES APPLY ONLY TO DC-600 WITH A

MULTI-PROCESS SWITCH INSTALLED.
SCR SCR SCR TO STICK ELECTRODE HOLDER OR
2 4 6 WORK +
J3 J6 J4 J7 AIR-CARBON ARC TORCH
1 1 2 1 3 1 4
N.D., N.F. N.D. N.E.
A G2 A G4 A G6 ELECTRODE
TO "WORK" USED WITH STICK
2 3 4 4 6 5 8 - OR AIR-CARBON ARC
J2 J1 J5 OUTPUT RECTIFIER
1 5 1 7 1 8 ASSEMBLY
OPTIONAL USER SUPPLIED JUMPER FOR
STICK WORK LEAD NOT
THOSE SITUATIONS WHERE IT IS NOT
OPTIONAL USED WHEN JUMPER IS
6 10 8 14 8 16 NECESSARY TO HAVE SEPARATE GROUND
MULTI-PROCESS USED.
CABLES FOR STICK AND SEMI-AUTOMATIC
CONNECTOR CAVITY NUMBERING SEQUENCE SWITCH WELDING.
(VIEWED FROM COMPONENT SIDE OF BOARD)
ELECTRICAL SYMBOLS PER E1537

B.01
G3506-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2
CONNECTION OF LN-742 TO THE CV-655, DC-655 OR DC-600 POWER SOURCE
F-3
Turn off (0) the power switch on the Welding
Power Source before connecting the wire feeder.
LINCOLN
Only qualified persons should install, use or
POWER SOURCE
N.D. service this machine.
14 PIN
AMPHENOL
LN-742
WIRE
FEEDER N.A. WELDING CABLE MUST BE SIZED FOR CURRENT
+ AND DUTY CYCLE OF APPLICATION.
-
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO
CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLES AT
POWER SOURCE AND SET WIRE FEEDER
VOLTMETER POLARITY SWITCH ON POWER
TO WORK SOURCE TO PROPER POLARITY.
LN-742
DC-600
INPUT CABLE N.C. PINS NOT LISTED ARE NOT CONNECTED
ELECTRODE CABLE
ASSEMBLY ON CABLE.
DIAGRAMS
N.D. IF USING K589-1, REMOTE CONTROL KIT,

SET POWER SOURCE CONTROL SWITCH
TO "REMOTE" POSITION.
FUNCTIONS ARE LISTED FOR REFERENCE K=42

K=42
ONLY AND EACH MAY OR MAY NOT BE
PRESENT IN YOUR EQUIPMENT.
I=41
(SEE APPROPRIATE WIRING DIAGRAM)
I=41
PIN LEAD FUNCTION
H=21 C=2
C 2 TRIGGER CIRCUIT
D 4 TRIGGER CIRCUIT C=2 H=21

E 77 OUTPUT CONTROL
F 76 OUTPUT CONTROL G=75 D=4
D=4 G=75
G 75 OUTPUT CONTROL
E=77 F=76 F=76 E=77
H 21 WORK
14-SOCKET BOX RECEPTACLE, FRONT VIEW 14-SOCKET BOX RECEPTACLE, REAR VIEW
I 41 42V AC
AND 14-PIN CABLE PLUG, REAR VIEW AND 14-PIN CABLE PLUG, FRONT VIEW
K 42 42V AC 1-28-94
F-3
S20409
CONNECTION OF LN-7 TO THE CV-655, DC-655 OR DC-600 POWER SOURCE
F-4
14-PIN
RECEPTACLE
POWER SOURCE CONTROL CABLE
Do not operate with covers removed.
FOR CONTROL CABLE
WITH 14 PIN MS-TYPE Disconnect power source before
PLUG CONNECTOR servicing.
LN-7 TO INPUT
Do not touch electrically live parts.
CABLE PLUG
21
OR Only qualified persons should install, use or
LN-7 CONTROL
FOR CONTROL CABLE service this machine.
CABLE
WITH TERMINAL STRIP
LEAD CONNECTORS
N.A. Welding cables must be of proper capacity for the current and
duty cycle of immediate and future applications. See LN-7
Operating Manual for proper sizes.
+21 - 21 41 4 2 31 32 75 76 77
N.E. N.B. If LN-7 is equipped with a meter kit, extend LN-7 control cable
lead #21 from control cable with terminal strip connectors or from
14-pin receptacle using #14 AWG or larger insulated wire physically
N.F. suitable for the installation. An S16586-[LENGTH] remote
voltage sensing work lead may be ordered for this purpose.
32
Connect it directly to the work piece independent of the welding
31
2 work cable connection. For convenience, this extended #21 lead
4 should be taped to the welding work lead. (If the length of
welding work cable is short, less than 25 feet, and connections
N.B. & N.C. GND
can be expected to be reliable, then control cable lead #21 does
DC-600
N.D. not need to be extended and can be directly connected to
NEGATIVE POSITIVE
terminal #21 on the terminal strip. Note that this is not the
21
preferred connection because it adds error to the LN-7 voltmeter
DIAGRAMS
reading.)
N.G. N.C. Tape up bolted connection if lead #21 is extended.
ELECTRODE CABLE N.D. Connect the control cable ground lead to the frame terminal
TO WIRE FEED UNIT marked near the power source terminal strip. The power
source grounding terminal (marked and located near the power
N.A. source input power connections) must be properly connected to
electrical ground per the power source operating manual.
N.E. If an optional remote voltage control is used, connect it to

TO WORK this terminal strip.
N.F. If lead #21 is to be connected to the terminal strip,

connect to the #21 terminal that matches work polarity. This
REMOTE VOLTAGE SENSING LEAD
connection must be changed whenever the electrode polarity is
changed.
Above diagram shows electrode connected positive. To change polarity,
turn power off, reverse the electrode and work leads at the power N.G. Illustration does not necessarily represent actual position of
source and position the switch on wire feeder (if equipped ) appropriate output studs. Refer to power source operating manual
to proper polarity. Also refer to note N.F. for more information.
For proper setting of switches on power source,

see power source operating manual.
10-30-98F
F-4
S22976
CONNECTION OF LN-8 OR LN-9 TO THE CV-655, DC-655 OR DC-600 POWER SOURCE
F-5
14-PIN
RECEPTACLE
FOR CONTROL CABLE
21 Do not touch electrically live parts.

TO LN-8 OR LN-9
INPUT CABLE PLUG OR
N.F. Only qualified persons should install, use or
FOR CONTROL CABLE service this machine.
CONTROL CABLE
WITH TERMINAL STRIP
LEAD CONNECTORS
duty cycle of immediate and future applications.
N.B. Extend lead #21 from control cable with terminal strip connectors or
+21 - 21 41 4 2 31 32 75 76 77 from 14-pin receptacle using #14 AWG or larger insulated wire
N.E.
physically suitable for the installation. An S16586-[LENGTH]
remote voltage sensing work lead may be ordered for this purpose.
C Connect it directly to the work piece keeping it electrically
N.G.
B N.E. separate from the welding work lead circuit and connection. For
A convenience, this extended #21 lead should be taped to the
32
31 welding work lead. (If the length of work lead circuit is
2 short, and connections can be expected to be reliable, then
4
control cable lead #21 does not need to be extended and can be
N.B. & N.C. GND directly connected to terminal #21 on the terminal strip. Note
DC-600
that this is not the preferred connection because it adds error
NEGATIVE POSITIVE N.D. to the wire feeder voltmeter reading.)
21
N.C. Tape up bolted connection if lead #21 is extended.
DIAGRAMS
N.D. Connect the control cable ground lead to the frame terminal
N.H.
marked near the power source terminal strip. The power
ELECTRODE CABLE
source input power connections) must be properly connected to
TO WIRE FEED UNIT
electrical ground per the power source operating manual.
N.A. N.E. If using an older LN-8 control cable: connect lead #75 to #75 on
terminal strip, connect lead #76 to #76 on terminal strip, connect
lead #77 to #77 on the terminal strip.
TO WORK
N.F. The LN-9 voltage control jumpers must be connected as follows
(refer to LN-9 Operating Manual):
White jumper on voltage board to pin "S" .
Blue jumper on voltage board (later units only),
or on start board (earlier units), to pin "B".
Above diagram shows electrode connected positive. To change polarity, N.G. If lead #21 is to be connected to the terminal strip, connect to
turn power off, reverse the electrode and work leads at the power the #21 terminal that matches work polarity. This connection must be
source and position the switch on wire feeder (if equipped ) changed whenever the electrode polarity is changed.
to proper polarity. Also refer to note N.F. N.H. Illustration does not necessarily represent actual position of appropriate
output studs. Refer to power source instruction manual for more info.
10-30-98F
F-5
S22977
CONNECTION OF NA-3, LT-5 OR LT-7 TO THE CV-655, DC-655 OR DC-600 POWER SOURCE
F-6
14-PIN
RECEPTACLE
FOR CONTROL CABLE

21 TO AUTOMATIC
CONTROL BOX OR Only qualified persons should install, use or
service this machine.
CONTROL CABLE FOR CONTROL CABLE
WITH TERMINAL STRIP
LEAD CONNECTORS
+21 - 21 41 4 2 31 32 75 76 77
N.B. Extend lead #21 from control cable with terminal strip connectors
or from 14-pin receptacle using #14 AWG or larger insulated wire
77 remote voltage sensing work lead may be ordered for this purpose.
N.F. 76
Connect it directly to the work piece keeping it electrically
75
32
separate form the welding work lead circuit and connection. For
31 convenience, this extended #21 lead should be taped to the
4
short, and connections can be expected to be reliable, then
N.B. & N.C. GND control cable lead #21 does not need to be extended and can be
DC-600
directly connected to terminal #21 on the terminal strip. Note
NEGATIVE POSITIVE N.D. that this is not the preferred connection because it adds error
21 to the wire feeder voltmeter reading.)
DIAGRAMS
N.C. Tape up bolted connection if lead #21 is extended.
N.G. N.D. Connect the control cable ground lead to the frame terminal
marked near the power source terminal strip. The power
ELECTRODE CABLE source grounding terminal (marked and located near the power
TO AUTOMATIC source input power connections) must be properly connected to
EQUIPMENT electrical ground per the power source operating manual.
N.A. N.E. If a variable voltage board is present in the automatic controls,

the jumper lead on the VV board must be connected to pin "L" to
permit the inch down button to operate. This jumper, however,
TO WORK will disable the cold starting/autostop feature of the automatic
controls, permitting only hot starting techniques to be used.
N.F. If lead #21 is to be connected to the terminal strip,

REMOTE VOLTAGE SENSING LEAD connect to the #21 terminal that matches work polarity. This
connection must be changed whenever the electrode polarity is
changed.
Above diagram shows electrode connected positive. To change polarity,
turn power off, reverse the electrode and work leads at the power N.G. Illustration does not necessarily represent actual position of
source. Reverse the leads on the back of the ammeter and voltmeter appropriate output studs. Refer to power source operating
in the automatic control box. Also refer to note N.F. manual for more information.

10-30-98F
S22978
F-6
CONNECTION OF NA-5/-5R TO THE CV-655, DC-655 OR DC-600 POWER SOURCE
F-7
14-PIN
RECEPTACLE
POWER SOURCE CONTROL CABLE Do not operate with covers removed.
FOR CONTROL CABLE Disconnect power source before

WITH 14 PIN MS-TYPE servicing.
PLUG CONNECTOR
21
TO NA-5/-5R
INPUT CABLE PLUG OR
CONTROL CABLE FOR CONTROL CABLE
WITH TERMINAL STRIP
LEAD CONNECTORS
N.B. Extend lead #21 from control cable with terminal strip connectors
or from 14-pin receptacle using #14 AWG or larger insulated wire
+21 - 21 41 4 2 31 32 75 76 77
remote voltage sensing work lead may be ordered for this purpose.
Connect it directly to the work piece keeping it electrically
C
N.F. separate from the welding work lead circuit and connection. For
B
A convenience, this extended #21 lead should be taped to the
31
2 short, and connections can be expected to be reliable, then
4 control cable lead #21 does not need to be extended and can be
N.B. & N.C. GND directly connected to terminal #21 on the terminal strip. Note
DC-600
that this is not the preferred connection because it adds error
NEGATIVE POSITIVE N.D. to the NA-5/-5R voltmeter reading.)
21 N.C. Tape up bolted connection if lead #21 is extended.
DIAGRAMS
N.D. Connect the control cable ground lead to the frame terminal
N.H. marked near the power source terminal strip. The power
BOLT TO CABLES FROM NA-5/-5R source input power connections) must be properly connected to
WIRE CONTACT AS'BLY electrical ground per the power source operating manual.
N.E. The jumpers on the NA-5/-5R voltage board must be connected as follows:
N.A. Connect red jumper to pin "S".
N.D. & N.F.
Connect white jumper to pin "B".
When using NA-5/-5R controls above Code 8300, the NA-5/-5R Inch Down
TO WORK button will not operate unless a jumper is connected between the two
tab terminals, labeled "AUTO", located above the transformer on the
NA-5/-5R Voltage P.C. board. This jumper, however, will disable the
Cold Starting/Auto-Stop/Touching-Work feature of the NA-5/-5R,
permitting only Hot Starting techniques to be used.
Above diagram shows electrode connected positive. To change polarity, N.F. If lead #21 is to be connected to the terminal strip, connect to the #21
turn power off, reverse the electrode and work leads at the power source. terminal that matches work polarity. This connection must be changed
Refer to NA-5 or NA-5R Operating Manual for required NA-5 or NA-5R control
whenever the electrode polarity is changed.
box polarity connections. Also refer to note N.F. N.G. For proper NA-5/-5R operation, the electrode cables must be snugged under
the clamp bar on the left side of the NA-5/-5R control box.
FOR ADDITIONAL INSTALLATION INSTRUCTIONS, SEE NA-5 OR NA-5R OPERATING MANUAL.
N.H. Illustration does not necessarily represent actual position of
For proper setting of switches on power source, appropriate output studs. Refer to power source operating manual
see power source operating manual. for more information.
10-30-98F
S22979
F-7
CONNECTION OF DH-10 OR LN-10 TO POWER SOURCE WITH 14 PIN AMPHENOL
F-8
Disconnect power source before
LINCOLN servicing.
WIRE
POWER SOURCE Do not touch electrically live parts.
FEEDER
N.E.
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT
AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO
- + CHANGE POLARITY, TURN POWER "OFF",
14 PIN 9 PIN
REVERSE ELECTRODE AND WORK CABLES AT
AMPHENOL AMPHENOL POWER SOURCE.
N.C. PINS NOT LISTED ARE NOT CONNECTED

ON CABLE.
N.D. IF LEAD #21 IS TO BE CONNECTED TO THE
TERMINAL STRIP, CONNECT TO THE #21
ELECTRODE CABLE WIRE FEEDER TERMINAL THAT MATCHES WORK POLARITY.
INPUT CABLE THIS CONNECTION MUST BE CHANGED WHENEVER
TO WORK THE ELECTRODE POLARITY IS CHANGED.
ASSEMBLY
N.E. ILLUSTRATION DOES NOT NECESSARILY REPRESENT
DC-600
ACTUAL POSITION OF APPROPRIATE OUTPUT STUDS.
FOR PROPER SETTINGS OF SWITCHES ON POWER SOURCE,
REFER TO POWER SOURCE OPERATING MANUAL FOR
SEE POWER SOURCE OPERATING MANUAL.
MORE INFORMATION.
DIAGRAMS
FUNCTIONS ARE LISTED FOR REFERENCE K=42 K=42

A J J A
ONLY AND EACH MAY OR MAY NOT BE
PRESENT IN YOUR EQUIPMENT.
(SEE APPROPRIATE WIRING DIAGRAM) B=GND I=41 I=41 B=GND
PIN LEAD FUNCTION

C=2 H=21 H=21 C=2
B GND CHASSIS CONNECTION
C 2 TRIGGER CIRCUIT L N N L
D 4 TRIGGER CIRCUIT G=75 D=4

E 77 OUTPUT CONTROL D=4 G=75
F 76 OUTPUT CONTROL E=77 M F=76 F=76 M E=77
G 75 OUTPUT CONTROL 14-SOCKET BOX RECEPTACLE, FRONT VIEW 14-SOCKET BOX RECEPTACLE, REAR VIEW
H 21 WORK AND 14-PIN CABLE PLUG, REAR VIEW AND 14-PIN CABLE PLUG, FRONT VIEW
I 41 42V AC
K 42 42V AC 10-30-98F
F-8
S22980
F-9
DC-600 DIMENSION PRINT (WITH K817P UNDERCARRIAGE)
THIS DIMENSION WILL VARY

WITH POSITION OF HANDLE
38.00 22.25
17.75 11.12
5.90
3.25
27.50
DC-600
39.95
DIAGRAMS
9.20
4.75 * .94 20.00

*
*
29.93
27.87
1-20-89A
* LOCATION OF BASE MOUNTING HOLES M12244-6

F-9
F-10
DC-600 DIMENSION PRINT (WITH K842 UNDERCARRIAGE)

23.28
54.91
22.25
38.00 5.19
11.12
17.76
3.25
27.50
37.86
DC-600
DIAGRAMS
7.11
29.93
*
* .94 *
* 20.00
36.12
49.89 27.65
LOCATION OF BASE MOUNTING HOLES 6-18-93C

* M15200-3
F-10
NOTES
DC-600
NOTES
DC-600
● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.

● Insulate yourself from work and
ground.
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.
PRECAUCION ● Aislese del trabajo y de la tierra.
French ● Ne laissez ni la peau ni des vête- ● Gardez à l’écart de tout matériel ● Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
German ● Berühren Sie keine stromführenden ● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec- ● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
● Isole-se da peça e terra.
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 ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or
● Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
● Los humos fuera de la zona de res- Spanish
● Desconectar el cable de ali- ● No operar con panel abierto o
piración.
● Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux French
● Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
● Vermeiden Sie das Einatmen von ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
● Mantenha seu rosto da fumaça. ● Não opere com as tampas removidas. ● Mantenha-se afastado das partes
● Use ventilação e exhaustão para ● Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. ● Não opere com os paineis abertos ATENÇÃO
● Não toque as partes elétricas nuas. ou guardas removidas.
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.
• 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 WEB SITE: www.lincolnelectric.com

Arco Sumergido Manual Cr10

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Arco Sumergido Manual Cr10

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CR-10

Roller - Idler Welder

SECTION 2: CR-10 IDLER/ROLLER WELDER SPECIFICATIONS ........……………………..… 2-5

SECTION 3: INSTALLATION ............………………………………………………………………... 6-9

SECTION 4: USING THE WELDER ……........................................………………………………. 10 - 17

SECTION 5: PREVENTATIVE MAINTENANCE ……………………………………………………. 24 - 25

SECTION 6: TROUBLESHOOTING WELDER PROBLEMS .......................……………………. 26

SECTION 7: RECOMMENDED SPARE PARTS …………………………………………………… 27

SECTION 8: CONSUMABLE GUIDE ………………………………………………………………… 28

APPENDIX: ASSEMBLY AND PARTS DRAWINGS ……………………………………………… 29

DANGER! - Information about risks to life

SECTION 2 - CR-10 SPECIFICATIONS

Weight Width Height Length

WELDING POWER SUPPLIES

FLUX RECOVERY SYSTEM

WATER COOLING SYSTEM (Optional)

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE

Upper Flux Hopper D1500 CR-10 Idler/Roller Rebuilder

Bottom Flux Yoke

YOKE TILT - tilts the yoke and workpiece clockwise or anti-clockwise.

Control Identification (Continued)

AUTOMATIC DIRECTION SPEED MANUAL

2) ARC START - Starts the welding cycle

WTC Machinery Corporation

4) INCH - Manually moves the Left and Right welding wire 0 10

ARC START DOWN DOWN

5) SPINDLE INDEX - Lights at the Step-over point

2 WTCMACHINERY CORPORATION OCONOMOWOC, WI. 53066

CIRC (Circumferential or Stringer) Mode constantly 26 27

7) LEFT VOLTMETER - Displays the voltage of the Left Torch Head

8) MOVEUP AUTOMATIC MODE - selects the Moveup mode

Control Identification (Continued)

25) SPINDLE JOG - manually rotates the idler or roller

CR-10 Idler Roller Welder

Wire Load Access

B) SETTING UP THE PAY-OUT PAKS

Focus on one of the Pay-out Paks. Loosen the bolts

Repeat the above steps with the other Pay-out Pak.

C) SETTING UP THE WELDING POWER SUPPLY UNITS

D) SETTING UP THE FLUX PUMP

E) CONNECTING THE YOKE-TILT CABLE

F) INSTALLING THE UPPER FLUX HOPPER

Install the Flux Limit Switch to the Upper Flux Hopper,

G) CONNECTING THE AIR SUPPLY Air Connection

Connect a compressed air supply line to the Air Supply Regulator/Filter at

H) TESTING THE MACHINE

The CR-10 is now ready for operation.

SECTION 4 - USING THE WELDER

GENERAL APPROACHES TO IDLER AND ROLLER REBUILDING -

Generally, rebuilding begins by leveling the tread surface. Use a

Checking the Dimensions -

The correct step-over distance leaves a smooth, level surface.

GENERAL APPROACHES TO IDLER AND ROLLER REBUILDING - (CONTINUED)

Weld Quality and Bead Profile -

Voltage - is usually specified by the welding wire Welding Process -

onto the workpiece. This is directly related to the

and the weld penetration (bonding of the weld CL WORKPIECE

The peaked bead (cool weld) leaves an uneven surface, and

SETTING THE BEAM CARRIAGE HEIGHT -

To make sure there is enough clearance for the workpiece,

This distance should be larger than the distance from the

To raise the Beam Carriage, set the "MOVEUP DIRECTION"

LOADING DISASSEMBLED IDLERS AND ROLLERS -

Adjust the Spindle Shaft by loosening the