Lincoln Electric 9535 Operator'S Manual Download Page 2

i

SAFETY

i

FOR ENGINE
powered equipment.

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.

____________________________________________________

1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel-
ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers

and devices in position and in good
repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f.  Do not put your hands near the engine fan. Do not attempt to

override the governor or idler by pushing on the throttle con-
trol rods while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

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.

WARNING

Mar ‘95

ELECTRIC AND 
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes 

localized Electric and Magnetic Fields (EMF). Welding 
current creates EMF fields around welding cables and 
welding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure

them with tape when possible.

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

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right 
side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

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

1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
hot.

CALIFORNIA PROPOSITION 65 WARNINGS

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

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines

Summary of Contents for 9535

Page 1: ...part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful For use wit...

Page 2: ...R 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...

Page 3: ...ical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for co...

Page 4: ...cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid weldi...

Page 5: ...appropri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise pais...

Page 6: ...ion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number __________...

Page 7: ...lation Section A Input Power Connection A 1 Duty Cycle A 1 Output Connections A 1 Operating Instructions Section B Accessories Section C Maintenance Section D Troubleshooting Section E Troubleshooting...

Page 8: ...ound lead to the ground stud marked with the symbol Install the reconnect panel for the proper input voltage per the diagram pasted inside the access panel cover DUTY CYCLE The maximum output rating o...

Page 9: ...ol dial labeled I on the front of the machine indicates the output current On the R3R 375 I there is only one dial On the R3R 500 I and 600 I there are two dials The A range controls the current over...

Page 10: ...WITCH Remote Output Current Control F POLARITY SWITCH Factory installed option on domestic models only Electrode Polarity Positive Electrode Polarity Negative Do Not Switch While Welding G RATING PLAT...

Page 11: ...ROL AND K870 FOOT AMPTROL Connect directly to the 6 pin Amphenol on the front of the power source POCKET AMPTROL factory installed only The Pocket Amptrol option provides a remote current control for...

Page 12: ...required The probe tip should be kept in condition to provide sharp edges at the ends to assure penetration of heavy oxide coatings on the work piece A blunted tip could result in giving different wel...

Page 13: ...i ties that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause If you do not understand or are unable to perform t...

Page 14: ...ed 6 Input contactor coil open 7 Open winding on 115V pilot transformer 8 Power ON OFF switch not closing 9 Lead broken or loose connec tion in 115V starter circuit 10 Thermostats defective High Tempe...

Page 15: ...Electrode or work lead loose or broken 2 Open transformer primary or secondary circuit 3 Supply line fuse blown 4 Input line grounded causing single phase input 5 Input leads not connected to contact...

Page 16: ...Troubleshooting Section E 1 Input fuse blown Machine is single phased 2 One phase of main transformer windings open 3 Defective power bridge 1 Improper ventilation 2 Loaded beyond rating 3 Fan inoper...

Page 17: ...baffle 1 Poor work or electrode cable connection 2 Current too low 3 Welding leads too small 4 Open SCR or diode in power rectifier bridge 5 Control circuit problems 1 Input contactor contacts frozen...

Page 18: ...COURSE OF ACTION L Optional remote current control not functioning See Troubleshooting Section C before connecting 1 Current control switch in the wrong position 2 Leads 75 76 and 77 not con nected t...

Page 19: ...ng and replacing check repair are OK one at a time changes OCV each gate lead one at a time does NOT change OCV Codes below 9500 with power off remove leads from Identify gate lead that when Codes abo...

Page 20: ...rent control rheostat or the control circuit Only the green lead can and should be grounded to the machine case When extending the standard remote control make sure the leads are the same and the spli...

Page 21: ...crew Reading should be infinite 5 If either step 3 or step 4 fails replace the switch I REMOTE CONTROL CHECK For codes above 9500 the remote control Amphenol pin assignments are pin C 75 pin B 76 and...

Page 22: ...d a much higher resistance in Step c K POWER SILICON CONTROLLED REC TIFIER TEST The SCR must be mounted in the heat sink when making this test a Connect the ohmmeter set to the X10 scale leads to the...

Page 23: ...208 209 224 OPTIONAL METER KIT VM AM FRAME GROUND 217 217 A A 115 V 201 202 203 7 S S 10 1 4 5 6 66V BOTTOM PRIMARY TOP PRIMARY T1 X1 X2 X3 SEC SEC SEC 16 17 18 ARE PRESENT ON 380 500 OR 460 575 MACH...

Page 24: ...375 I 500 I AND 600 I F 2 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 machin...

Page 25: ...RING DIAGRAMS IDEALARC R3R 375 I 500 I AND 600 I F 3 R3R 375 I 500 I and 600 I K817 or K817R K841 not shown Part No Type A B C D F G H M12244 7 R3R 32 00 15 39 3092 1 44 30 02 11 33 07 06 94 M12244 7...

Page 26: ...NOTES IDEALARC R3R 375 I 500 I AND 600 I...

Page 27: ...NOTES IDEALARC R3R 375 I 500 I AND 600 I...

Page 28: ...NOTES IDEALARC R3R 375 I 500 I AND 600 I...

Page 29: ...NOTES IDEALARC R3R 375 I 500 I AND 600 I...

Page 30: ...CHTEN Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aisl...

Page 31: ...Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el ca...

Page 32: ...and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Pr...

Reviews: