Lincoln Electric CLASSIC 300G 11135, CLASSIC 300G 10659, CLASSIC 300G 10912, IM659-B User Manual

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CLASSIC ® 300G

IM659-B

December, 2004

For Machines with Code Numbers 10659,10912,11135

Safety Depends on You

Lincoln arc welding equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part . DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.

And, most importantly, think before you act and be careful.

R NRTL/C

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

Lincoln Electric CLASSIC 300G 11135, CLASSIC 300G 10659, CLASSIC 300G 10912, IM659-B User Manual

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel Engines

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 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 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 welding arc or when the engine is running.

Stop the engine and allow it to cool before refueling 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 control 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.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

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.

Mar ‘95

ii

 

SAFETY

 

ii

 

 

 

 

 

 

 

 

 

ELECTRIC SHOCK can

kill.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

Semiautomatic DC Constant Voltage (Wire) Welder.

DC Manual (Stick) Welder.

AC Welder with Reduced Voltage Control.

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

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

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

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

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

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

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

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

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

FUMES AND GASES can be dangerous.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

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

5.d. Read and understand the manufacturer’s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

iii

SAFETY

iii

WELDING SPARKS can

cause fire or explosion.

6.a. Remove fire hazards from the welding area.

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

materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI

Standard Z49.1) and the operating information for the equipment being used.

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

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

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

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

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

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

7.c. Cylinders should be located:

Away from areas where they may be struck or subjected to physical damage.

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

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

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

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

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

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

Mar ‘95

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1.Protegez-vous contre la secousse électrique:

a.Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b.Faire trés attention de bien s’isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

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

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

e.Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

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

2.Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

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

a.Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au soudage à l’aide d’écrans appropriés et non-inflammables.

4.Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons 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 zones où l’on pique le laitier.

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

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

8.S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9.Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10.Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

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

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1.Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

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

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

4.Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

v

Thank You

v

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

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.

vi

 

 

TABLE OF CONTENTS

 

 

 

 

vi

 

 

 

 

Page

 

 

 

Installation .......................................................................................................

Section A

 

 

 

Technical Specifications ........................................................................................

A-1

 

 

 

Safety Precautions.................................................................................................

A-2

 

 

 

Pre-Operation Installation......................................................................................

A-2

 

 

 

Exhaust Spark Arrester ...................................................................................

A-2

 

 

 

Location/Ventilation.........................................................................................

A-2

 

 

 

Machine Grounding.........................................................................................

A-2

 

 

 

Lift Bail ............................................................................................................

A-2

 

 

 

Trailers ............................................................................................................

A-2

 

 

 

Polarity Control and Cable Sizes ....................................................................

A-3

 

 

 

Pre-Operation Service ...........................................................................................

A-3

 

 

 

Oil....................................................................................................................

A-3

 

 

 

Fuel .................................................................................................................

A-3

 

 

 

Cooling System ...............................................................................................

A-3

 

 

 

Battery Charging .............................................................................................

A-4

 

 

 

 

 

 

 

 

 

 

 

 

Operation .........................................................................................................

Section B

 

 

 

General Description...............................................................................................

B-1

 

 

 

Design Features ....................................................................................................

B-1

 

 

 

Starting The GM 3.0L Engine..........................................................................

B-2

 

 

 

Stopping the engine ........................................................................................

B-2

 

 

 

Welder Operation...................................................................................................

B-2

 

 

 

Duty Cycle.......................................................................................................

B-2

 

 

 

Control of Welding Current..............................................................................

B-3

 

 

 

Idler Operation ................................................................................................

B-3

 

 

 

Auxiliary Power ...............................................................................................

B-3

 

 

 

Throttle Body Deicing......................................................................................

B-3

 

 

 

 

 

 

 

 

 

 

 

Accessories .....................................................................................................

Section C

 

 

 

Optional Equipment (Field Installed) .....................................................................

C-1

 

 

 

 

 

 

 

 

 

 

Maintenance ....................................................................................................

Section D

 

 

 

Safety Precautions ................................................................................................

D-1

 

 

 

General Instructions ..............................................................................................

D-1

 

 

 

Cooling System .....................................................................................................

D-1

 

 

 

Bearings ................................................................................................................

D-1

 

 

 

Commutator and Brushes .....................................................................................

D-1

 

 

 

Idler Control Maintenance .....................................................................................

D-2

 

 

 

Nameplates ...........................................................................................................

D-2

 

 

 

Purging Air from Fuel System................................................................................

D-2

 

 

 

Engine Maintenance .............................................................................................

D-2

 

 

 

Engine Service Chart ............................................................................................

D-3

 

 

 

 

 

 

 

 

 

 

Troubleshooting ..............................................................................................

Section E

 

 

 

Safety Precautions.................................................................................................

E-1

 

 

 

Troubleshooting ..............................................................................................

E-2,E-3

 

 

 

Electronic Idler Troubleshooting Guide...........................................................

E-4,E-5

 

 

 

Troubleshooting .....................................................................................

E-5, E-6,E-7

 

 

 

 

 

 

 

 

 

Diagrams ..........................................................................................................

Section F

 

 

 

Wiring Diagram (Classic 300G) .......................................................................

F-1,F-2

 

 

 

Dimension Print......................................................................................................

F-3

 

 

 

 

 

 

 

 

 

 

 

Parts List ......................................................................................................

P379 Series

 

 

 

 

 

 

 

 

 

 

A-1

 

 

 

INSTALLATION

 

 

A-1

 

TECHNICAL SPECIFICATIONS – CLASSIC 300G (K1754-1)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

INPUT - GASOLINE ENGINE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Make/Model

Description

 

Speed (RPM)

 

Displacement

Ignition

 

Capacities

 

 

 

 

 

 

 

 

 

cu. in. (Ltrs.)

System

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

High Idle 1800

 

 

Delco Voyager

 

Fuel: 15 gal.

 

 

 

 

4 Cylinder

 

 

 

 

High Energy

 

57 Ltrs.

 

 

GM

4 Cycle

 

 

 

 

 

 

 

 

 

3.0 Liter

Water-Cooled

 

Full Load 1800

 

 

Distributor Type

 

Oil: 4.5 Qts.

 

 

 

 

Gasoline Engine

 

 

 

 

 

 

4.3 Ltrs.

 

 

Classic 300G

Cast Iron Cylinder

 

 

 

183.0(3.0)

Electronic

 

 

 

 

(K1754-1)

Block/Crankcase

 

Low Idle 1360

 

 

 

 

 

 

 

 

 

 

 

 

Cooling 9.9 Qts.

 

 

 

 

53.0 HP @

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9.4 Ltrs.

 

 

 

 

1800 RPM

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RATED OUTPUT - WELDER

 

 

 

 

 

DESCRIPTION

 

RATED DC OUTPUT*

DUTY CYCLE

DC CURRENT RANGE

 

 

 

 

 

VOLTS @ RATED AMPS

Fine Adjustment in each Range

 

 

300 Amp DC Welder

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

30V @ 250A

100%

 

 

 

 

 

All Copper Windings

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

40-350 Amps

 

 

Pure DC Power

 

 

NEMA Rating

 

 

 

 

 

 

 

 

 

 

 

32V @ 300A

60%

 

 

 

 

 

Generator

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT - GENERATOR

Auxiliary Power 1

3000 Watts, 60 Hz. AC

(26 Amps @ 115V), (13 Amps @ 230V)

ENGINE OPERATING LOAD

FUEL CONSUMPTION

Low Idle (1360 RPM)-No Load

.89 gal/hr (3.37 ltrs/hr)

 

High Idle (1800 RPM)-No Load

1.32 gal/hr (5.00 ltrs/hr)

 

AC Auxiliary-115 Volts-26 Amps

1.42 gal/hr (5.32 ltrs/hr)

 

50 Amps @ 22 Volts @ 60% Duty Cycle

1.24 gal/hr (4.70 ltrs/hr)

 

100 Amps @ 24 Volts @ 60 % Duty Cycle

1.27 gal/hr (4.82 ltrs/hr)

 

150 Amps @ 26 Volts @ 60% Duty Cycle

1.33 gal/hr (5.04 ltrs/hr)

 

200 Amps @ 28 Volts @ 60 % Duty Cycle

1.47 gal/hr (5.57 ltrs/hr)

 

250 Amps @ 30 Volts @ 60 % Duty Cycle

1.66 gal/hr (6.27 ltrs/hr)

 

300 Amps @ 32 Volts @ 60 % Duty Cycle

1.83 gal/hr (6.91 ltrs/hr)

 

250 Amps @ 30 Volts @ 100 % Duty Cycle

2.15 gal/hr (8.12 ltrs/hr)

 

 

 

 

PHYSICAL DIMENSIONS

HEIGHT

WIDTH

DEPTH

WEIGHT

40.94** in.

24.00 in.

66.91in.

 

1039.9 mm

609.6 mm

1700 mm

1330 lbs. (603kg.)

 

 

 

 

**Top of enclosure, add 8.0” (203.2mm) for exhaust

 

 

 

 

 

 

(1) 115V will operate either 60 Hz. or 50/60 Hz. power tools, lights etc.

* Based on a 10 min. period.

CLASSIC 300G

A-2

INSTALLATION

A-2

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.

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

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

Insulate yourself from work and ground

Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust outside.

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

MOVING PARTS can injure.

Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

See additional warning information at

the front of this operator’s manual.

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

PRE-OPERATION INSTALLATION

EXHAUST SPARK ARRESTER

Some federal, state or local laws may require that engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard muffler included with this welder does not qualify as a spark arrester. When required by local regulations, a suitable spark arrester must be installed and properly maintained.

CAUTION

Use of an incorrect arrester may lead to engine damage or performance loss. Contact the engine manufacturer for specific recommendations.

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

LOCATION / VENTILATION

Always operate the welder with the doors closed. Leaving the doors open changes the designed air flow and may cause overheating.

The welder should be located to provide an unrestricted flow of clean, cool air. Also, locate the welder so that engine exhaust fumes are properly vented to an outside area.

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

Where there is a combustible surface directly under stationary or fixed electrical equipment, the surface shall be covered with a steel plate at least

.06”(1.6mm) thick, which shall extend not more than 5.90”(150mm) beyond the equipment on all sides.

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MACHINE GROUNDING

According to the United States National Electrical Code, the frame of this portable generator is not required to be grounded and is permitted to serve as the grounding means for cord connected equipment plugged into its receptacle.

Some state, local, or other codes or unusual operating circumstances may require the machine frame to be grounded. It is recommended that you determine the extent to which such requirements may apply to your particular situation and follow them explicitly. A machine grounding stud marked with the symbol

is provided on the welding generator frame foot. In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints, or to the metal framework of a building which has been effectively grounded. The U.S. National Code lists a number of alternate means of grounding electrical equipment.

LIFT BAIL

A lift bail is provided for lifting with a hoist.

WARNING

 

• Lift only with equipment of

 

adequate lifting capacity.

 

• Be sure machine is stable

 

when lifting.

 

• Do not lift this machine using

 

lift bail if it is equipped with a

 

heavy accessory such as trail-

 

er or gas cylinder.

FALLING

• Do not lift machine if lift bail is

EQUIPMENT can

damaged.

cause injury.

• Do not operate machine while

 

suspended from lift bail.

CLASSIC 300G

A-3

INSTALLATION

A-3

 

 

 

TRAILER (See ACCESSORY Section)

If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be considered are as follows:

1.Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachments.

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

3.Proper placement of the equipment on the trailer to ensure stability side to side and front to back when being moved and when standing by itself while being operated or serviced.

4.Typical conditions of use, i.e., travel speed, roughness of surface on which the trailer will be operated; environmental conditions, likely maintenance.

5.Conformance with federal, state and local laws. (1)

(1)Consult applicable federal, state and local laws regarding specific requirements for use on public highways.

WARNING

VEHICLE MOUNTING

Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail.

Only transport this Equipment on serviceable vehicles which are rated and designed for such loads.

Distribute, balance and secure loads so vehicle is stable under conditions of use.

Do not exceed maximum rated loads for components such as suspension, axles and tires.

Mount equipment base to metal bed or frame of vehicle.

Follow vehicle manufacturer’s instructions.

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When welding at a considerable distance from the welder, be sure you use ample size welding cables.

RECOMMENDED COPPER CABLE SIZES

 

 

 

Cables Sizes for Combined Length

 

 

 

of Electrode Plus Work Cable

 

 

 

Up to 200 ft.

200 to 250 ft.

 

Amps

Duty Cycle

60.96 m

200 to76.2 m

 

250

100%

1

1/0

 

 

 

 

 

 

300

60%

1/0

2/0

 

 

 

 

 

PRE-OPERATION SERVICE

CAUTION

READ the engine operating and maintenance instructions supplied with this machine.

WARNING

GASOLINE can cause fire or explosion.

Stop engine while fueling.

Do not smoke when fueling.

Keep sparks and flame away from tank.

Do not leave unattended while fueling.

Wipe up spilled fuel and allow fumes to clear before starting engine.

Do not overfill tank, fuel expansion may cause overflow.

GASOLINE FUEL ONLY

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OIL

This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W/30 oil. This oil should be acceptable for most typical ambient temperatures.

Consult the engine operation manual for specific engine manufacturer’s recommendations. Upon receipt of the welder, check the engine dipstick to be sure the oil is at the “full” mark. DO NOT overfill.

POLARITY CONTROL AND CABLE SIZES

With the engine off, route the electrode and work cables through the strain relief bracket on the base and connect to the studs located below the fuel tank mounting rail. (See size recommendations below.) For Positive polarity, connect the electrode cable to the terminal marked “+”. For Negative polarity, connect the electrode cable to the “-” stud. These connections should be checked periodically and tightened if necessary.

FUEL

Fill the fuel tank with the grade of fuel recommended in the Engine Operator’s manual. Make sure the fuel valves on the sediment bowl and the water separator are in the open positions.

COOLING SYSTEM

The radiator has been filled at the factory with a 50-50 mixture of ethylene glycol antifreeze and water. Check the radiator level and add a 50-50 solution as needed (see engine manual or antifreeze container for alternate antifreeze recommendations)

CLASSIC 300G

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