Lincoln Electric CLASSIC 300D User Manual

For Machines with Code Numbers 10545, 10546, 10657, 10658, 10911 and 10927

R

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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.

CLASSIC

®

300 D

IM631-B

May, 2006

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

Copyright © 2006 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

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.

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

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.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.

___________________________________________________

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.

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.

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.

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.

5.b.

Do not weld in locations near chlorinated hydrocarbon

coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
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

vapors

to

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.

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

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.

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

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.

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

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_________________________________________________________________________

vv

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

“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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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

Page

Installation .......................................................................................................Section A

Technical Specifications ........................................................................................A-1

General Description...............................................................................................A-2

Design Features ....................................................................................................A-2

Pre-Operation Installation......................................................................................A-3

Safety Precautions ..........................................................................................A-3

Exhaust Spark Arrester ...................................................................................A-3

Location/Ventilation.........................................................................................A-3

Machine Grounding.........................................................................................A-3

Lift Bail ............................................................................................................A-3

Trailers ............................................................................................................A-4

Polarity Control and Cable Sizes ....................................................................A-4

Pre-Operation Service ...........................................................................................A-4

Oil....................................................................................................................A-4

Fuel .................................................................................................................A-4

Cooling System ...............................................................................................A-4

Engine Break-in, Battery Charging..................................................................A-5

________________________________________________________________________

Operation .........................................................................................................Section B

Engine Operation...................................................................................................B-1

Starting The Perkins 104-22 Engine ...............................................................B-1

Stopping the engine ........................................................................................B-1

Welder Operation...................................................................................................B-2

Duty Cycle.......................................................................................................B-2

Control of Welding Current..............................................................................B-2

Idler Operation ................................................................................................B-2

Auxiliary Power ...............................................................................................B-3

________________________________________________________________________

Accessories.....................................................................................................Section C

Optional Features (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 Maintenance..................................................................................................D-2

Nameplates ...........................................................................................................D-2

Purging Air from Fuel System................................................................................D-2

Engine Service Chart ....................................................................................D-3, D-4

GFCI Receptacle Testing and Reseting Procedure (Optional)..............................D-5

________________________________________________________________________

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

Welder Troubleshooting ........................................................................................E-2

Electronic Idler Troubleshooting Guide...........................................................E-3,E-4

Engine Troubleshooting Guide .....................................................................E-5, E-6

________________________________________________________________________

Diagrams ..........................................................................................................Section F

Wiring Diagram (Classic 300 D) ......................................................................F-1,F-2

Connection Diagram ..............................................................................................F-3

Dimension Print......................................................................................................F-4

________________________________________________________________________

Parts List ......................................................................................................P337 Series

vi

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - CLASSIC 300D

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

System

A-1

Perkins 4 cylinder High Idle 1800 135.6 cu. in

104-22 Diesel 4 Cycle Low Idle 1350 (2.2 L)

Engine 32.7 HP @ Full Load 1725

(Water Cooled) 1800 RPM Bore x Stroke Oil: 8.7 Qts.

3.875” x 5.00”

(98.4 mm x 127.0mm) Coolant: 7.9 gal.

12VDC batteries
(2

) & Starter 57 L

Fuel: 15 gal.

8.2 L

7.5 L

RATED OUTPUT - WELDER

WELDING OUTPUT*

Current/Voltage/Duty Cycle

250A / 30V / 100%

300A / 32V / 60%

HEIGHT WIDTH DEPTH

OPEN CIRCUIT

VOLTAGE

98 Max.

@ 1800 RPM

PHYSICAL DIMENSIONS

OUTPUT RANGE

AMPS

40-350A

220A-MAX.

160-240A
120-240A
120-190A

80-130A

Min.-90A

(2)

AUXILIARY POWER

115/230 VAC

3000 Watts, 60 Hz.

26 Amps @ 115V
13 Amps @ 230V

WEIGHT

(1)

45.50 in. 24.00 in. 65.00 in.

1156 mm 610 mm 1651 mm

* Based on a 10 min. period.

(1) 115V will operate either 60 Hz. or 50/60 Hz. power tools, lights etc.
(2) Height to top of exhaust elbow.

PERKINS 104-22 DIESEL ENGINE TYPICAL FUEL CONSUMPTION DATA

Low Idle (1375 RPM)-No Load @ 45 Volts

High Idle (1800 RPM)-No Load @ 96.6 Volts

50 Amps @ 22 Volts

100 Amps @ 24 Volts

150 Amps @ 26 Volts

200 Amps @ 28 Volts

250 Amps @ 30 Volts

300 Amps @ 32 Volts

K1643-1

K1643-2

0.28 gal/hr ( 1.06 ltrs/hr)

0.45 gal/hr ( 1.70 ltrs/hr)

0.51 gal/hr ( 1.93 ltrs/hr)

0.58 gal/hr ( 2.19 ltrs/hr)

0.70 gal/hr ( 2.65 ltrs/hr)

0.85 gal/hr ( 3.21 ltrs/hr)

1.05 gal/hr ( 3.97 ltrs/hr)

1.31 gal/hr ( 4.95 ltrs/hr)

1354 lbs.

(616 kg)

1354 lbs.

(616 kg)

350 Amps @ 34 Volts

1.68 gal/hr ( 6.35 ltrs/hr)

CLASSIC 300D

A-2

INSTALLATION

GENERAL DESCRIPTION

The Classic®300 D is a heavy duty, engine driven,
DC arc welding power source, capable of providing
constant current output for stick welding or DC TIG
welding. This welder is wound with all copper coils,
rated at 300 amps/32 Volts, and provides other
Classic features such as improved door latches and
stainless hinges. With the addition of the optional

K623-1 Wire Feed Module™, the Classic 300 D will
provide constant voltage output for running the LN-7,
LN-23P, or LN-25 wire feeders. (The Wire Feed
Module is factory installed on the K1643-2). The
optional K924-4 or K924-5 Remote Control Kit (Both
field installed) See Section C for description.

The Classic 300 D has Diesel Engine Protection. In
the event of sudden low oil pressure or high coolant
temperature, the engine immediately shuts down.
The Classic 300 D has a current range of 40-350 DC
amps with output ratings as follows:

RATED OUTPUT DUTY CYCLE

250A @ 30V
300A @ 32V

100%

60%

A-2

DESIGN FEATURES

Control Panel

Both the engine and the welder controls are located
on one recessed panel at the exciter end of the
machine. The welder controls consist of a five step
“Current Range Selector” switch and a “Fine Current
Adjustment” rheostat. The welder is equipped with a
“Start” button, an “Ignition” switch, an “Idler” control
switch, and a “Glow Plug” button for easier cold
weather starting.

The control panel also contains an engine tempera­ture gauge, a battery charging ammeter, an oil pres­sure gauge, two three prong grounding type recepta­cles and four circuit breakers for auxiliary power.

All Copper Windings - For long life and dependable
operation.

Engine Idler - The Classic 300 D is equipped with an
electronic automatic engine idler. It automatically
increases and decreases engine speed when start-

ing and stopping welding or using auxiliary
power. A built-in time delay permits changing elec-

trodes before the engine slows to its low idle speed.
The “Idler” control switch on the panel locks the idler
in high idle position when desired.

These units are also capable of providing 3 kVA of
115/230 volts of 60 cycle AC auxiliary power.

The Classic 300 D uses the Perkins 104-22 industrial
water-cooled diesel engine.

Auxiliary Power - 3.0 kVA of nominal 115/230V,
60Hz, AC. Output voltage is maintained within ± 10%
at all loads up to rated capacity. (See Optional
Features for Power Plug Kit.)

Welder Enclosure - The complete welder is rubber
mounted on a rugged steel “C” channel base.

The output terminals are placed at the side of the
machines so that they are protected by the door. The
output terminals are labeled (+) and (-).

Cranking System - A 12 volt electric starter is stan­dard.

Air Cleaner - Heavy duty two stage dry type.

Muffler - A muffler and stainless steel exhaust outlet

elbow are standard.

Engine Hour Meter - A meter to record hours of oper­ation.

Engine Protection - The system shuts the engine
down in the event of sudden low oil pressure or high
coolant temperature. A warning light on the control
panel will indicate such a fault. To reset the engine for
restarting, turn the ignition switch off then on.

CLASSIC 300D

A-3

INSTALLATION

A-3

PRE-OPERATION INSTALLATION

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.

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

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

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 side.s.

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

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

CAUTION

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

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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.

CLASSIC 300D

• Lift only with equipment of
adequate lifting capacity.

• Be sure machine is stable
when lifting.

• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trail­er or gas cylinder.

FALLING • Do not lift machine if lift bale is

damaged.

EQUIPMENT can • Do not operate machine while

cause injury. suspended from lift bale.

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A-4

INSTALLATION

TRAILER (See Optional Features)

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, rough-

ness of surface on which the trailer will be operated;
environmental conditions, likely maintenance.

5. Conformance with federal, state and local laws.

(1)

Consult your federal, state and local laws regarding specific

requirements for use on public highways.

(1)

VEHICLE MOUNTING

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

• Only transport this equipment on serviceable vehi-

cles 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 compo-

nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of

vehicle.

• Follow vehicle manufacturer’s instruction.

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A-4

RECOMMENDED COPPER CABLE SIZES

Amps Duty Cycle Up to 200ft.(61m) 200 to 250ft.

250 100% 1 1/0

300 60% 1/0 2/0

Cables Sizes for Combined Length
of Electrode Plus Work Cable

(61 to 76m)

PRE-OPERATION SERVICE

CAUTION

READ the engine operating and maintenance instruc-

tions supplied with this machine.

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WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away
from tank.

• Do not leave unattended while

fueling.

DIESEL FUEL

can cause fire.

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

• Do not overfill tank, fuel
expansion may cause over­flow.

DIESEL FUEL ONLY

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

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.

Fuel

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.

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

CLASSIC 300D

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).