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.

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

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.

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

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.

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

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.

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

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).

A-5

INSTALLATION

A-5

ENGINE BREAK-IN

Lincoln Electric selects high quality, heavy-duty indus­trial engines for the portable welding machines we
offer. While it is normal to see a small amount of
crankcase oil consumption during initial operation,
excessive oil use, wetstacking (oil or tar like sub­stance at the exhaust port), or excessive smoke is not
normal.

Larger machines with a capacity of 350 amperes and
higher, which are operated at low or no-load condi­tions for extended periods of time are especially sus­ceptible to the conditions described above. To
accomplish successful engine break-in, most diesel­powered equipment needs only to be run at a reason­ably heavy load within the rating of the welder for
some period of time during the engine’s early life.
However, if the welder is subjected to extensive light
loading, occasional moderate to heavy loading of the
engine may sometimes be necessary. Caution must
be observed in correctly loading a diesel/generator
unit.

1. Connect the welder output studs to a suit­able resistive load bank. Note that any
attempt to short the output studs by con­necting the welding leads together, direct
shorting of the output studs, or connecting
the output leads to a length of steel will
result in catastrophic damage to the gener­ator and voids the warranty.

Battery Charging

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes
away.

BATTERY ACID can burn eyes and
skin.

• Wear gloves and eye protection and

be careful when boosting, charging or
working near battery.

To prevent EXPLOSION when:

a) Installing a new battery - disconnect the

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

b) Connecting a battery charger - remove the

battery from the welder by disconnecting the
negative cable first, then the positive cable and
battery clamp. When reinstalling, connect the
negative cable last.

c) Using a booster - connect the positive lead to

the battery first, then connect the negative lead to
the ground lead on the base.

To prevent ELECTRICAL DAMAGE when:

a) Installing a new battery.
b) Using a booster.

Use correct polarity - Negative Ground.

2. Set the welder controls for an output cur­rent and voltage within the welder rating
and duty cycle. Note that any attempt to
exceed the welder rating or duty cycle for
any period of time will result in catastrophic
damage to the generator and voids the
warranty.

3. Periodically shut off the engine and check
the crankcase oil level.

To prevent BATTERY DISCHARGE, if you have an

ignition switch, turn it off when engine is not
running.

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

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

The Classic 300 D is equipped with a wet charged
battery. The charging current is automatically regulat­ed when the battery is low (after starting the engine)
to a trickle current when the battery is fully charged.

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

CLASSIC 300D

B-1

OPERATION

B-1

ENGINE OPERATION

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.

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

7. Allow the engine to run at high idle speed for sev­eral minutes to warm the engine. Stop the engine
and recheck the oil level, after allowing sufficient
time for the oil to drain into the pan. If the level is
down, fill it to the full mark again. The engine con­trols were properly set at the factory and should
require no adjusting when received.

COLD WEATHER STARTING:

With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
about -15°F (-26°C), it maybe desirable to install cold­starting aides.

Note: Extreme cold weather staring may require
longer glow plug operation.

WARNING

Under NO
starting fluids be used!

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

Stopping the Engine

conditions should ether or other

See additional warning information at the

front of this operator’s manual.

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

Operate the welder with the doors closed. Leaving
the doors open changes the designed air flow and can
cause overheating.

Starting the Classic 300 D Perkins 104-22
Diesel Engine

1. Turn the “IDLER” switch to “HIGH”.

2. Turn the “IGNITION” switch to “ON”.

3. Press the Glow Plug button for 20 to 30 seconds.
(maximum 60 seconds).

4. Press the Start button. When the engine starts
running, release both buttons. If the engine fails to
start in 20 seconds, wait 30 seconds and repeat
the above procedure.

5. Observe the oil pressure. If no pressure shows
within 30 seconds, stop the engine and consult
the engine operating manual. To stop the engine,
turn the “IGNITION” switch to “OFF”.

6. If the engine protection warning light comes on
during cranking or after start up, the “IGNITION”
switch must be turned “OFF” to reset the engine
protection system.

1. Turn the “IGNITION” switch to “OFF”

At the end of each day’s welding, check the crankcase
oil level, drain accumulated dirt and water from the
sediment bowl under the fuel tank and refill the fuel
tank to minimize moisture condensation in the tank.
Also, running out of fuel tends to draw dirt into the fuel
system.

When hauling the welder between job sites, close the
fuel feed valve beneath the fuel tank.

If the fuel supply is cut off or runs out while the fuel
pump is operating, air may be entrapped in the fuel
distribution system. If this happens, bleeding of the
fuel system may be necessary. Use qualified person­nel to do this per the instructions in the MAINTE­NANCE section of this manual.

CLASSIC 300D

B-2

WELDER OPERATION

OPERATION

Range Selector” to the 190-120 position and then
adjust the “Fine Current Adjustment” for 175 amps.

B-2

WARNING

ELECTRIC SHOCK can kill.

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

• Insulate yourself from work and ground.

FUMES & GASES can be dangerous.

• Keep your head out of the fumes.

• Use ventilation or exhaust to remove
fumes from breathing zone.

WELDING SPARKS can cause fire or
explosion.

• Keep flammable material away.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Duty Cycle

The NEMA output rating of the Classic 300 D is 300
amperes at 32 arc volts on
Specifications in this manual
Duty cycle is based on a ten minute period; thus, the
welder can be loaded at rated output for six minutes
out of every ten minute period.

Control of Welding Current

a 60% duty cycle (consult

for alternate ratings).

CAUTION

DO NOT TURN THE “CURRENT RANGE SELEC­TOR” WHILE WELDING because the current may
arc between the contacts and damage the switch.

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

The “Current Range Selector” provides five overlap­ping current ranges. The “Fine Current Adjustment”
adjusts the current from minimum to maximum within
each range. Open circuit voltage is also controlled by
the “Fine Current Adjustment” permitting control of the
arc characteristics.

A high open circuit voltage setting provides the soft
“buttering” arc with best resistance to pop-outs pre­ferred for most welding. To get this characteristic, set
the “Current Range Selector” to the lowest setting that
still provides the current you need and set the “Fine
Current Adjustment” near maximum. For example: to
obtain 175 amps and a soft arc, set the “Current

When a forceful “digging” arc is required, usually for
vertical and overhead welding, use a higher “Current
Range Selector” setting and lower open circuit volt­age. For example: to obtain 175 amps and a forceful
arc, set the “Current Range Selector” to the 240-160
position and the “Fine Current Adjustment” setting to
get 175 amps.

Some arc instability may be experienced with EXX10
electrodes when trying to operate with long arc tech­niques at settings at the lower end of the open circuit
voltage range.

CAUTION

DO NOT attempt to set the “Current Range Selector”
between the five points designated on the nameplate.

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

These switches have a spring loaded cam which
almost eliminates the possibility of setting this switch
between the designated points.

Idler Operation

Start the engine with the “Idler” switch in the “High”
position. Allow it to run at high idle speed for several
minutes to warm the engine. See Specifications for
operating speeds.

The idler is controlled by the “Idler” toggle switch on
the welder control panel. The switch has two posi­tions as follows:

1. In the “High” position, the idler solenoid acti-
vates, and the engine goes to high idle speed. The
speed is controlled by the governor.

2. In the “Auto” / position, the idler oper-
ates as follows:

a. When welding or drawing power for lights or tools

(approximately 100-150 watts minimum) from the
receptacles, the idler solenoid activates and the
engine operates at high idle speed.

b. When welding ceases or the power load is turned

off, a preset time delay of about 15 seconds
starts. This time delay cannot be adjusted.

c. If the welding or power load is not re-started

before the end of the time delay, the idler sole­noid deactivates and reduces the engine to low
idle speed.

CLASSIC 300D

B-3

Auxiliary Power

The AC auxiliary power, supplied as a standard, has a
rating of 3.0 kVA of 115/230 VAC (60 hertz).

With the 3.0 kVA, 115/230 VAC auxiliary power, one
115V duplex and one 230V duplex, grounding type
receptacle are provided. The circuit is protected with
circuit breakers.

The rating of 3.0 kVA permits a maximum continuous
current of 13 amps to be drawn from the 230 volt
duplex receptacle. Or a total of 26 amps can be drawn
from the 115 volt duplex receptacle. The 115 volt
duplex receptacle has a configuration which permits
20 amps to be drawn from either half. The total com­bined load of all receptacles is not to exceed 3.0 kVA.

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

OPERATION

B-3

CLASSIC 300D

C-1

ACCESSORIES

C-1

OPTIONAL FEATURES (Field Installed)

GENERAL OPTIONS

WARNING

Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly. The use of an arc
welder for pipe thawing is not approved by the
CSA, nor is it recommended or supported by
Lincoln Electric.

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

Power Plug Kit (K802D) - A power plug kit for the
auxiliary power receptacles is available. (Provides a
plug for each receptacle.)

GFCI Receptacle Kit (K1690-1) - Includes one UL
approved 115V ground fault circuit interrupter duplex
type receptacle with cover and installation instruc­tions. Replaces the factory installed 115V duplex
receptacle. Each receptacle of the GFCI duplex is
rated at 20 amps. Maximum total current from the
GFCI duplex is limited to 20 amps. See the MAINTE­NANCE section for detailed information on testing and
resetting the GFCI receptacle.

Spark Arrestor Kit (K903-1) - Includes a heavy gage
steel, approved spark arrestor, clamp and adapter for
mounting to the muffler exhaust pipe.

Remote Control Kit (K924-4) - Contains switch,
receptacle, remote control rheostat, and 100 ft
(30.5m) cable for adjusting the OCV at the welding
site.(For Codes below 10911.)

Remote Control Kit (K924-5) - Contains remote
control rheostat and 100 ft. (30.5 m) cable for adjust­ing the OCV at the welding site. (For Codes 10911
and above.)

Remote Control Kit (K2464-1) - Contains remote
control rheostat (for adjusting the CC “STICK OVC),
remote control potentiometer (for adjusting the CV
“WIRE” OCV) and 100 ft. (30.5 m) cable.

TIG OPTIONS

TIG Module (K930-2) - Provides high frequency and

shielding gas control for AC and DC GTAW (TIG)
welding applications. Its compact case is designed for
easy carrying, complete with a handle. High frequen­cy bypass is built in.The K938-1 Contactor Kit must
be field installed in the TIG Module when used with a
ZR-10. Additionally, the K936-3 control cable is
required if remote control is used. If remote control is
not used the K936-4 control cable is required.

PTA-26V TIG Torch K1783-9-Air cooled 200 amp­torch equipped with valve for gas flow control. 25Ft.
length.

Magnum Parts Kit For PTA-26V TIG Torch KP509

K953-1 TRAILER - Two-wheeled trailer with optional fender

and light package. For highway use, consult applicable feder­al, state, and local laws regarding possible additional require­ments. There is a choice of 2 hitches, a fender & a light pack­age.

K953-1 Trailer
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-1 Fender & Light Kit
K965-1 Cable Rack

OIL DRAIN KIT K1586-1 - Includes ball valve, hose

and clamp.

STICK OPTIONS

K704 ACCESSORY SET - Includes 35 feet (10 m) of

electrode cable and 30 feet (9 m) of work cable, head­shield, work clamp and electrode holder. Cable is
rated at 500 amps, 60% duty cycle.

Remote Control Cable (K936-4) - Control cable for
connecting the K930-2 TIG Module to a ZR-10 not
equipped with a K892-1 Remote Kit. 9-Socket to a
grounded 115 V plug and a 6 pin MS-connector.
(Contains circuits 31, 32, and ground)

Arc Start Switch K814

Contactor Kit K938-1

Control Cable Extension K937-45-Cable is 45Ft. in

length.

Water Valve Kit K844-1-For use with a water-cooled
TIG torch. Installs inside TIG Module.

CLASSIC 300D

C-2

ACCESSORIES

C-2

Wire Feed Module (K623-1) - Provides constant

voltage (CV) output with improved arc stability for
Innershield welding. Excellent for MIG welding.
Recommended wire feeders are the LN-7, LN-23P
and LN-25. (Factory installed on the K1643-2).

LN-25 Wire Feeder K449-Portable CC/CV unit for
flux-cored and MIG welding. Includes Gas Solenoid &
Internal Contactor. Requires Wire Feed Module.

Remote Voltage Control Kit for LN-25 K444-2

Provides 25 ft. (7.5m) of remote output voltage control
and output jumper (2 and 4) for machines having 14
pin MS-type connector.

Magnum® 350 Innershield Gun (for LN-25)K126-2-

For self-shielded wire with 15 ft. (4.5m) cable. For
.062-3/32” (1.6-2.8mm) wire.

Magnum® 200 MIG Gun (for LN-25)K497-3-With
15 ft. (4.5m) cable. For .025 (0.6m) wire.

Magnum Gun Connector KiT-Connects Magnum
200 MIG gun to LN-25 Wire Feeder.

SG Control Module K488-The interface between the
power source and the spool gun. Provides control of
wire speed and gas flow.

Input Cable K691-10.-For Lincoln engine drives with
14-pin MS-type connection, separate 115V NEMA
receptacle and output stud connections. 10 ft.
length.

LN-23P Wire Feeder K316L-1-Portable CV unit for
Innershield pipe welding. Control cable operates con­tactor inside Wire Feed Module for “cold” electrode.
Requires LN-23P Adapter Kit (K350-1) and Gun and
Cable Assembly.

LN-23P Adapter Kit K350-1-Required to adapt LN­23P to any Lincoln power source. Makes 14 pin con­nection at power source.

Magnum® 250 Innershield Gun (for LN-23P) K355­10-For lighter weight and easier handling. Rated 250

amps, 60% duty cycle. For .068 through 5/64” (1.7
through 2.0 mm) Innershield wire and includes
reduced speed switch. For pipewelding, an M11476
62° gun tube is recommended.

62° gun tube for Pipe Welding KP1909-1-

Recommended modification for K355-X or K345-x
guns with 90° gun tubes. Compatible with K126-1,­2,K264_8 and K355-10.

SPOOL GUN WELDER

Magnum Spool Gun K487-25-Hand held semiauto­matic wire feeder requires SG Control Module. 25 ft.
length.

CLASSIC 300D

D-1

MAINTENANCE

D-1

MAINTENANCE

WARNING

Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. 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.

Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.

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

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

front of this operator’s manual.

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

General Instructions

1. Blow out the welder and controls with an air hose at

least once every two months. In particularly dirty loca­tions, this cleaning may be necessary once a week.
Use low pressure air to avoid driving dirt into the insu­lation.

2. “Current Range Selector” contacts should not be
greased. To keep the contacts clean, rotate the cur­rent control through its entire range frequently. Good
practice is to turn the handle from maximum to mini­mum setting twice each morning before starting to
weld.

4. When necessary, remove the sediment bowl, if so
equipped, from beneath the fuel tank and clean out
any accumulated dirt and water.

5. Follow the engine service schedule in this manual

and the detailed maintenance and troubleshooting in
the engine manufacturer’s manual.

Cooling System

The Classic 300 D is equipped with a pressure radia­tor. Keep the radiator cap tight to prevent loss of
coolant. Clean and flush the cooling system periodi­cally to prevent clogging the passage and overheating
the engine. When antifreeze is needed, always use
the permanent type. Capacity = 9.5 qts (9.0 Ltrs.).

Bearings

This welder is equipped with a double-shielded ball
bearing having sufficient grease to last indefinitely
under normal service. Where the welder is used con­stantly or in excessively dirty locations, it may be nec­essary to add one half ounce of grease per year. A
pad of grease one inch wide, one inch long, and one
inch high weighs approximately one half ounce. Over­greasing is far worse than insufficient greasing.

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

Commutator and Brushes

WARNING

Uncovered rotating equipment can be dangerous.
Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself
from particles that may be thrown out by the rotat­ing armature when stoning the commutator.

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

Shifting of the commutator brushes may result in:

- Change in machine output

- Commutator damage

- Excessive brush wear

Periodically inspect the commutator, slip rings, and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.

3. Put a drop of oil on the “Current Range Selector”
shaft at least once every month.

CLASSIC 300D

D-2

Replace brushes when they wear within 1/4” of the
pigtail. A complete set of replacement brushes should
be kept on hand. Lincoln brushes have a curved face
to fit the commutator. Have an experienced mainte­nance man seat these brushes by lightly stoning the
commutator as the armature rotates at full speed until
contact is made across the full face of the brushes.
After stoning, blow out the dust with low pressure air.

To seat slip ring brushes, position the brushes in
place. Then slide one end of a piece of fine sandpaper
between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres­sure on top of the brushes, pull the sandpaper around
the circumference of the rings - in direction of rotation
only - until brushes seat properly. In addition, stone
slip ring with a fine stone. Brushes must be seated
100%.

Arcing or excessive exciter brush wear indicates a
possible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.

MAINTENANCE

D-2

Purging Air from Fuel System (Perkins
104-22 Engine)

WARNING

Keep fuel clear of open flames or arcs, allow
engine to cool before working on the fuel system.
Wipe up any spilled fuel and do not start engine
until fumes clear.

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

If the engine is running rough and you suspect air has
been trapped in the fuel system, (e.g. the engine was
allowed to run out of fuel) perform the following steps
using qualified personnel:

1. Loosen by two or three turns, the vent screw
(Figure D.1) on the fuel inlet connection.

Idler Maintenance

CAUTION

Before doing electrical work on the idler printed
circuit board, disconnect the battery.

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

When installing a new battery or using a jumper bat­tery to start the engine, be sure the battery polarity is
connected properly. The correct polarity is negative
ground. Damage to the engine alternator and the
printed circuit board can result from incorrect connec­tion.

1. The solenoid plunger must work freely and not

bind. Dust the plunger about once a year with
graphite powder.

2. Proper operation of the idler requires good ground-

ing of the printed circuit board, reed switch, and
battery.

3. Idler solenoid is activated for high idle.

Vent Screw

Priming

Lever

FIGURE D.1

For Engines Equipped with a mechanical fuel pump:

2.

Operate the priming lever on the fuel lift pump until
fuel, free of air, flows from the vent point. Tighten
the vent screw. If the pump is at the point of maxi­mum lift, it will not be possible to operate the prim­ing lever. If this occurs, turn the crankshaft one
revolution.

For Engines Equipped with an electric fuel pump:

Operate the electric fuel pump by turning the
“Ignition” switch “ON” until fuel, free of air, flows
from the vent point. Tighten the vent screw.

3. Contact your Perkins Engine repair facility if prob­lems persist.

4. If desired, the welder can be used without automat-

ic idling by setting the “Idler” switch to the “High”
position.

Nameplates

Whenever routine maintenance is performed on this
machine - or at least yearly - inspect all nameplates
and labels for legibility. Replace those which are no
longer clear. Refer to the parts list for the replace­ment item number.

CLASSIC 300D

I

EVERY 400 HOURS OR 12 MONTHS

EVERY 200 HOURS OR 6 MONTHS

EVERY 100 HOURS OR 3 MONTHS

FIRST SERVICE-(20 / 50 HOURS)

EVERY DAY OR EVERY 8 HOURS

If necessary use shorter periods.

These preventive maintenance periods apply to average conditions of operation.

Perkins #1300366120

TYPE OR QUANTITY

Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.

Perkins #140517000

(3) Fill slowly! Ensure correct quantity is used.

8.7qrts, (8.2L) (including filter)

(2) Consult Engine Operators Manual for additional maintenance schedule information.

9.5qrts, (9.0L)

(1) Consult Engine Operators Manual for oil recommendations.

NOTES:

Alternator drive belt Perkins # 080109080

Alternator drive belt wear

R

Tension of alternator drive belt

I

Drain water separator & fuel strainer

Engine oil (NOTE 1 & 3)

R

Engine oil level (NOTE 1)

Coolant (NOTE 3)

MAINTENANCE ITEM

Concentration of antifreeze 50/50 Water/Ethylene Glycol

C

I

R

Coolant level

R

C

R

R

I

R

ENGINE SERVICE

I

EVERY 600 HOURS OR 18 MONTHS

Fuel filter canister

5/06
S20919-2

BCI Group 24

Contact Perkins

Intake .008", exhaust .008"

Donaldson #P181050 or Nelson #70206N

R = ReplaceC = Clean

Battery

Leaks or engine damage

I

Injector performance

All nuts and bolts for tightness

I = Inspect

Electrical systems

I

I

Valve clearances

I

Tighten cylinder head

I

I

Check and adjust idle speed

I

Air filter element

Air filter (earlier check may be req'd.)

R

I

CC

Engine oil filter

ENGINE SERVICE (NOTE 2)

MAINTENANCE

FOR CODES 10658 AND BELOW

D-3D-3

CLASSIC 300D

D-4

FOR CODES 10911 AND ABOVE

ENGINE SERVICE

EVERY DAY OR EVERY 8 HOURS

FIRST SERVICE-(20 / 50 HOURS)

EVERY 100 HOURS OR 3 MONTHS

EVERY 200 HOURS OR 6 MONTHS

EVERY 400 HOURS OR 12 MONTHS

EVERY 600 HOURS OR 18 MONTHS

ENGINE SERVICE (NOTE 2)

MAINTENANCE

D-4

MAINTENANCE ITEM

I

I

R

R
R

R

C

C

I

CC

I

I

I = Inspect

Notes:

(1) Consult Engine Operators Manual for oil recommendations.
(2) Consult Engine Operators Manual for additional maintenance schedule information.
(3) Fill slowly! Ensure correct quantity is used.

Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.
These preventive maintenance periods apply to average conditions of operation.
If necessary use shorter periods.

Coolant level

I

Concentration of antifreeze
Coolant (NOTE 3)

R

Engine oil level (NOTE 1)
Engine oil (NOTE 1 & 3)
Engine oil filter
Drain water separator & fuel strainer

R

Fuel filter canister
Tension of alternator drive belt
Alternator drive belt wear

I

Alternator drive belt

R

Air filter (earlier check may be req’d.)
Air filter element

R

Check and adjust idle speed
Tighten cylinder head

I

Valve clearances

I

Electrical systems

I

All nuts and bolts for tightness

I

Injector performance

I

Leaks or engine damage
Battery

I

R = ReplaceC = Clean

50/50 Water/Ethylene Glycol

9.5qrts., 9.0L

8.7qrts, 8.2L (including filter)
Perkins #140517000

Perkins #26560017

Perkins #080109080

Donaldson #P181050, Nelson #70206N

Intake .008", exhaust .008"

Contact Perkins

TYPE OR QUANTITY

S25557

CLASSIC 300D

D-5

MAINTENANCE

GFCI RECEPTACLE TESTING AND RESET­TING PROCEDURE

The GFCI receptacle should be properly tested at
least once every month or whenever it is tripped. To
properly test and reset the GFCI receptacle:

• If the receptacle has tripped, first carefully remove
any load and check it for damage.

• If the equipment has been shut down, it must be
restarted.

• The equipment needs to be operating at high idle
speed and any necessary adjustments made on the
control panel so that the equipment is providing at
least 80 volts to the receptacle input terminals.

• The circuit breaker for this receptacle must not be
tripped. Reset if necessary.

• Push the "Reset" button located on the GFCI recep­tacle. This will assure normal GFCI operation.

• Plug a night-light (with an "ON/OFF" switch) or other
product (such as a lamp) into the GFCI receptacle
and turn the product "ON".

• Push the "Test" button located on the GFCI recepta­cle. The night-light or other product should go
"OFF".

• Push the "Reset" button, again. The light or other
product should go "ON" again.

D-5

If the light or other product remains "ON" when the
"Test" button is pushed, the GFCI is not working prop­erly or has been incorrectly installed (miswired). If
your GFCI is not working properly, contact a qualified,
certified electrician who can assess the situation,
rewire the GFCI if necessary or replace the device.

CLASSIC 300D

E-1

TROUBLESHOOTING

TROUBLESHOOTING

E-1

WARNING

Have qualified personnel do the troubleshooting
work. Turn the engine off before working inside
the machine. 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.

Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.

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

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

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

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.

CLASSIC 300D

E-2

TROUBLESHOOTING

WELDER TROUBLESHOOTING

TROUBLE CAUSES WHAT TO DO

1. Machine fails to hold a. Rough or dirty commutator. a. Commutator should be turned or
the output (heat) consistently. cleaned.

b. Brushes may be worn down to b. Replace brushes.

limit.

c. Field circuit may have variable c. Check field current with ammeter to

resistance connection or discover varying current. This
intermittent open circuit due to applies to both the main generator
loose connection or broken wire. and exciter.

d. Electrode lead or work lead d. Tighten all connections.

connection may be poor.

e. Wrong grade of brushes may e. Use Lincoln brushes.

have been installed on generator.

f. Field rheostat may be making f. Inspect and clean the rheostat.

poor contact and overheating.

2. Welder starts but fails a. Generator or exciter brushes a. Be sure that all brushes bear on the
to generate current. may be loose or missing. commutator and have proper spring

tension.

E-2

b. Exciter may not be operating. b. Check exciter output voltage with

voltmeter or lamp.

c. Field circuit of generator or c. Check for open circuits in rheostat,

exciter may be open. field leads, and field coils. Check

rectifier bridge.

d. Exciter may have lost excitation. d. Flash fields. (1) Check flashing

diode at 5 o’clock brushholder in
generator.

e. Series field and armature circuit e. Check circuit with ringer or voltmeter.

may be open-circuited.

(1) FLASHING THE FIELDS:

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

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

3. Using a 12 volt automotive battery, connect it’s negative terminal to the negative brushholder. The
negative brushholder is the one nearest to the rotor lamination. See the wiring diagram. With the
engine NOT running, touch the positive battery terminal to the positive brushholder. Remove the
battery from the circuit.

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

3. Welding arc is loud and a. Current setting may be too high. a. Check setting and current output with ammeter.
spatters excessively

b. Polarity may be wrong. b. Check polarity. Try reversing polarity or try an

electrode of the opposite polarity.

4. Welding current too great or too a. Exciter output low causing low output a. Check exciter field circuit.
small compared to indication on compared to dial indication.
the dial.

b. Operating speed too low or too high. b. Adjust speed with screw stops at throttle linkage.

(High idle - 1800 RPM, Low idle - 1375 RPM)

5. Arc continuously pops out. a. “Current Range Selector” switch may be a. Set the switch at the center of the current range

set at an intermediate position. desired.

CLASSIC 300D

E-3

TROUBLESHOOTING

ELECTRONIC IDLER TROUBLESHOOTING GUIDE

With Idler Control Switch in the Auto Position,

Engine Will Not Return to Low Idle in Approximately 15 Seconds

After Welding and Auxiliary Loads are Removed

Set Idler Control Switch

to the Auto Position

Check for Continuity through Idler

Control Switch

Open Closed

Measure DC Voltage on Replace Idler

Idler Solenoid Coil Control Switch

E-3

12 VDC 0 VDC

Check Continuity of Check for Jamming

Reed Switch in Weld Circuit of the Idler Solenoid

Mechanism or a broken

Return Spring

Open Closed

1. Check Wiring in Replace Reed
Idler Solenoid Switch
Circuit

2. Replace Idler
P.C. Board

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.

CLASSIC 300D

E-4

TROUBLESHOOTING

ELECTRONIC IDLER TROUBLESHOOTING GUIDE

With Idler Control Switch in the AUTO Position,

Engine Will Not Pick Up Speed When:

E-4

The Arc is Struck

Reed Switch in Weld Circuit

Defective -- Will Not Close

To Check: Short the Red Lead

on P.C. Board to Welder Frame.

Engine Picks Up Speed

1. Check for Break in
Red Lead and Repair

2. Replace Reed Switch
in Weld Circuit.

Engine Does Not Pick Up

Speed

1. Check Continuity of Idler
Solenoid Coil (8.5-9.0
ohms) and Replace as
Required.

2. Check for Jamming of
the Idler Solenoid
Mechanism.

The Auxiliary Power Load is Turned ON

Power Load Too Small

Try Load Above 150 Watts

Engine Does Not Pick Up Speed

1. Check Continuity of Idler Solenoid Coil
(8.5-9.0 ohms) and Replace as
Required.

2. Check for Jamming of the Idler
Solenoid Mechanism.

3. Check for Continuity of Current
Transformer (Toroid). Replace as
Required.

4. Check Idler Circuit Wiring and Repair
as Required.

5. Replace Idler P.C. Board.

3. Check Idler Circuit
Wiring and Repair as
Required.

4. Replace Idler P.C.
Board.

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.

CLASSIC 300D

E-5

TROUBLESHOOTING

ENGINE TROUBLESHOOTING

TROUBLE CAUSES WHAT TO DO

1. Engine does not start Faulty Ignition switch and or Injector pump solenoid Correct the connection and contact.
Insufficient charging or complete discharge of the battery
Lack of fuel Supply fuel.
Air mixed in the fuel system Bleed air (To be done by qualified personnel only)
Clogged fuel filter Replace.
Irregular and faulty fuel supply (Injector pump trouble) Repair in an authorized service shop.
Glow plug not heated Breakage of the glow plug; replace.
Improper viscosity of the lubricating oil Inspect and replace.
Clogged air cleaner Clean or replace.
No compression Repair in a service shop.
Engine protection light is ON 60 second start period elapsed, Turn ignition switch

2. Irregular running of the engine Air mixed in the fuel system Bleed air (To be done by qualified personnel only)
Uneven fuel injection (Faulty fuel injector pump) Repair in an authorized service shop.
Clogged fuel filter Replace.
Defective governor Check and correct.
Engine itself defective Repair in an authorized service shop.

3. Engine stops during operation Lack of fuel in the fuel tank

and the Engine Protection light Clogged fuel filter Replace.
does not turn on. Air mixed in the fuel system Bleed air (To be done by qualified personnel only)

Faulty function of the engine Repair in a service shop.

4. Engine stops during operation a. Overheat of the Engine

and the Engine Protection light Lack of Coolant Supply coolant. Inspect leakage and correct.
does turn on. Loose or slipping fan belt Remove oil, dust, etc. and tighten.

Damaged fan belt Replace.
Clogged radiator Flush the radiator.
Clogged radiator fin Clean.
Dust or scale clogged in the cooling water passage Flush the system.
Faulty function of the thermostat Inspect or replace thermostat.
Lack of lubricating oil. Add oil.
Overloading Decrease the load.
Faulty Idler/Engine Protection P.C. Board Replace.

b. Loss of Engine Oil Pressure

Lack of engine oil Supply oil up to the specified level.
Fault in the Oil Pressure Switch Replace the switch.
Oil leakage from the lubricating system Inspect and retighten.
Clogged oil filter Replace with new one.
Oil too light Drain and refill with proper grade.
Faulty Idler/Engine Protection P.C. Board Replace.

5. White or Blue Smoke Excess engine oil Inspect and correct the level.
Too low viscosity of the engine oil Inspect and replace the oil with proper grade.
Faulty injection timing Repair in a service shop.

6. Dark Grey Smoke Unsuitable fuel Inspect and replace with correct grade.
Excess injection Inspect and adjust (in a service shop).
Faulty function of the engine Repair in a service shop.
Overloading Reduce the load.
Clogged air cleaner Clean.

7. Faulty Charging Loose fan belt Correct the tension.
Faulty wiring Inspect and correct.
Faulty battery Repair.
Worn out alternator brush Replace.

8. Starter Motor does not run Loose or damaged wiring Inspect and tighten.
Drained voltage from battery Charge the battery.
Damaged starter motor (including solenoid) Repair in a service shop.

9. Engine Protection Light not Broken Light Bulb Replace the bulb.

coming on (after the ignition Faulty light wiring (to GND or P.C. Board) Correct.
switch has been in the ON Faulty Idler/Engine Protection P.C. Board Replace.
position for more than 60
seconds with the engine
not started).

Charge.

OFF & ON - See #4 Below.

Supply fuel and bleed air (To be done by qualified personnel only)

E-5

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.

CLASSIC 300D

F-1

CONTROL PANEL COMPONENTS

LEAD COLOR CODE

B

R

+

-

+

-

Y

R

W

B

B

SLIP RINGS

TO IRON

R

N

A

54

32

1

ALTERNATOR

AUXILIARY

POWER

WINDINGS

CURRENT

TRANSFORMER

CB3

CB1

115 VOLT

RECEPTACLE

230 VOLT

RECEPTACLE

Y

NEGATIVE

SELECTOR

SWITCH

WELDER

LEAD BLOCK

AC

AC

CR2 REED

RELAY

42

602A

G

U

CB2

CB4

FUSE

15A.

1

2
3

456

7
89

10
11

12

1

2

345

6

600A

41

GENERATOR

N

-W

+Y

G

G

B

600B

610

610

602B

IGNITION

SWITCH

START

STARTING

MOTOR

ENGINE

+

52

IDLER

SWITCH

+

A

IDLER

SOLENOID

ALTERNATOR

ROTOR

SLIP RING

NEAREST

-

HOUR

METER

J5

P9

J8

POSITIVE

ELECTRICAL SYMBOLS

PER E1537

P10

+Y

-W

N

U

W

B

-

51

60

56

RHEOSTAT

EXC

ALTERNATOR

+

OIL PRESSURE

GLOW

PLUG

PUMP SOLENOID

TEMPERATURE

GAUGE

GLOW PLUGS

50

50B

53

(CC-)

(CC+) & (CV+ WITH W.F.M.)

S

B

W

G

PLUG FOR

REMOTE CONTROL

POTENTIOMETER

B

*

REMOTE CONTROL RECEPTACLE & SWITCH

X

Y

#2 HEAVY LEAD

WIRE FEED MODULE (OPTIONAL)

WIRE FEED

MODULE

}

W.F.M.

CONTROL

PANEL

NEG.

POS.

OUTPUT TERMINALS

CONNECT TO POS. & NEG.

{

CONNECT TO NEG.

BRUSH HOLDER

608

609

#2 HEAVY LEAD

#8 LEAD

NEGATIVE CV

OUTPUT TERMINAL

PANEL

MACHINE MUST NOT BE RUNNING

WHEN MAKING THESE CONNECTIONS.

*

ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".

CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.

PLUG

(P5)

250 AMP

THERMOSTAT

ASSEMBLY

INLINE

CONNECTORS

REMOTE CONTROL

POTENTIOMETER BOX

L10877

+

CLASSIC 300D WIRING DIAGRAM (FOR CODES 10658 AND BELOW)

GROUND

TO BASE

GROUND

TO ENGINE

B

B

B

SHOWN AS VIEWED FROM REAR.

CONNECT

TO CASE

G

’

NEUTRAL BONDED TO FRAME

NEUTRE RACCORDE AU BATI

(GROUND SCREW

NEAR FUSE)

ENGINE GAUGES)

(GROUND SCREW NEAR

THE RED AND BLACK LEADS ARE USED ON CLASSIC I MACHINES ONLY AND ARE NOT

CONNECTED ON THIS MACHINE. DAMAGE T O THE REMOTE CONTROL AND/OR MACHINE

R

1

2

3

4

12 34 56

7

8

9

10

IDLER/ENGINE

PROTECTION

P.C. BOARD

J1

J2

CB1

W

W

ENGINE

FAILURE

LAMP

60C

61

60A

58A

51A

53B

57

56A

G

G

54B

54

59

58

50A

K924-4 REMOTE CONTROL (OPTIONAL)

WITH MACHINE NOT RUNNING, REMOVE PLUG "P9" ON MACHINE FROM CONNECTOR "J8".

RESISTORS

CAUTION: DAMAGE CAN OCCUR

TO THE REMOTE CONTROL

SWITCH IF IT IS USED WITHOUT

THE "P11" PLUG INSTALLED OR A

WIRE FEED MODULE INSTALLED.

123456789101112

P11 SEE BELOW

**

THEN CONNECT PLUG "P8" ON REMOTE CONTROL TO CONNECTOR "J8" ON MACHINE.

UNCONNECTED PLUG "P10" (IF ONE IS ON THE MACHINE). FASTEN THE NEW PLUG "P11"

NEARBY, LEAVING IT UNCONNECTED.

"P10" ON THE MACHINE FROM CONNECTOR "J5". CONNECT PLUG "P11" FROM THE REMOTE

CONTROL KIT TO CONNECTOR "J5" ON THE MACHINE.**IF NO WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISCONNECT P LUG

IF A WIRE FEED MODULE IS INSTALLED, W ITH THE MACHINE OFF, DISPOSE OF THE

WILL RESULT IF THE RED AND BLACK LEADS ARE CONNECTED IN THE CLASSIC 300D.

7-13-2001G

CIRCUIT BREAKER

CB1 APPEARS ON

EARLIER UNIT S ONLY

FUEL PUMP

ELECTRIC FUEL

PUMP DOES NOT

APPEAR ON

EARLIER UNITS

SWITCH (N.C.)

B-BLACK OR

GRAY

G-GREEN

N-BROWN

R-RED OR

PINK

U-BLUE

W-WHITE

Y-YELLOW

YB

SEE

BELOW

*

P8

1

234

5

6

X

600

42

602

W

R

BELOW

SEE

*

SWITCH FOR LOCAL OR

REMOTE CONTROL SHOWN

IN LOCAL POSITION.

A

G

41

W

R

R

R

602

W

REMOTE SWITCH WIRED

THIS WAY ON EARLIER

UNITS

DIAGRAMS

F-1

CLASSIC 300D

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

C

L11865

CONTROL PANEL COMPONENTS

LEAD COLOR CODE

610A

600C

+

-

+

-

810

820

02/20

/2004

B

SLIP RINGS

TO IRON

R

N

A

54

321

ALTERNATOR

AUXILIARY

POWER

WINDINGS

CURRENT

TRANSFORMER

CB3

CB1

115 VOLT

RECEPTACLE

230 VOLT

RECEPTACLE

214

NEGATIVE

SELECTOR

SWITCH

WELDER

LEAD BLOCK

AC

AC

CR2 REED

RELAY

42

602A

GND-E

U

CB2

CB4

FUSE

15A.

1

2

3

456

7
89

C
11

12

1

234

5

6

600A

41

GENERATOR

N

-W

+Y

G

G

B

600B

610

610

602B

IGNITION

SWITCH

START

STARTING

MOTOR

ENGINE

+

52

IDLER

SWITCH

+

AMMETER

IDLER

SOLENOID

ALTERNATOR

ROTOR

- SLIP RING

NEAREST

-

HOUR

METER

J5

J8

POSITIVE

ELECTRICAL SYMBOLS

PER E1537

P10

+Y

-W

N

U

W

B

-

51

60

56

RHEOSTAT

EXC

ALTERNATOR

+

TEMPERATURE

GLOW

PLUG

PUMP SOLENOID

TEMPERATURE

GAUGE

GLOW PLUGS

50

51C

53

(CC-)

(CC+) & (CV+ WITH W.F.M.)

S

B

W

G

PLUG FOR

REMOTE CONTROL

POTENTIOMETER

B

X

Y

#2 HEAVY LEAD

WIRE FEED MODULE (OPTIONAL)

WIRE FEED

MODULE

}

W.F.M.

CONTROL

PANEL

NEG.

POS.

OUTPUT TERMINALS

CONNECT TO POS. & NEG.

{

CONNECT TO NEG.

BRUSH HOLDER

608

609

#2 HEAVY LEAD

#8 LEAD

NEGATIVE CV

OUTPUT TERMINAL

PANEL

MACHINE MUST NOT BE RUNNING

WHEN MAKING THESE CONNECTIONS.

*

ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".

CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.

PLUG

(P5)

250 AMP

THERMOSTAT

ASSEMBLY

INLINE

CONNECTORS

REMOTE CONTROL

POTENTIOMETER BOX

+

CLASSIC 300D WIRING DIAGRAM (FOR CODES 10911 AND ABOVE)

GROUND

TO BASE

GROUND

TO ENGINE

B

B

B

SHOWN AS VIEWED FROM REAR.

CONNECT

TO CASE

G

’

NEUTRAL BONDED TO FRAME

NEUTRE RACCORDE AU BATI

(GROUND SCREW

NEAR FUSE)

ENGINE GAUGES)

(GROUND SCREW NEAR

R

1

2

3

4

12 34 56

7

8

9

10

IDLER/ENGINE

PROTECTION

P.C. BOARD

J1

J2

W

W

ENGINE

FAILURE

LAMP

60C

61

60A

58A

51A

53B

57

56A

G

G

54B

54

59

58

50A

K924-5 REMOTE CONTROL (OPTIONAL)

RESISTORS

FUEL PUMP

SWITCH/SENDER

B-BLACK OR

GRAY

G-GREEN

N-BROWN

R-RED OR

PINK

U-BLUE

W-WHITE

Y-YELLOW

Y

X

600

42

602

W

SWITCH FOR LOCAL

OR REMOTE CONTROL

SHOWN IN LOCAL

G

41

W

R

58H

OIL PRESSURE

GAUGE

51G

OIL PRESSURE

SWITCH/SENDER

WK

G

54D

212B

S

GND-N

GND-M

S

212A

WATER

20A

20A

15A

15A

POSITION.

P8

G

W

G

I

I

G

11 11A

215

21

DIAGRAMS

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 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.

CLASSIC 300D

F-3

DIAGRAMS

K2464-1 REMOTE CONTROL
WIRING / CONNECTION DIAGRAM

F-3

RESISTORS

REMOTE CONTROL BOX

Y

BG

W

CC "STICK CONTROL

CONNECT TO CASE

CLASSIC 300D

X

CV "WIRE" CONTROL POT

CCW

ORANGE

RED

BLUE

CABLE CONNECTION TABLE

PIN

E

F
G

C
D

LEAD COLOR
RED

ORANGE

BLUE

WHITE JUMPER
WHITE JUMPER

A

S26097

F-4

A

A

A

A

18.50

20.62

A

A

40.94

A

A

24.00

A

A

37.12

A

A

F

A

A

G

A

A

B

A

H

A

A

D

A

A

A

A

23.00

A

A

A

A

A

A

C

4.00

4.00

.56 SKID
O

MOUNTING

HOLE

O

.56 SKID

MOUNTING

HOLE

N.A.

N.B.

NOTES:

OIL AND WATER IN ENGINE,

BUT NO FUEL.

N.A. CENTER OF GRAVITY WITH

O

N.B. .56 TRAILER MOUNTING

HOLES.

J

A

A

K

S10766

S10766-6, -8, -9, AND -10, ADDED DIMENSION L AND NOTE N.C.

C

PART NO.

WELDER A B C D F G H

J K

S10766-8

65.00 57.70 8.70

27.94

12.82 41.66

3.25

CLASSIC 300D

L

45.5

CONTROL PANEL

A

L

N.C.

N.C. DIMENSION TO TOP OF

EXHAUST ELBOW OR

RAINCAP.

A

A

A

A

DIAGRAMS

F-4

CLASSIC 300D

WARNING

Spanish

AVISO DE

PRECAUCION

● 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 moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

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 HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

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: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com