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For Machines with Code Numbers 10545, 10546, 10657, 10658, 10911 and 10927
Safety Depends on You
Lincoln arc welding equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part . DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
And, most importantly, think before you act and be careful.
R
OPERATOR’S MANUAL
Copyright © 2006 Lincoln Global Inc.
•World's Leader in Welding and Cutting Products •
•Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes
outdoors.
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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.
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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.
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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.
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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.
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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
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SAFETY |
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ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
•Semiautomatic DC Constant Voltage (Wire) Welder.
•DC Manual (Stick) Welder.
•AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.
5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95
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SAFETY
iii
WELDING SPARKS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to physical damage.
•A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
Mar ‘95
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1.Protegez-vous contre la secousse électrique:
a.Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b.Faire trés attention de bien s’isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c.Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le refroidir.
e.Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f.Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.
2.Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.
3.Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a.Utiliser un bon masque avec un verre filtrant approprié ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.
b.Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au soudage à l’aide d’écrans appropriés et non-inflammables.
4.Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5.Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.
6.Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.
7.Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8.S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.
9.Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10.Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11.Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1.Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2.Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.
3.Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4.Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ‘93
v
Thank You
v
for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then “Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
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TABLE OF CONTENTS |
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Installation ....................................................................................................... |
Section A |
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Technical Specifications ........................................................................................ |
A-1 |
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General Description............................................................................................... |
A-2 |
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Design Features .................................................................................................... |
A-2 |
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Pre-Operation Installation...................................................................................... |
A-3 |
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Safety Precautions .......................................................................................... |
A-3 |
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Exhaust Spark Arrester ................................................................................... |
A-3 |
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Location/Ventilation......................................................................................... |
A-3 |
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Machine Grounding......................................................................................... |
A-3 |
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Lift Bail ............................................................................................................ |
A-3 |
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Trailers ............................................................................................................ |
A-4 |
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Polarity Control and Cable Sizes .................................................................... |
A-4 |
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Pre-Operation Service ........................................................................................... |
A-4 |
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Oil.................................................................................................................... |
A-4 |
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Fuel ................................................................................................................. |
A-4 |
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Cooling System ............................................................................................... |
A-4 |
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Engine Break-in, Battery Charging.................................................................. |
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Operation ......................................................................................................... |
Section B |
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Engine Operation................................................................................................... |
B-1 |
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Starting The Perkins 104-22 Engine ............................................................... |
B-1 |
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Stopping the engine ........................................................................................ |
B-1 |
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Welder Operation................................................................................................... |
B-2 |
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Duty Cycle....................................................................................................... |
B-2 |
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Control of Welding Current.............................................................................. |
B-2 |
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Idler Operation ................................................................................................ |
B-2 |
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Auxiliary Power ............................................................................................... |
B-3 |
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Accessories ..................................................................................................... |
Section C |
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Optional Features (Field Installed) ........................................................................ |
C-1 |
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Maintenance .................................................................................................... |
Section D |
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Safety Precautions ................................................................................................ |
D-1 |
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General Instructions .............................................................................................. |
D-1 |
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Cooling System ..................................................................................................... |
D-1 |
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Bearings ................................................................................................................ |
D-1 |
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Commutator and Brushes ..................................................................................... |
D-1 |
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Idler Maintenance.................................................................................................. |
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Nameplates ........................................................................................................... |
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Purging Air from Fuel System................................................................................ |
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Engine Service Chart .................................................................................... |
D-3, D-4 |
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GFCI Receptacle Testing and Reseting Procedure (Optional).............................. |
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Troubleshooting .............................................................................................. |
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Safety Precautions................................................................................................. |
E-1 |
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Welder Troubleshooting ........................................................................................ |
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Electronic Idler Troubleshooting Guide........................................................... |
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Engine Troubleshooting Guide ..................................................................... |
E-5, E-6 |
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Diagrams .......................................................................................................... |
Section F |
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Wiring Diagram (Classic 300 D) ...................................................................... |
F-1,F-2 |
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Connection Diagram .............................................................................................. |
F-3 |
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Dimension Print...................................................................................................... |
F-4 |
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Parts List ...................................................................................................... |
P337 Series |
A-1 |
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INSTALLATION |
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A-1 |
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TECHNICAL SPECIFICATIONS - CLASSIC 300D |
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INPUT - DIESEL ENGINE |
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Displacement |
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System |
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Perkins |
4 cylinder |
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High Idle 1800 |
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135.6 cu. in |
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12VDC batteries |
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Fuel: 15 gal. |
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104-22 Diesel |
4 Cycle |
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Low Idle 1350 |
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57 L |
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Engine |
32.7 HP @ |
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Full Load 1725 |
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Bore x Stroke |
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(Water Cooled) |
1800 RPM |
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Oil: 8.7 Qts. |
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8.2 L |
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3.875” x 5.00” |
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(98.4 mm x 127.0mm) |
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Coolant: 7.9 gal. |
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7.5 L |
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RATED OUTPUT - WELDER |
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WELDING OUTPUT* |
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OPEN CIRCUIT |
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OUTPUT RANGE |
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AUXILIARY POWER(1) |
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Current/Voltage/Duty Cycle |
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VOLTAGE |
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AMPS |
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40-350A |
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250A / 30V / 100% |
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98 Max. |
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220A-MAX. |
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115/230 VAC |
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3000 Watts, 60 Hz. |
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300A / 32V / 60% |
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@ 1800 RPM |
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160-240A |
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26 Amps @ 115V |
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120-240A |
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13 Amps @ 230V |
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120-190A |
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80-130A |
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Min.-90A |
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PHYSICAL DIMENSIONS(2) |
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HEIGHT |
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WIDTH |
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DEPTH |
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WEIGHT |
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45.50 in. |
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24.00 in. |
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65.00 in. |
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K1643-1 |
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1354 lbs. |
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(616 kg) |
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1156 mm |
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610 mm |
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1651 mm |
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K1643-2 |
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1354 lbs. |
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(616 kg) |
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* 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 |
0.28 gal/hr |
( 1.06 |
ltrs/hr) |
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High Idle (1800 RPM)-No Load @ 96.6 Volts |
0.45 gal/hr |
( 1.70 |
ltrs/hr) |
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50 Amps @ 22 Volts |
0.51 gal/hr |
( 1.93 |
ltrs/hr) |
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100 Amps @ 24 Volts |
0.58 gal/hr |
( 2.19 ltrs/hr) |
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150 Amps @ 26 Volts |
0.70 gal/hr |
( 2.65 |
ltrs/hr) |
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200 Amps @ 28 Volts |
0.85 gal/hr |
( 3.21 |
ltrs/hr) |
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250 Amps @ 30 Volts |
1.05 gal/hr |
( 3.97 |
ltrs/hr) |
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300 Amps @ 32 Volts |
1.31 gal/hr |
( 4.95 |
ltrs/hr) |
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350 Amps @ 34 Volts |
1.68 gal/hr |
( 6.35 |
ltrs/hr) |
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CLASSIC 300D
A-2 |
INSTALLATION |
A-2 |
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 |
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250A |
@ |
30V |
100% |
300A |
@ |
32V |
60% |
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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.
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 starting and stopping welding or using auxiliary power. A built-in time delay permits changing electrodes 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.
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 |
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INSTALLATION |
A-3 |
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PRE-OPERATION INSTALLATION |
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CAUTION |
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WARNING |
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DO NOT MOUNT OVER COMBUSTIBLE SUR- |
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FACES. |
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Do not attempt to use this equipment until you |
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Where there is a combustible surface directly under |
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have thoroughly read the engine manufacturer’s |
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stationary or fixed electrical equipment, the surface |
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manual supplied with your welder. It includes |
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important safety precautions, detailed engine |
shall be covered with a steel plate at least |
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starting, operating and maintenance instructions, |
.06”(1.6mm) thick, which shall extend not more than |
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and parts lists. |
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5.90”(150mm) beyond the equipment on all side.s. |
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------------------------------------------------------------------------ |
---------------------------------------------------------------------- |
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ELECTRIC SHOCK can kill.
•Do not touch electrically live parts or Machine Grounding electrode with skin or wet clothing.
•Insulate yourself from work and According to the United States National Electrical
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.
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.
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• Lift only with equipment of |
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adequate lifting capacity. |
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• Be sure machine is stable |
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when lifting. |
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• Do not lift this machine using |
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lift bale if it is equipped with a |
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heavy accessory such as trail- |
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er or gas cylinder. |
FALLING |
• Do not lift machine if lift bale is |
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damaged. |
EQUIPMENT can |
• Do not operate machine while |
cause injury. |
suspended from lift bale. |
------------------------------------------------------------------------
CLASSIC 300D
A-4 |
INSTALLATION |
A-4 |
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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, roughness of surface on which the trailer will be operated; environmental conditions, likely maintenance.
5.Conformance with federal, state and local laws. (1)
(1)Consult your federal, state and local laws regarding specific requirements for use on public highways.
VEHICLE MOUNTING
Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail.
•Only transport this equipment on serviceable vehicles which are rated and designed for such loads.
•Distribute, balance and secure loads so vehicle is stable under conditions of use.
•Do not exceed maximum rated loads for components such as suspension, axles and tires.
•Mount equipment base to metal bed or frame of vehicle.
•Follow vehicle manufacturer’s instruction.
----------------------------------------------------------------------------
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.
RECOMMENDED COPPER CABLE SIZES
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Cables Sizes for Combined Length |
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of Electrode Plus Work Cable |
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Amps |
Duty Cycle |
Up to 200ft.(61m) |
200 to 250ft. |
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(61 to 76m) |
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250 |
100% |
1 |
1/0 |
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300 |
60% |
1/0 |
2/0 |
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PRE-OPERATION SERVICE
CAUTION
READ the engine operating and maintenance instructions 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.
• 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 |
Fill the fuel tank with the grade of fuel recommended in the Engine Operator’s manual. Make sure the fuel valves on the sediment bowl and the water separator are in the open positions.
Cooling System
The radiator has been filled at the factory with a 50-50 mixture of ethylene glycol antifreeze and water. Check the radiator level and add a 50-50 solution as needed (see engine manual or antifreeze container for alternate antifreeze recommendations).
CLASSIC 300D
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