Lincoln Electric SVM194-A User Manual
CLASSIC®300 D & 300 G
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For use with machine code number: 10545, 10546, 10657, 10658,10911, 10927,11110
Classic® 300G: 10659, 10912, 11135
Safety Depends on You
Lincoln arc welding and cutting
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.
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SVM194-A
October, 2009
11111, 11112, 11113, 11243, 11244, 11248, 11249,
11280, 11281, 11411, 11412, 11413, 11414, 11472,
11473, 11474, 11475
View Safety Info View Safety Info View Safety Info View Safety Info
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i i
SAFETY
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.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.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
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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 ʻ95
CLASSIC® 300D & 300G
ii ii
SAFETY
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 within applicable OSHA PEL and
ACGIH TLV limits 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. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
5.c.
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.
vapors
to
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5.d. 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.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Jan ʻ09
CLASSIC® 300D & 300G
iii iii
SAFETY
WELDING and CUTTING
SPARKS can cause fire or
explosion.
6.a.
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 adjcent 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.
Remove fire hazards from the welding area.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
If
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.
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
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 manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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Jan ʻ09
CLASSIC® 300D & 300G
iv iv
SAFETY
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 LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent 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 nʼimporte quelle partie du
corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible de
la zone de travail quʼil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dʼautres 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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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
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a. Utiliser un bon masque avec un verre filtrant approprié ainsi
quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, 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 lʼon pique le laitier.
CLASSIC® 300D & 300G
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar ʻ93
v v
SAFETY
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturerʼs
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
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h) the time of day that welding or other activities are to be carried out.
L10093 3-1-96H
CLASSIC® 300D & 300G
vi vi
SAFETY
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturerʼs recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturerʼs recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturerʼs recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
1
tions.
_________________________
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1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”
CLASSIC® 300D & 300G
L10093 3-1-96H
I I
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Aʼs
Classic® 300D Perkins 104-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.1
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.2
Classic® 300D Kubota V2203M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.3
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.4
Classic® 300G GM 3.0 Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Bʼs
Classic® 300D Perkins 104-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.1
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.2
Classic® 300D Kubota V2203M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.3
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.4
Classic® 300G GM 3.0 Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.5
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Cʼs
Classic® 300D Perkins 104-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.1
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.2
Classic® 300D Kubota V2203M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.3
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.4
Classic® 300G GM 3.0 Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Dʼs
Classic® 300D Perkins 104-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D.1
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D.2
Classic® 300D Kubota V2203M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D.3
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D.4
Classic® 300G GM 3.0 Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D.5
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-337, P-379, P-498, P-507
Classic® 300D Perkins 104-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-337
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-507
Classic® 300D Kubota V2203M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-498
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-507
Classic® 300G GM 3.0 Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-379
CLASSIC® 300D & 300G
A1.1 A1.1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.3
Pre-Operation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.4
Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5
Polarity Control & Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6
TABLE OF CONTENTS - INSTALLATION SECTION
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CLASSIC® 300D & 300G
A1.2 A1.2
INSTALLATION
TECHNICAL SPECIFICATIONS - CLASSIC® 300D
INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
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)
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350 Amps @ 34 Volts
1.68 gal/hr ( 6.35 ltrs/hr)
CLASSIC® 300D & 300G
A1.3 A1.3
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
These units are also capable of providing 3 kVA of
115/230 volts of 60 cycle AC auxiliary power.
100%
60%
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
in Section C for Power Plug Kit.)
The Classic® 300 D uses the Perkins 104-22 industrial water-cooled diesel engine.
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.
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CLASSIC® 300D & 300G
A1.4 A1.4
INSTALLATION
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PRE-OPERATION INSTALLATION
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
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 operatorʼs 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
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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CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, the surface
shall be covered with a steel plate at least .06”(1.6mm)
thick, which shall extend not more than 5.90”(150mm)
beyond the equipment on all sides.
----------------------------------------------------------------------
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
FALLING EQUIPMENT can cause injury.
• 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.
• Do not lift machine if lift bale is damaged.
• Do not operate machine while suspended from
lift bale.
------------------------------------------------------------------------
CLASSIC® 300D & 300G
A1.5 A1.5
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.
INSTALLATION
RECOMMENDED COPPER CABLE SIZES
Cables Sizes for Combined Length
of Electrode Plus Work Cable
Amps Duty Cycle Up to 200ft.(61m) 200 to 250ft.
(61 to 76m)
250 100% 1 1/0
300 60% 1/0 2/0
PRE-OPERATION SERVICE
CAUTION
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 manufacturerʼs instruction.
----------------------------------------------------------------------------
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.
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 manufacturerʼs recommendations.
Upon receipt of the welder, check the engine dipstick to
be sure the oil is at the “full” mark. DO NOT overfill.
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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 pos-
itive 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.
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Fuel
Fill the fuel tank with the grade of fuel recommended in
the Engine Operatorʼs 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 & 300G
A1.6 A1.6
INSTALLATION
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 diesel-powered equipment needs only to be run at a reasonably heavy load
within the rating of the welder for some period of time
during the engineʼs 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.
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.
Use correct polarity - Negative Ground.
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.
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CLASSIC® 300D & 300G
B1.1 B1.1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.2
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.2
Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.3
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.4
TABLE OF CONTENTS - OPERATION SECTION
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CLASSIC® 300D & 300G
B1.2 B1.2
OPERATION
ENGINE OPERATION
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
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 sev-
eral 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
fluids be used!
------------------------------------------------------------------------
Stopping the Engine
conditions should ether or other starting
See additional warning information at the
front of this operatorʼs manual.
-----------------------------------------------------------
Operate the welder with the doors closed. Leaving the
doors open changes the designed air flow and can
cause overheating.
Starting the Classic® 300D 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 dayʼs 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.
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CLASSIC® 300D & 300G
B1.3 B1.3
WELDER OPERATION
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.
OPERATION
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
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 Range
Selector” to the 190-120 position and then adjust the
“Fine Current Adjustment” for 175 amps.
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.
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CLASSIC® 300D & 300G
B1.4 B1.4
OPERATION
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.
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CLASSIC® 300D & 300G
C1.1 C1.1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1.2
Wire Feed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1.3
TABLE OF CONTENTS - ACCESSORIES SECTION
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CLASSIC® 300D & 300G
C1.2 C1.2
ACCESSORIES
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.
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CLASSIC® 300D & 300G
C1.3 C1.3
ACCESSORIES
Wire Feed Module (K623-1) - Provides constant volt-
age (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-
15 ft. (4.5m) cable. For .025 (0.6m) wire.
Magnum Gun Connector KiT-Connects Magnum 200
MIG gun to LN-25 Wire Feeder.
3-With
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 pipe welding, 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.
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SPOOL GUN WELDER
Magnum Spool Gun K487-25-Hand held semiautomatic wire feeder requires SG Control Module. 25 ft.
length.
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CLASSIC® 300D & 300G
C1.4 C1.4
NOTES
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CLASSIC® 300D & 300G
D1.1 D1.1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.2
Idler Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.3
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.4/D1.5
GFCI Receptacle Testing & Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.6
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.7
TABLE OF CONTENTS - MAINTENANCE SECTION
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CLASSIC® 300D & 300G
D1.2 D1.2
MAINTENANCE
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 operatorʼs 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.
3. Put a drop of oil on the “Current Range Selector”
shaft at least once every month.
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 manufacturerʼs 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.
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CLASSIC® 300D & 300G
D1.3 D1.3
MAINTENANCE
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.
Idler Maintenance
CAUTION
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 D1.3) on the fuel inlet connection.
Vent Screw
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.
4. If desired, the welder can be used without automat-
ic idling by setting the “Idler” switch to the “High”
position.
Nameplates
Priming
Lever
FIGURE D1.3
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.
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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.
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CLASSIC® 300D & 300G
D1.4 D1.4
I
EVERY 400 HOURS OR 12 MONTHS
EVERY 200 HOURS OR 6 MONTHS
E
VERY 100 HOURS OR 3 MONTHS
F
IRST 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.
P
erkins #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)
C
oolant (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
E
VERY 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
E
ngine oil filter
ENGINE SERVICE (NOTE 2)
MAINTENANCE
FOR CODES 10658 AND BELOW
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CLASSIC® 300D & 300G
D1.5 D1.5
I
EVERY 400 HOURS OR 12 MONTHS
E
VERY 200 HOURS OR 6 MONTHS
EVERY 100 HOURS OR 3 MONTHS
FIRST SERVICE-(20 / 50 HOURS)
EVERY DAY OR EVERY 8 HOURS
Perkins #140517000
If necessary use shorter periods.
These preventive maintenance periods apply to average conditions of operation.
Perkins #26560017
TYPE OR QUANTITY
Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.
9.5qrts., 9.0L
(3) Fill slowly! Ensure correct quantity is used.
8.7qrts, 8.2L (including filter)
(2) Consult Engine Operators Manual for additional maintenance schedule information.
(1) Consult Engine Operators Manual for oil recommendations.
Notes:
Alternator drive belt
Alternator drive belt wear
R
Tension of alternator drive belt
Fuel filter canister
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
C
I
R
Coolant level
R
C
R
R
I
R
ENGINE SERVICE
I
EVERY 600 HOURS OR 18 MONTHS
S25557
Contact Perkins
Intake .008", exhaust .008"
Donaldson #P181050, 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)
50/50 Water/Ethylene Glycol
Perkins #080109080
MAINTENANCE
FOR CODES 10911 AND ABOVE
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CLASSIC® 300D & 300G
D1.6 D1.6
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.
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.
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CLASSIC® 300D & 300G
D1.7 D1.7
9
1
3
4
2
8
5
7
11
10
6
MAINTENANCE
1. Case Front Assembly
2. Engine Assembly
3. Radiator Assembly
4. Fuel Tank & Mounting
5. Base & Lift Bale Assembly
6. Welding Generator & Coupling (1 of 2)
7. Welding Generator & Coupling (2 of 2)
8. Solenoid Assembly
9. Roof & Doors
10. Alternator Brush Holder
11. Generator Brush Holder
FIGURE D1.7 - MAJOR COMPONENT LOCATION
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CLASSIC® 300D & 300G
D1.8 D1.8
NOTES
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CLASSIC® 300D & 300G
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