Lincoln Electric 300 D Portable Generator User Manual
Contents
1. 1Sv9 OL Bis qaad AYIM 4 93N 504 OL LOANNOD 1 2 am rts 4 V GSTIVISNI l id IHL amr noa SONUS 5 G3SN SI LI 41 HOLIMS La ze MO 3103 JHL OL Y E AAA S 30290 NVO Se R SHOLO3NNOO x 009 ANINI 335 yy Lu wem HALANOILNALOd S pas 348 bn mal H HNIHOVW NO 8 1 OL WM NO L9HNNOO 1 SLOWSY 4 Y Y X 4 HOLOSNNOO WOH ON ld SAOWY INIHOYN NO El ESR 2 HOLIMS 903 1OHLNOO SLOWSY CAS A9 8 09 C92 asva oL INLISOd 3ALLVO3N ivan WORDS ONCE SINIONS OL N fl 9 Au N M ca 40078 H3IHOJSNVHL M S a338 zuo Gecke beers 9 7 asn4 YVAN GNNOYS tet m 65 Wis HOLON HOJIVHJN3O SONIGNIN ZE Some ONILYVLS d H3MOd HOLIMS 3univsadwaL M cao 5 3unssaud 10 HOLVNH3LTV avs SUNN NO LON S300 E 8 ZC D ie vis 1V1SO3HH t H gt ud zs EIS 9209 HOLIMS D el asna o 5 NOILINOI zy 14808 1 anna2. Inspect Clean R Replace NOTES 1 Consult Engine Operators Manual for oil recommendations 2 Consult Engine Operators Manual for additional maintenance schedule information 3 Fill slowly Ensure correct quantity is used Above operations to be carried out by trained personnel with reference to the workshop manual where necessary These preventive maintenance periods apply to average conditions of operation If necessary use shorter periods CLASSIC 300D LINCOLN 5 4 FOR CODES 10911 AND ABOVE D 4 ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS FIRST SERVICE 20 50 HOURS EVERY 100 HOURS OR 3 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 400 HOURS OR 12 MONTHS EVERY 600 HOURS OR 18 MONTHS ENGINE SERVICE NOTE 2 MAINTENANCE ITEM TYPE OR QUANTITY Coolant level Concentration of antifreeze 50 50 Water Ethylene Glycol Coolant NOTE 3 9 5qrts 9 0L Engine oil level NOTE 1 Engine oil NOTE 1 amp 3 8 7qrts 8 2L including filter Engine oil filter Perkins 14051 7000 ojd Drain water separator amp fuel strainer Fuel filter canister Perkins 26560017 Tension of alternator drive belt Alternator drive belt wear Alternator drive belt Perkins 080109080 Air filter earlier check may be req d Air filter element Donaldson P 181050
3. FUMES AND GASES can be dangerous 5 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 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 6 5 LINCOLN 5 Shielding gases used for arc welding can displace air cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 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 practice
4. e SAUTER Do not operate with panel open guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes com os paineis abertos ou guardas removidas NKWROPAN FERWALEEE CH B EHTEEUSXVCREU SER HGTBI BUSUR ERE e maol wel Me z AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO it is BIR Chinese oe lue chal TAU Gall bacs ga d arin Mall oe us ibas Ao Qi uu 0 juil ale AREY cuts UI ai tha Jada y e Aale Cut Al dl LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SBM BHO X HD OHBRBEE lt K HA EL TRHOKRERE HAM Rr BUR B 09 EL OR o 0 SALAD HAY zeit TAS PSP HHCH alal dl illai Jud al ply Gail ag ls Ca L LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland
5. 26 9 11OA 0 2 LOA SEL 9 noH pc NE P GION310S 3NION3 ONd HOLIMS VE MO19 8009 SLINN ar 8209 9v H d OL NO SHVaddV 189 ves 019 15 4 weg LINDO ONIY dS H 019 8 a 180 rit SONI AIS MOIS g 85 209 E 1n HOLVNH3LTV ILIHM M NMOHS N 4 H divi nu N amen N3349 9 06829657621 in nd 8 Y3YYY 3uniiv4 de M AVHO 3 f i UGG uer TE LZevsga Leeda 3HLOGN 3802 40102 19 f OL veia yoo HV3H WOHL GAMAIA SV NMOHS Gane AS TONLNOO MO 38 8990 58802 INVHOVIG ONIHIM 1006 2155 70 CLASSIC 3000 LINCOLN E N Jequunu epoo 1ueuudinbe y e 29S o1 M s ou J sjeued y JO euo y LL pejsed si epoo sejnomed Jenueui siy Aq 10 eq jou AjUO JO SI SIUL 310 DIAGRAMS F 2 898111 SNOLLO3NNOO JSH 9NDIVIN wl LON LSNW 3NIHOVIW y 062 2
6. GH Oa CRM ER e Xe a Sal Weal AMI Qi el all oa Y O el ai ANI d o lala AA ll dan Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos OA VE amp 0 0 BEER THEW EKA e 2 07 Vi S BET freA eis Jo al gh a88 Ad AIX ole Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo HRUSHICRBRELTE EU OMAR HRSRSORENE ez 119 Sal daig 4 Lilly lan alg ar Daun READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE E
7. 62 gun tube for Pipe Welding 1909 1 Recommended modification for K355 X or K345 x guns with 90 gun tubes Compatible with K126 1 2 K264 8 and K355 10 SPOOL GUN WELDER Magnum Spool Gun K487 25 Hand held semiauto matic wire feeder requires SG Control Module 25 ft length 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 CLASSIC 300D LINCOLN 5 1 D 1 MAINTENANCE A WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the machine In some cases it may be neces sary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is com plete Always use the greatest care when work ing 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 e Insulate yourself from work and ground Always wear dry insulating gloves e ENGINE EXHAUST can kill Use in open we
8. IM631 B CLASSIC 300 D dE 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 6 OPERATOR S MANUAL LINCOLN Copyright 2006 Lincoln Global e World s Leader in Welding and Cutting Products e 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 l A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines 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 OPERAT
9. electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 L ARC RAYS 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 287 standards 4 b Use suitable clothing made from durable flame resistant 5 b material to protect your skin and that of your helpers from the arc rays 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
10. M nv JYLNIN OL uva SV NMOHS 1OHLNO9 8 379v143934 LTOA SLL MOTISA A SLIHM M NMOHS8 N ama n N3349 9 AVHO HOODVIS amp S 3009 40109 Qv31 42913 S IO8WAS TWOIN LOATS S3ON3S HO LIMS sunss3ud 10 ONILYVLS HAON3S HOLIMS sunivssdWaL 3envo tae o HALVM avs dnd VIS EE HOLIMS NOILINOI GION310S dnd AT 14916 zr 0V08 Od NOIL9310Hd 209 3NION3 H3 dI ad 459 rt Bu G 19 vog SOT MOIE ANY 1260 58809 ONIMIM 1006 9ISSV IO CLASSIC 3000 LINCOLN 8 F 3 DIAGRAMS F 3 K2464 1 REMOTE CONTROL WIRING CONNECTION DIAGRAM 96 80 o o o Coo ae 4 G B c wm qno RESISTORS N CC STICK CONTROL BLUE 4 ORANGE CABLE CONNECTION TABLE PIN LEAD COLOR F ORANGE REMOTE CONTROL BOX CONNECT TO CASE TEER A 526097 CLASSIC 3000 LINCOLN 5 DIAGRAMS F 4 F 4 992015 29
11. Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
12. Provides constant voltage CV output with improved arc stability for Innershield welding Excellent for MIG welding Recommended wire feeders are the LN 7 LN 23P and LN 25 Factory installed on the K1643 2 LN 25 Wire Feeder K449 Portable CC CV unit for flux cored and MIG welding Includes Gas Solenoid amp 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 Gun for LN 25 K497 3 With 15 ft 4 5m cable For 025 0 6m wire Magnum Gun Connector KiT Connects Magnum 200 MIG gun to LN 25 Wire Feeder LN 23P Wire Feeder K316L 1 Portable CV unit for Innershield pipe welding Control cable operates con tactor inside Wire Feed Module for cold electrode Requires LN 23P Adapter Kit 50 1 and Gun and Cable Assembly LN 23P Adapter Kit K350 1 Required to adapt LN 23P to any Lincoln power source Makes 14 pin con nection at power source Magnum 250 Innershield Gun for LN 23P K355 10 For lighter weight and easier handling Rated 250 amps 6096 duty cycle For 068 through 5 64 1 7 through 2 0 mm Innershield wire and includes reduced speed switch For pipewelding an M11476 62 gun tube is recommended
13. WHAT TO DO Commutator should be turned or cleaned Replace brushes Check field current with ammeter to discover varying current This applies to both the main generator and exciter Tighten all connections Use Lincoln brushes Inspect and clean the rheostat Be sure that all brushes bear on the commutator and have proper spring tension Check exciter output voltage with voltmeter or lamp Check for open circuits in rheostat field leads and field coils Check rectifier bridge Flash fields 1 Check flashing diode at 5 o clock brushholder in generator Check circuit with ringer or voltmeter 1 Stop the engine welder and remove the cover from the exciter 2 Turn the Fine Current Adjustment to 100 on the dial 3 Using a 12 volt automotive battery connect it s negative terminal to the negative brushholder The negative brushholder is the one nearest to the rotor lamination See the wiring diagram With the engine NOT running touch the positive battery terminal to the positive brushholder Remove the battery from the circuit 4 Replace the exciter cover Start the welder and the generator voltage should build up Welding arc is loud and spatters excessively Welding current too great or too small compared to indication on the dial Arc continuously pops out Current setting may be too high Polarity may be wrong Exciter output low causing low output
14. exerum RT B 1 Starting The Perkins 104 22 Engine B 1 Stopping the engine nennen nennen snnt B 1 Welder C B 2 DUV 2 Control of Welding Current B 2 idler e TEMERE 2 Auxillary B 3 foL LII Section Optional Features Field Installed C 1 Maintenance e Section D Safety Precautions D 1 General D 1 Cooling SYStOM EE D 1 EE D 1 Comimutatorand 5 ee reet er et Rc aeg ne ed D 1 fs EE D 2 Nameplate D 2 Purging Air from Fuel System D 2 Engine Service Chart ceci e T v Ee IR n e D 3 D 4 Receptacle Testing and Reseting Procedure Optional D 5 Troubleshooting ss Section E 22222200 near ee nn di 1 Welder Troubleshooting 2 Electronic Idler Troubleshooting E 3 E 4 Engine Troubleshooting Guide E 5 E 6 rim Section F Wiring Diagram Classic 300 D F 1 F 2 Connection Diagram senten F 3 DIMENSION ul LE 4 Parts I P337 Series B INS
15. venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 ape PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER SS TRANSF
16. 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 tech niques at settings at the lower end of the open circuit voltage range CAUTION DO NOT attempt to set the Current Range Selector between the five points designated on the nameplate These switches have a spring loaded cam which almost eliminates the possibility of setting this switch between the designated points Idler Operation Start the engine with the Idler switch in the High position Allow it to run at high idle speed for several minutes to warm the engine See Specifications for operating speeds The idler is controlled by the Idler toggle switch on the welder control panel The switch has two posi tions 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 v 1 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
17. MOVING PARTS can injure Do not put your hands near the engine cooling Do not operate with doors open or blower fan If a problem cannot be corrected by guards off following the instructions take the machine to Ke SE before Rear the nearest Lincoln Field Service Shop Pep away MOm parts See additional warning information at the front of this operator s manual A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CLASSIC 300D LINCOLN 5 TROUBLESHOOTING E 2 WELDER TROUBLESHOOTING Machine fails to hold the output heat consistently Welder starts but fails to generate current FLASHING THE FIELDS TROUBLE CAUSES Rough or dirty commutator Brushes may be worn down to limit Field circuit may have variable resistance connection or intermittent open circuit due to loose connection or broken wire Electrode lead or work lead connection may be poor Wrong grade of brushes may have been installed on generator Field rheostat may be making poor contact and overheating Generator or exciter brushes may be loose or missing Exciter may not be operating Field circuit of generator or exciter may be open Exciter may have lost excitation Series field and armature circuit may be open circuited
18. compared to dial indication Operating speed too low or too high Current Range Selector switch may be set at an intermediate position CLASSIC 300D LINCOLN 5 Check setting and current output with ammeter Check polarity Try reversing polarity or try an electrode of the opposite polarity Check exciter field circuit Adjust speed with screw stops at throttle linkage High idle 1800 RPM Low idle 1375 RPM Set the switch at the center of the current range desired E 3 TROUBLESHOOTING E 3 ELECTRONIC IDLER TROUBLESHOOTING GUIDE With Idler Control Switch in the Auto Position Engine Will Not Return to Low Idle in Approximately 15 Seconds After Welding and Auxiliary Loads are Removed Set Idler Control Switch to the Auto Position Check for Continuity through Idler Control Switch Open Closed Measure DC Voltage on Replace Idler Idler Solenoid Coil Control Switch qo Y Y 12 VDC 0 VDC Check Continuity of Check for Jamming Reed Switch in Weld Circuit of the Idler Solenoid Mechanism or a broken Return Spring Open Closed 1 Check Wiring in Replace Reed Idler Solenoid Switch Circuit 2 Replace Idler P C Board CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CLASSIC 300D LINCOLN 5 4 TR
19. con necting 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 gener ator and voids the warranty 2 Set the welder controls for an output cur rent 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 INSTALLATION A 5 Battery Charging A WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes 3 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 Using a booster connect the positive lead to the battery first then connect the negative lead to the ground lead on the base To prevent ELECTRICAL DAMAGE when a Installing a new battery b Using a booster Use correct polar
20. equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework 3 Proper placement of the equipment on the trailer to ensure stability side to side and front to back when being moved and when standing by itself while being operated or serviced 4 Typical conditions of use i e travel speed rough ness of surface on which the trailer will be operated environmental conditions likely maintenance 5 Conformance with federal state and local laws 1 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 compo nents to fail Only transport this equipment on serviceable vehi cles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for compo nents such as suspension axles and tires Mount equipment base to metal bed or frame of vehicle Follow vehicle manufacturer s instruction 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
21. from incorrect connec tion 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 Whenever routine maintenance is performed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those which are longer clear Refer to the parts list for the replace ment item number Purging Air from Fuel System Perkins 104 22 Engine A WARNING Keep fuel clear of open flames or arcs allow engine to cool before working on the fuel system Wipe up any spilled fuel and do not start engine until fumes clear If the engine is running rough and you suspect air has been trapped in the fuel system e g the engine was allowed to run out of fuel perform the following steps using qualified personnel 1 Loosen by two or three turns the vent screw Figure D 1 on the fuel inlet connection FIGURE D 1 2 For Engines Equipped with a mechanical fuel pump 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 maxi lift it will not be possib
22. load is not re started before the end of the time delay the idler sole noid deactivates and reduces the engine to low idle speed CLASSIC 300D LINCOLN B 3 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 com bined 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 CLASSIC 300D LINCOLN 1 ACCESSORIES 1 OPTIONAL FEATURES Field Installed GENERAL OPTIONS A 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 re
23. not turn on Engine stops during operation and the Engine Protection light does turn on White or Blue Smoke Dark Grey Smoke Faulty Charging Starter Motor does not run Engine Protection Light not coming on after the ignition switch has been in the ON position for more than 60 seconds with the engine not started TROUBLESHOOTING ENGINE TROUBLESHOOTING TROUBLE CAUSES WHAT DO Faulty Ignition switch and or Injector pump solenoid Insufficient charging or complete discharge of the battery Lack of fuel Air mixed in the fuel system Clogged fuel filter Irregular and faulty fuel supply Injector pump trouble Glow plug not heated Improper viscosity of the lubricating oil Clogged air cleaner No compression Engine protection light is ON Air mixed in the fuel system Uneven fuel injection Faulty fuel injector pump Clogged fuel filter Defective governor Engine itself defective Lack of fuel in the fuel tank Clogged fuel filter Air mixed in the fuel system Faulty function of the engine a Overheat of the Engine Lack of Coolant Loose or slipping fan belt Damaged fan belt Clogged radiator Clogged radiator fin Dust or scale clogged in the cooling water passage Faulty function of the thermostat Lack of lubricating oil Overloading Faulty Idler Engine Protection P C Board b Loss of Engine Oil Pressure Lack of engine oil Fault in the Oil Pressure Switch Oil leakage from the lubricating system Clogged oil fi
24. polarity connect the electrode cable to the terminal marked For Negative polarity con nect the electrode cable to the stud These con nections 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 Cables Sizes for Combined Length of Electrode Plus Work Cable Duty Cycle Up to 200ft 61m 200 to 250ft 61 to 76m 100 60 PRE OPERATION SERVICE CAUTION READ the engine operating and maintenance instruc tions supplied with this machine Stop engine while fueling Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling DIESEL FUEL e Wipe up spilled fuel and allow can cause fire fumes to clear before starting engine e Do not overfill tank fuel expansion may cause over flow DIESEL FUEL ONLY f 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 manufacturers 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 the Engine Operator s manual Make sure the fuel valves on the se
25. safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A 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 TABLE CONTENTS Page Installation uhren eed iesus Section A Technical 1 General leen 2 Design o 2 5 t etr EES A 3 Safety mte A 3 cn nnt e ne eet A 3 Location Ventilation ss A 3 Machine oder A 3 ae taba 3 4 Polarity Control and Cable Sizes A 4 2 4 canes 4 4 COOlING Syste ET 4 Engine Break in Battery 5 EIERE Section
26. the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY PRECAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tens
27. 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 con stantly or in excessively dirty locations it may be nec essary 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 Over greasing 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 rotat ing 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 clot
28. 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
29. 02 m 31OH ONILNNOW ans 95 amp EE scs Se 99 Lr C8 Cl 00 59 0006 DISSVIO 8 99 0 5 00 vc ONILNNOW ans 95 amp 9 O N ALON ONY 1 NOISNANIQ Q3QQv OL ONY 6 8 9 99 01S TANVd dVONIVS HO MO813 LSNVHXA 30 dO OL NOISN3WIG Sd IOH ONILNNOW H3 TIVS L 962 Tana ON JNION3 H3 1VM ANY 110 HLIM ALIAVSHO 40 SALON CLASSIC 3000 LINCOLN E Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG it ies BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes 0 los electrodos bajo carga con la piel moja a Aislese del trabajo y de la tierra Ne laissez la peau des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra o REPOR LiH ELE LATE NTUSHILT FSU e E GUB MIU
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31. ING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase of Safety in Welding amp Cutting ANSI Standard 249 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 X 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS may be dangerous 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 vaporiz ing 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 2 Electric current flowing through any conductor causes localiz
32. MPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entliiftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRcocuc 9 fsUPBHEILTASESUCFEU KEE za 24758 MAS sis PARAH 587E Assis power off before servicing Desconectar el cable de ali mentaci n de poder la maquina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico toque as partes el tricas nuas e X7TTLA UAVCRUD PRE gt
33. Nelson 70206N Check and adjust idle speed Tighten cylinder head Valve clearances Intake 008 exhaust 008 Electrical systems All nuts and bolts for tightness Injector performance Contact Perkins Leaks or engine damage Battery Inspect Notes Clean R Replace 1 Consult Engine Operators Manual for oil recommendations 2 Consult Engine Operators Manual for additional maintenance schedule information 3 Fill slowly Ensure correct quantity is used Above operations to be carried out by trained personnel with reference to the workshop manual where necessary These preventive maintenance periods apply to average conditions of operation If necessary use shorter periods CLASSIC 300D LINCOLN D 5 MAINTENANCE GFCI RECEPTACLE TESTING AND RESET TING PROCEDURE 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 neces
34. ONES LON 3HV ANY A MO S3NIHOVI 1 2ISSV 19 NO SAYIT OV 18 JNIHO VW 3H L NO St HO LO3NNOO OL UN TOHINOO SNINN 38 LON LSNW 3NIHOVIA dV 052 SONN IHL WOY L93NNOO 7 57 HOLO3NNOO WOY 3NIHOVI IHL NO Sfr ld 193NNOOSIG 440 3NIHOVW IHL HLIM G3TIV LSNI SI 21000 334 33M ON 31 QV31AAV3H 2 O3193NNOOND LI YALAWOILNALOd N31SV IHL NO SI INO 40 01 ON Id Q3193NNOONn DIN OL1O3NNOO TOHLNO9 SLOWSY 40 8604610 340 3NIHOVI 1 GATIVLSNI SI SINGOW 4283 V dl y y 87 HOLO3NNOO OL TOH INOO 3 L0W3 NO 1 1814 1 WOY 3NIHOVIN NO SAOWSY LON 3NIHOVIN HLIM y Tanya W CH TN VNINY3L 1Nd1NO 1V201 NI AO AALLVOAN SENS NMOHS TOHLNOO LOWY SHOLSIS34 UM 3103 lt HO 1 201 HOLIMS oan STVNINYAL 1Nd1NO 1 54 M H JINAON
35. ORMATEUR ET A a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de et des projections quand soude ou quand on regarde l arc i Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN 5 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 V for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to
36. OUBLESHOOTING E 4 ELECTRONIC IDLER TROUBLESHOOTING GUIDE With Idler Control Switch in the AUTO Position Engine Will Not Pick Up Speed When The Arc is Struck The Auxiliary Power Load is Turned ON Reed Switch in Weld Circuit Power Load Too Small Defective Will Not Close Try Load Above 150 Watts To Check Short the Red Lead Engine Does Not Pick Up Speed on P C Board to Welder Frame 1 Check Continuity of Idler Solenoid Coil 8 5 9 0 ohms and Replace as Required 2 Check Jamming of the Idler Solenoid Mechanism Engine Picks Up Speed Engine Does Not Pick Up Speed 3 Check for Continuity of Current 1 Check for Break in Transformer Toroid Replace as Red Lead and Repair 1 Check Continuity of Idler Required Solenoid Coil 8 5 9 0 2 Replace Reed Switch ohms and Replace as 4 Check Idler Circuit Wiring and Repair in Weld Circuit Required as Required 2 Check for Jamming of 5 Replace Idler P C Board the Idler Solenoid Mechanism 3 Check Idler Circuit Wiring and Repair as Required 4 Replace Idler P C Board A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CLASSIC 300D LINCOLN 5 Engine does not start Irregular running of the engine Engine stops during operation and the Engine Protection light does
37. TALLATION A 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 12VDC batteries Fuel 15 gal 104 22 Diesel 4 Cycle Low Idle 1350 2 2 L 2 amp Starter 571 32 7 Full Load 1725 Water Cooled 1800 RPM Bore x Stroke Oil 8 7 Qts 8 2L 3 875 x 5 00 98 4 mm x 127 0mm Coolant 7 9 gal 7 5L RATED OUTPUT WELDER WELDING OUTPUT OPEN CIRCUIT OUTPUT RANGE AUXILIARY POWER Current Voltage Duty Cycle VOLTAGE AMPS 40 350A 115 230 VAC 250A 30V 100 98 Max 220A MAX 3000 Watts 60 Hz 1800 RPM 160 240A 26 Amps 115V 300A 32V 60 120 240A 13 Amps 230V 120 190A 80 130A Min 90A PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 1354 Ibs 45 50 24 00 65 00 616 1156 mm 610 1651 1354 1 5 616 Based 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 1 High Idle 1800 RPM No Load 96 6 Volts 0 45 gal hr 1 70 Itrs hr 50 Amps 22 Volts 0 51 gal hr 1 93 Itrs hr 150 Amps 26 Volts 0 70 gal hr 2 65 Itrs hr 200 Amps 28 Volts 0 85 gal hr 3 21 Itrs hr 100 Am
38. ceptacle GFCI Receptacle Kit K1690 1 Includes one UL approved 115V ground fault circuit interrupter duplex type receptacle with cover and installation instruc tions Replaces the factory installed 115V duplex receptacle Each receptacle of the GFCI duplex is rated at 20 amps Maximum total current from the duplex is limited to 20 amps See the MAINTE NANCE 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 K953 1 TRAILER Two wheeled trailer with optional fender and light package For highway use consult applicable feder al state and local laws regarding possible additional require ments There is a choice of 2 hitches a fender amp a light pack age K953 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 1 Fender amp 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 head shield work clamp and electrode holder Cable is rated at 500 amps 60 duty cycle 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 remo
39. diment 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 LINCOLN 5 5 ENGINE BREAK IN Lincoln Electric selects high quality heavy duty indus trial 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 sub stance 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 condi tions for extended periods of time are especially sus ceptible to the conditions described above To accomplish successful engine break in most diesel powered equipment needs only to be run at a reason ably heavy load within the rating of the welder for some period of time during the engine s early life However if the welder is subjected to extensive light loading occasional moderate to heavy loading of the engine may sometimes be necessary Caution must be observed in correctly loading a diesel generator unit 1 Connect the welder output studs to a suit able resistive load bank Note that any attempt to short the output studs by
40. ed Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety minimize exposure to EMF fields from the welding circuit 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 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 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 sho
41. h or paper for this purpose CLASSIC 300D LINCOLN 5 D 2 MAINTENANCE D 2 Replace brushes when they wear within 1 4 of the pigtail A complete set of replacement brushes should be kept on hand Lincoln brushes have a curved face to fit the commutator Have an experienced mainte nance 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 pres sure 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 A CAUTION Before doing electrical work on the idler printed circuit board disconnect the battery When installing a new battery or using a jumper bat tery 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
42. he 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 tempera ture gauge a battery charging ammeter an oil pres sure gauge two three prong grounding type recepta cles and four circuit breakers for auxiliary power All Copper Windings For long life and dependable operation Engine Idler The Classic 300 D is equipped with an electronic automatic engine idler It automatically increases and decreases engine speed when start ing and stopping welding or using auxiliary power A built in time delay permits changing elec trodes before the engine slows to its low idle speed The Idler control switch on the panel locks the idler in high idle position when desired 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 star
43. ion quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr
44. ith the doors closed Leaving the doors open changes the designed air flow and can cause overheating Starting the Classic 300 D Perkins 104 22 Diesel Engine 1 Turn the IDLER switch to HIGH 2 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 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 con trols 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 cold starting aides Note Extreme cold weather stari
45. ity 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 regulat ed when the battery is low after starting the engine to a trickle current when the battery is fully charged When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed This system is NEGATIVE GROUND CLASSIC 300D LINCOLN 5 B 1 OPERATION B 1 ENGINE OPERATION WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK 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 e Use in open well ventilated areas or 3 CA vent exhaust outside MOVING PARTS can injure Do not operate with doors open guards off Stop engine before servicing Keep away from moving parts See additional warning information at the front of this operator s manual Operate the welder w
46. le to operate the prim ing 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 prob lems persist CLASSIC 300D LINCOLN 5 D 3 MAINTENANCE D 3 FOR CODES 10658 AND BELOW ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS FIRST SERVICE 20 50 HOURS EVERY 100 HOURS OR 3 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 400 HOURS OR 12 MONTHS EVERY 600 HOURS OR 18 MONTHS ENGINE SERVICE NOTE 2 Coolant level Concentration of antifreeze 50 50 Water Ethylene Glycol Coolant NOTE 3 9 5qrts 9 0L Engine oil level NOTE 1 Engine oil NOTE 1 amp 3 8 7qrts 8 2L including filter Engine oil filter Perkins 14051 7000 Drain water separator amp fuel strainer Fuel filter canister Perkins 1300366120 Tension of alternator drive belt Alternator drive belt wear Alternator drive belt Perkins 080109080 Air filter earlier check may be req d Air filter element Donaldson P181050 or Nelson 70206N Check and adjust idle speed Tighten cylinder head Valve clearances Intake 008 exhaust 008 Electrical systems All nuts and bolts for tightness Injector performance Contact Perkins Leaks or engine damage Battery BCI Group 24
47. ll ventilated areas or vent exhaust outside 3 MOVING PARTS can injure Do not operate with doors open or guards off A Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual General Instructions 1 Blow out the welder and controls with an air hose at least once every two months In particularly dirty loca tions this cleaning may be necessary once a week Use low pressure air to avoid driving dirt into the insu lation 2 Current Range Selector contacts should not be greased To keep the contacts clean rotate the cur rent control through its entire range frequently Good practice is to turn the handle from maximum to mini mum 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 manufacturer s manual Cooling System The Classic 300 D is equipped with a pressure radia tor Keep the radiator cap tight to prevent loss of coolant Clean and flush the cooling system periodi cally to prevent clogging the passage and overheating the engine When antifreeze is needed always use the permanent
48. lter Oil too light Faulty Idler Engine Protection P C Board Excess engine oil Too low viscosity of the engine oil Faulty injection timing Unsuitable fuel Excess injection Faulty function of the engine Overloading Clogged air cleaner Loose fan belt Faulty wiring Faulty battery Worn out alternator brush Loose or damaged wiring Drained voltage from battery Damaged starter motor including solenoid Broken Light Bulb Faulty light wiring to GND or P C Board Faulty Idler Engine Protection P C Board Correct the connection and contact Charge Supply fuel Bleed air To be done by qualified personnel only Replace Repair in an authorized service shop Breakage of the glow plug replace Inspect and replace Clean or replace Repair in a service shop 60 second start period elapsed Turn ignition switch OFF amp ON See 4 Below Bleed air To be done by qualified personnel only Repair in an authorized service shop Replace Check and correct Repair in an authorized service shop Supply fuel and bleed air To be done by qualified personnel only Replace Bleed air To be done by qualified personnel only Repair in a service shop Supply coolant Inspect leakage and correct Remove oil dust etc and tighten Replace Flush the radiator Clean Flush the system Inspect or replace thermostat Add oil Decrease the load Replace Supply oil up to the specified level Replace the switch Inspec
49. ng may require longer glow plug operation A WARNING Under NO conditions should ether or other starting fluids be used Stopping the Engine 1 Turn the IGNITION switch to OFF At the end of each day s welding check the crankcase oil level drain accumulated dirt and water from the sediment bowl under the fuel tank and refill the fuel tank to minimize moisture condensation in the tank Also running out of fuel tends to draw dirt into the fuel system When hauling the welder between job sites close the fuel feed valve beneath the fuel tank If the fuel supply is cut off or runs out while the fuel pump is operating air may be entrapped in the fuel distribution system If this happens bleeding of the fuel system may be necessary Use qualified person nel to do this per the instructions in the MAINTE NANCE section of this manual CLASSIC 300D LINCOLN B 2 OPERATION B 2 WELDER OPERATION A WARNING e ELECTRIC SHOCK Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground FUMES amp GASES can be dangerous Keep your head out of the fumes e Use ventilation or exhaust to remove fumes from breathing zone Sa Vj WELDING SPARKS can cause fire or gt explosion Keep flammable material away ARC RAYS can burn e Wear eye ear and body protection K Duty Cycle The NEMA o
50. ommended 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 gen eral 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 insulat ed 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 A WARNING 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 trail er or gas cylinder Do not lift machine if lift bale is damaged EQUIPMENT can Do not operate machine while cause injury suspended from lift bale FALLING CLASSIC 300D LINCOLN 5 4 INSTALLATION A 4 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 dam age the welding equipment Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln
51. or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 5 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow
52. ps 24 Volts 0 58 gal hr 2 19 Itrs hr 300 Amps 32 Volts 1 31 gal hr 4 95 Itrs hr 350 Amps 34 Volts 1 68 gal hr 6 35 Itrs hr CLASSIC 300D LINCOLN 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 250A 30V 300A 32V 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 t
53. rs 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 unrestrict ed flow of clean cool air Also locate the welder so that engine exhaust fumes are properly vented to an outside area CAUTION DO NOT MOUNT OVER COMBUSTIBLE SUR FACES Where there is a combustible surface directly under stationary or fixed electrical equipment the surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not more than 5 90 150mm beyond the equipment on all side s Machine Grounding According to the United States National Electrical Code the frame of this portable generator is not required to be grounded and is permitted to serve as the grounding means for cord connected equipment plugged into its receptacle Some state local or other codes or unusual operating circumstances may require the machine frame to be grounded It is rec
54. s MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Mar 95 SAFETY WELDING SPARKS gt 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 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 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 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 Vent hollow castings
55. sary Push the Reset button located on the GFCI recep tacle 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 recepta cle 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 is not working prop erly or has been incorrectly installed miswired If your is not working properly contact a qualified certified electrician who can assess the situation rewire the GFCI if necessary or replace the device CLASSIC 300D LINCOLN aa TROUBLESHOOTING E TROUBLESHOOTING ELECTRIC SHOCK can kill WARNING A 2 Do not touch electrically live parts or electrode with skin or wet clothing Have qualified personnel do the troubleshooting e Insulate yourself from work work Turn the engine off before working inside ground the machine In some cases it be neces Always wear dry insulating gloves sary to remove safety guards to perform required maintenance Remove guards only 23 RE Se when necessary and replace them when the vent exhaust outside maintenance requiring their removal is com O 40 plete Always use the greatest care when work ing near moving parts 4
56. t and retighten Replace with new one Drain and refill with proper grade Replace Inspect and correct the level Inspect and replace the oil with proper grade Repair in a service shop Inspect and replace with correct grade Inspect and adjust in a service shop Repair in a service shop Reduce the load Clean Correct the tension Inspect and correct Repair Replace Inspect and tighten Charge the battery Repair in a service shop Replace the bulb Correct Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CLASSIC 300D LINCOLN 5 DIAGRAMS F 1 F 1 Jequunu epoo juewudinbe y 104 eui 0 e qiGej si j sjeued einsoj oue y Jo euo uo episul pejsed si epoo sejnomed e 104 siy Aq eq jou AjUO JO SI 4141 310 9100 6 1 4 70006 2155 12 JHL NI 123 60 31 ANY JHL 41 110535 TIM 3INIHOVW TOHLNOO 1 OL 39 VINVO 3NIHOVMW SIHL NO Q3193NNOO SNOILO3NNOO 353 1 9NIMVIN NHHM ASI
57. te control rheostat and 100 ft 30 5 m cable for adjust ing 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 5 compact case is designed for easy carrying complete with a handle High frequen cy 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 amp torch equipped with valve for gas flow control 25Ft length Magnum Parts Kit For PTA 26V TIG Torch KP509 Remote Control Cable K936 4 Control cable for connecting the K930 2 TIG Module to a ZR 10 not equipped with a K892 1 Remote Kit 9 Socket to a grounded 115 V plug and a 6 pin MS connector Contains circuits 31 32 and ground Arc Start Switch K814 Contactor Kit K938 1 Control Cable Extension K937 45 Cable is 45Ft in length Water Valve Kit K844 1 For use with a water cooled TIG torch Installs inside TIG Module CLASSIC 300D LINCOLN 5 C 2 ACCESSORIES 2 Wire Feed Module K623 1
58. ter is stan dard 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 oper ation 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 LINCOLN 5 3 INSTALLATION A 3 PRE OPERATION INSTALLATION A WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK kill Do not touch electrically live parts or electrode with skin or wet clothing e 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 3 MOVING PARTS can injure not operate with doors open or guards off MT 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 arreste
59. uld also be on your right side X Connect the work cable to the workpiece as close as possible to the area being welded 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 Do not work next to welding power source Mar 95 LINCOLN 5 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 Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode
60. utput rating of the Classic 300 D is 300 amperes at 32 arc volts on a 60 duty cycle consult Specifications in this manual for alternate ratings 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 CAUTION DO NOT TURN THE CURRENT RANGE SELEC TOR WHILE WELDING because the current may arc between the contacts and damage the switch The Current Range Selector provides five overlap ping 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 pre ferred 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 When a forceful digging arc is required usually for vertical and overhead welding use a higher Current Range Selector setting and lower open circuit volt age For example to obtain 175 amps and a forceful arc set the
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