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Lincoln Electric 11572 Welder User Manual

1. 01 201 SET AIMS SIAD HA FYR ETEA Jali il gl easly 8 al gly olg ql AI agi LINCOLN E e World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
2. L 315V1d303u 209 HOLIMS 0 08 if 19 3DV1d323H GION11OS 0 C LIOA SLL vol 0 955 N3NIDN3 Dv 2009 NO I OL AS3HV3N dS 019 MOTIAA A ALIHM M NAOdd N N3385 5 Ups 9 31 V WELT 8 9 gue dem UNS IE dnoH 44 zee ES 201 TI GION31OS VNS3LIV SDNld dS 300 AVd5 QdH d HDV14 4 3Q02 40102 Qv11 a00 NV 3ddO OVd JYLNIN dAVu3 OL WHLNAN 11130 2 d 3NIDN3 UTTGI 3NIDN3 OL GALDINNOD SOIT dvd IA SV NMOHS SLN3NOdWOO HHNVd TOHLNOD 17911 OL9LL SIAOD IWVH5VIG ONIHIM SNDIH3d 006 21557710 CLASSIC 300D PERKINS LINCOLN 8 DIAGRAMS F 3 F 3 992015 6908 gt p A o Ud 3 10H ONILNNOW aims 99 1 A ON TdVd osy 99 Lv C8 Cl SNDIH3d 008 2155719 8 992015 1OH ONILNNON apis 95 dVONIVH HO I
3. EN gi STVNIWHL INdINO 504 DIN 9 SOd OL LIINNOD 199 TOdINO L wzM SYOLDINNOD ANIHDVW NO OL W 4M NO Sdu 123NNOD Sf HOLDINNOD WOY 014 3AOW H NIHOVW NO IVNOILdO 0334 SHIM WM HLIM 10 8 29 23 BNvd 1OHLNOD WO AIMI AAILISOd JALLVO3N U313WOIlLN3LOd 1OdINO 31OW38 Pr1d d 1 WOILN 1Od 3SV2 OL LD3NNOD 1OINO 1OWHH sdOLSISH 5 IVNOLLdO TOHLINOO 1OW H S t26M S19NV9 3NIDN3 3NIBN3OI 35VOL YVAN A825 ANNOYD ANNOHD T SV NMOHS NOLLISOd HSTJd Howims 4 veg WOIVH3N35 5NITISM 1 S1IO 1Odd 1NI aSN4 MIS QNOdD H2LIMS 3135 V QN5 4 AN9 U3WHSOJSNVH L LNIHHND ddN S HO1IWS 55 10 dolvNaary 15 NOLLD31Oud 6 3NIDN3 OL d 3onv5 MSS dd IO S qii 5319357 U3ON3S H2LIMS HTLVdddWL qui SONIGNIM 1NnHS 1OV1d D3d XnV 11v QNV HOLIMS 1OdINOO LOWY IVISO Hd Z09 M2 m 34 5 oo avo aziz MHHWWV Q9 5 nv 5 n VH3dW3l WLS 0 cv 009 lv
4. Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information SAFETY i PR CAUTIONS 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 tension 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 de
5. 983 HOLIMS NOLLINSI 2012 vos d zg 66 f 1H SETET YNOH u 3N dele QION 10S d WHOHSNVHL 8 HO MOV18 8 300v 3009 40109 av31 Qo0r ll V8 308099V SHLNAN ANV41 OL ddNOd TVHLNAN IN344N9 OL S QHVO 9 d 3NIBN3 H3 TI ANION3 OL GALOANNOO SQV31 uv3d Odd IA SV NWOHS SIN3NOdWO09 TANVd tv8 T Mii va Y eg ca 19 O d NOLLOALOUd 3NION H 1QI QeleT 62911 2911 S3309 INVH9VIG ONIHIM SNIyH d 006 OISSV 19 CLASSIC 300D PERKINS LINCOLN E DIAGRAMS F 2 F 2 jequinu 9D09 juawudinbo 3y juaurosedoJ e 10 uswyedag 99IAJ9S Y 0 SI 3y jj SI9UBd a1nsojoua 3y jo auo uo eu 9DISUI pejsed si epoo 1ejnoned 10 2112905 jenueui siy Aq D9 9A09 10 9je1n22e eq jou Aew yj juo 10 SI WeIHeIp SIUL 310N 80ScCIN SNOI1O NNOO 5 S9NDIVIN N3HM ONINNNE 38 LON LSNW 3NIHOVIN 18W SSV LVLSONHIHL dWV OSZ dd1OH 5 DAN OL D3NNO QV31AAV3H Cft 609 JINGOW a334 Sd wJ TWNIWYAL LNdLNO oAO3ALVO3N _ AYTI
6. 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 PERKINS LINCOLN 8 E 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Engine stops during operation andI1 Overheat of the Engine the Engine Protection light does turn on Lack of Coolant Supply coolant Inspect leakage and correct Loose or slipping fan belt Remove oil dust etc and tighten Damaged fan belt Replace Clogged radiator Flush the radia tor Clogged radiator fin Clean Dust or scale clogged in the cooling water passage Flush the system Faulty function of the thermostat Inspect or replace thermostat Lack of lubricating oil Add oil Overloading Decrease the load Faulty Idler Engine Protection Printed Circuit Board Replace Loss of Engine Oil Pressure Lack of engine oil Supply oil up to the specified level Fault in the Oil Pressure Switch Replace the switch Oil leakage from the lubricating System Inspect and retighten Clogged oil filter Replace with new one Oil too light Drain and refill with proper grade Faulty Idler Engine Protection P C Board Replace CAUTION If for any reason you do not underst
7. 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 elec trodes when trying to operate with long arc techniques at settings at the lower end of the open circuit voltage range A 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 CLASSIC 300D PERKINS LINCOLN P B 3 OPERATION B 3 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 deactivates and the engine goes to high idle speed The speed is controlled by the governor 2 In the Auto KT position the idler oper ates as follows a When welding or drawing power for lights or tools approximately 100 watts minimum from the receptacles the idler solenoid deactivates 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 ti
8. 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 replace ment item number PURGING AIR FROM FUEL SYSTEM PERKINS 404D 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 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 PERKINS LINCOLN D 3 MAINTENANCE D 3 ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS EVERY 100 HOURS OR 3 MONTHS EVERY 250 HOURS OR 6 MONTHS EVERY 500 HOURS OR 12 MONTHS EVERY 1000 HOURS ENGINE SERVICE NOTE 2 MAINTENANCE ITEM TYPE OR QUANTITY fif Concentration of antifreeze 50 50 Water Ethylene Glycol Coolant NOTE 3 95qts 90L engineoitievel NOTE SS
9. rs u819J84 10 SI SIUL 310N XO8 YALAWOILNALOd SLOWSY SHOLSISSY IWNOILdO TOH LNOO 1OW H S 7z6M S39nv9 NISN YVAN MIYOS GNNOYS EN HOIAS e AON HOIVH3N39 ONITISM 1 daold Q33d 4 qmi NNHS 2319143934 ONY HOLIMS IOH1NOO 10W H 1VISO3HE M 209 9 ov SrH YVAN M349S NEO5 8H HOLMS HOLO3TAS SONIGNIM H3MOd Xnv TIV 009 lv VL 312193939 V AN9 d WHOHSNVdl N ddTO pg o d NOI19310Hd ANIONS H IdI OL IOVld 9 H Ov 3009 VOLS HOIVNd ITV LTOA 082 NOHI OL lS3UV3N ONIY dS SONIY JIOA SEL 3NION3 OL NNOO asvg OL aNnou9 g aN9 6 E Ge YACNAS HOLIMS 39055399 10 1S 390v9 3unssdud HMS rn Eo HAGNAS HOLIMS 3univuadiaL 1949 9 be 9 aanva 6 d n ooz 9212 4 VIG HOLIMS 9 9 v8 uui qoos 2 9 19 AOTH aman JNd NMOHHN 8P ZIZ 909 er NISN VelZ
10. state and local laws 1 1 Consult your federal state and local laws regarding specific requirements for use on public highways VEHICLE MOUNTING WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail e Only transport this Equipment on serviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for compo nents such as suspension axles and tires Use appropriate nuts bolts and lockwashers to attach the equipment base to the metal bed or frame of vehicle Follow vehicle manufacturer s instructions POLARITY CONTROL AND CABLE SIZES With the engine off route the electrode and work cables through the strain relief bracket on the base and connect to the studs located below the fuel tank mounting rail See size recommendations below For positive polarity connect the electrode cable to the terminal marked For Negative polarity 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 RECOMMENDED COPPER CABLE SIZES INSTALLATION Cables Sizes for Combined Length of Electrode Plus Work Cable Duty Cycle Up to 200ft 61m 2
11. NEGATIVE GROUND CLASSIC 300D PERKINS LINCOLN 8 B 1 OPERATION B 1 ENGINE OPERATION 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 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 e ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure 0 Do not operate with doors open or quards 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 with the doors closed Leaving the doors open changes the designed air flow and can cause overheating STARTING THE CLASSIC 300D PERKINS 404D 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 ObDserve the oil pressure If no pressure shows withi
12. 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 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 3 MOVING PARTS can injure Do not operate with doors open or guards off ws Stop engine before servicing Keep away from moving parts See additional warning information at the front of this operator s manual EXHAUST SPARK ARRESTER Some federal state or local laws may require that engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations a suitable spark arrester must be installed and properly maintained CAUTION 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 t
13. PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES 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 o 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 e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria BEBE 42274 S4758 Belle S XACOE E 7 MASP Ash 221 27 amp Qual oe fyn dll sui e co gal biz Giga 31 Ar ggill arin oi iia ge oaa SI Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom v
14. R Engineoil NOTE1 amp 3 8 45qrts 8L including filter R Engine oil filter Perkins 140517050 R Water Separator Element Lincoln M20840A Drain water separator amp fuel strainer R Fuel filter canister Perkins 2656613 PTIT IL Tension of alternator drive belt i i Alternator drive belt wear R Alternator drive belt Perkins 080109107 Airfilter earlier check may be req d EE R Airfilter element Donaldson P821575 IR Renew the engine breather 6 i Tighten cylinder head t Valve clearances Intake 008 exhaust 008 i Electrical systems LT T p Ii All nuts and bolts for tightness RS t Injector performance Contact Perkins UT Leaks or engine damage J LII hn Ser Inspect C Clean R Replace H LI e i L a E E E E E 1 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 preventative maintenance periods apply to average conditions of opera
15. if the welder is subject ed to extensive light loading occasional moderate to heavy loading of the engine may sometimes be neces sary Caution must be observed in correctly loading a diesel generator unit 1 Connect the welder output studs to a suitable resis tive load bank Note that any attempt to short the output studs by connecting the welding leads togeth er direct shorting of the output studs or connecting the output leads to a length of steel will result in cat astrophic damage to the generator and voids the warranty 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 Periodically shut off the engine and check the crankcase oil level 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 amp GASES be dangerous Keep your head out of the fumes Use ventilation or exhaust to remove fumes from breathing zone DE We ARC RAYS can burn WELDING SPARKS can cause fire or explosion Keep flammable material away Wear eye ear and body protection NS DUTY CYCLE The NEMA output rating of the Classic 300D Per
16. 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 PERKINS LINCOLN 8 F 1 Enhanced Diagram DIAGRAMS F 1 Jequinu 9D09 zuawd nb y 1U9uu99gld9 e 10 jue unie deg 99IAl9S au 0 91M 8IIB9III SI ayy sjaued 9 nS0I9U9 3y jo auo uo LZ6LZIN HdVl TVOI 1 HLIM 1LV 1nSNI Q3193NNOO ST1VNIWH qV 1 d WOHJ S3HIM 9209 9 3AOIN3H WAM HLIM Q3ddlfnO3 Al FINGOW 0334 SHIM SNOLLO3NNOO 3S3H L ONDIVIN N3HM ONINNNE 38 LON LSNW 3NIHOVIN IHSSV LVLSOWYSHL dv 082 d 1OH Hsu DAN OL LOANNOO TVNIAH L LNdLNO oAO AIVS3N 3No STWNINWAL IndInO 504 DSN SOd 0119 NNOO T3NVd lOHLNOO Sd 9d y WAM JNIHOVW NO SPs HOLO3NNOO OL W3 M NO LOANNOO 1814 HOLOANNOO Odd Obd DA Id SAOWSY NO IVNOILdO SINGOW 4334 SHIM CM HLIM A9 8 99 3N1IS0d o TANVd TOHLNOO Q3N3lA SV NMOHS NOILISOd 99 AAILVO3N SHOLOANNOO YALAINOLLNALOd IOHLNOO SLOWSY HOH 9N1d eur 9DISUI pejsed si 9D09 1ejnonjed 10 21128905 ayy jenuew siu Aq D9 9A09 10 9je1n93e eq jou j Ajuo 99 ASVO OL LOANNOO
17. 00 to 250ft 100 60 A 4 PRE OPERATION SERVICE CAUTION READ the engine operating and maintenance instructions supplied with this machine WARNING Stop engine while fueling Do not smoke when fueling Keep sparks and flame away from tank not leave unattended while fueling DIESEL FUEL e Wipe up spilled fuel and allow fumes to clear before starting engine Do not overfill tank fuel expan sion may cause overflow DIESEL FUEL ONLY Low sulphur fuel or ultra low sulphur fuel in U S A and Canada can cause fire OIL This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W 30 oil This oil should be acceptable for most typical ambient temperatures Consult the engine operation manual for specific engine manufacturer s recommendations Upon receipt of the welder check the engine dipstick to be sure the oil is at the full mark DO NOT overfill FUEL gi Fill the fuel tank with the grade of fuel recommended in the Engine Operator s manual Make sure the fuel valve on the water separator is in the open position 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 PERKINS LINCOLN 8 AS
18. CV at the welding site 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 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 Control Cable K936 4 required for TIG Module Control cable for connecting the K930 2 TIG Module Arc Start Switch K814 required for TIG Module Comes with a 25ft 7 6m cable Attaches to the TIG torch for convenient finger control Contactor Kit K938 1 required for TIG Module Provide Cold tungsten Tip when welding with the TIG Module Control Cable Extension K937 45 Allows the TIG Module to be operated at distances up to 200 ft from the power source Available in 45 ft 13 7m Water Valve Kit K844 1 For use with a water cooled TIG torch Installs inside TIG Module CLASSIC 300D PERKINS LINCOLN c2 ACCESSORIES 2 WIRE FEEDER OPTIONS Wire Feed Module K623 1 Provides constant voltage CV output with improved arc stability for Innershield welding Excellent for MIG welding Recommended wire feeders are the LN 7 LN 23P and LN 25 Factory install
19. Check Idler Circuit Wiring and Repair as Required 4 Replace Idler P C Board CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CLASSIC 300D PERKINS LINCOLN 8 E 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual Engine does not start Lack of fuel Air mixed in the fuel system Clogged fuel filter Irregular and faulty fuel supply Injector pump trouble Glow plug not heated Clogged air cleaner No compression Engine protection light is ON Engine does not turn over Faulty Ignition switch and or Injector pump solenoid Insufficient charging or com plete discharge of the battery If all recommended possible areas Improper viscosity of the of misadjustment have been cating oil checked and the problem persists Contact your local Lincoln Irregular running of the engine A Air mixed in the fuel system Authorized Field Service Facility Uneven fuel injection Faulty fuel injector pump Clogged fuel filter Defective governor Engine itself defective Engine stops during operation and 1 Lack of fuel in the fuel tank the Engine Protection light does not turn on Clogged fuel filter Air mixed in the fuel system Faulty function of the engine
20. Exhaust Spark Arfester inner A 3 Location Afri A 3 Machine Grouhding ere teta ur A 3 E A 3 EE T TE A 3 Vehicle TET 4 Polarity Control and Cable Sizes A 4 Pre Operatior Servia A 4 OR A 4 gil EE A 4 Coolirig SY StS IM i cu neni A 4 Battery Chargirgi estote A 5 EL Section Engine 1 Starting The Perkins Engine sess B 1 High Altitude Operation issus B 1 Stopping the engine Engine Break In B 1 B 2 Vues ration m en 2 Bae B 2 Control of Welding Current 2 jeep HR B 3 Auxiliary Power Fuel Consumption Data B 3 ACGCeSSOIIBSEEEEEEEE errem exec ee sen nec cra ione Section C Optional Features Field Installed C 1 C 2 NET CEDE Section D Safety Precautions ciini D 1 General INStrUCTIONS ERR D 1 COOLING SYSTEM D 1 SR
21. INSTALLATION BATTERY CHARGING A WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away E BATTERY ACID can burn eyes and skin e 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 thenega tive cable from the old battery first and connect the negative cable to the new battery last b Connecting a battery charger remove the bat tery from the welder by disconnecting the nega tive cable first then the positive cable and bat tery clamp When reinstalling connect the neg ative cable last c Using a booster connect the positive lead to the battery first then connect the negative lead to the ground lead on the base To prevent ELECTRICAL DAMAGE when a Installing a new battery b Using a booster Use correct polarity Negative Ground To prevent BATTERY DISCHARGE if you have an ignition switch turn it off when engine is not run ning To prevent BATTERY BUCKLING tighten nuts on battery clamp until snug The Classic 300D Perkins is equipped with a wet charged battery The charging current is automatical ly 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
22. R ATAH SASS S24 BSS uu e 2x9 AAS OAR d gy Gill ela Quali pad ay gi Gil gs sit outils dax DE dus ule Y jo Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflamaveis bem guarda dos e e 18 2 VAM i SEL 248 YZ AIX nig ALI a gt Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo e RER HRAEBGHRRAR ei 119 A HSE HZA dil s due le Lily gadag cl gal 9 READ AND UNDERSTAND THE 5 INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES 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
23. R 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 amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance A work unless the maintenance work requires it to be running 2 m 1 h To avoid scalding do not remove the h OR ar radiator pressure cap when the engine is f 7 hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 23 ELECTRIC AND MAGNETIC FIELDS KR 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 cm 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 engin
24. RETURN TO MAIN MENU IM995 A CLASSIC 300 D PERKINS inane For Machines with Code Numbers 11572 11573 11640 11641 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 READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful C US OPERATOR S MANUAL Copyright Lincoln Global Inc LINCOLN amp e World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY 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 DOCTO
25. ST1VHX dOL OL NOISNANIG ON NL ONILNNON 4111V419S N ON NI H31VM 110 HLIM ALIAVHO 1N O VN Nvd 1OHLNO9 SALON CLASSIC 300D PERKINS LINCOLN E NOTES CLASSIC 300D PERKINS LINCOLN NOTES CLASSIC 300D PERKINS LINCOLN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Chinese Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground toque las partes o los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez la peau ni 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 toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pe a e terra o E PORTED NAHE e SFR CRA CRM ML H
26. ae ie D 1 Commutator and D 1 IdleriMalntenatiee s iecore ere reenter eed D 2 stanie S Ene e D 2 Purging Air from Fuel System us D 2 Engine Service Charts D 3 GFCI Module Testing and Resetting D 4 Troubleshooting inner Section E Safety PrECAULOMS ete oerte trot needed tes ane Eni e der an E 1 Welder Troubleshootlrig Pine E 2 Electronic Idler Troubleshooting Guide E 3 E 4 Engine Troubleshooting Guide E 5 E 6 E 7 DIEI ie EI RR Section F Winag NAG AIS ic cca crit ertt ttn e ert dat ea det ene F 1 F 2 Dimension iis ET F 3 Parts c E C P 594 A 1 INSTALLATION TECHNICAL SPECIFICATIONS CLASSIC 300D PERKINS Make Model Perkins 404D 22 EPA Tier 4 interim Compliant Description 4 Cylinder 4 Cycle Naturally Aspirated Water Cooled Diesel Engine Cast Iron Cylinder Block Crankcase INPUT DIESEL ENGINE Speed RPM Displacement 135 cu in 2 2 ltrs High Idle 1800 Low Idle 1400 Bore x Stroke Full Load 1725 3 3 x 3 9 84mm x 100mm 32 7HP 1800 RPM Starting System 12VDC battery Group 24 650 cold
27. and 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 PERKINS LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION White or Blue Smoke Dark Grey Smoke Faulty Charging Starter Motor does not run Engine Protection Light not com ing on No Auxiliary Power 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 Faulty Engine Control Unit Open circuit breakers Reset breaakers GFCI tripped Follow GFCI Module Testing and Resetting Procedure in the Maintenace Section of this Manual Faulty connections to auxiliary receptacles Check connections module may have If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test
28. case oil level drain accumulated dirt and water from the water separator located on the fuel rail 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 on the separator located on the fuel rail 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 PERKINS LINCOLN B 2 OPERATION B 2 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 wet stacking 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 success ful 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 engine s early life However
29. code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page EE Section A T chnical SpecificatiOris onec teneri tutis e iue uer enis Dr Nu hin A 1 General Description tede Goede ERR a utr A 2 Design Foal E isa des er ist cet un A 2 Pre Operation Installation A 3 Safety Precaution S es A 3
30. crank amps 2 0 KW Starter 65 A Alternator w built in reg RATED OUTPUT 104 F 40 C WELDER DESCRIPTION 300 Amp DC Welder All Copper Windings Pure DC Power Generator MODEL RATED DC OUTPUT VOLTS RATED AMPS 30V 250A 32V 300A 99V DC Max OCV 1800RPM Duty CYCLE Capacities Fuel 15 gal 57 L 10 30 Qts 9 75 L Oil Coolant 9 5 Qts 9 0 L DC CURRENT RANGE Fine Adjustments in each Range 40 350 Amps 220 Max 160 240 120 190 80 130 Min 90 RATED OUTPUT 104 F 40 C GENERATOR Auxiliary Power 3 000 Watts Continuous 60 Hz AC 26 Amps 115V 13 Amps 230V PHYSICAL DIMENSIONS WEIGHT K1643 7 CSA w o Wire Feed Module Code 11572 11640 K1643 8 CSA w Wire Feed Module Codes 11573 11641 Based on a 10 min period 45 5 in 1156 mm 65 0 in 1651 mm 1354 Ibs 616 kg 1389165 630 kg 1 Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced 2 Height to top of exhaust elbow CLASSIC 300D PERKINS LINCOLN 2 INSTALLATION A 2 GENERAL DESCRIPTION The Classic 300D Perkins 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 cop
31. der requires SG Control Module 25 ft length SG Control Module K488 For Magnum Spool Gun The interface between the power source and the Spool gun Provides control of wire speed and gas flow Input Cable K691 10 For SG Control Module For Lincoln engine drives with 14 pin MS type con nection separate 115V NEMA receptacle and output stud connections 10 ft length CLASSIC 300D PERKINS LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS 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 Insulate yourself from work and ground Always wear dry insulating gloves e ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside 3 SX 4 MOVING PARTS can injure Do not operate with doors open or guards off lt c Stop engine before servicing Keep awa
32. e 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 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 from incorrect connec tion 1 Proper operation of the idler requires good ground ing of the printed circuit board reed switch and battery 2 ldler solenoid is activated for low idle 3 If desired the welder can be used without automat ic idling by setting the Idler switch to the High position NAMEPLATES
33. e 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running Ow 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 LINCOLN 8 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 th
34. ed 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 Spark Arrestor Kit K903 1 Includes a heavy gage steel approved spark arrestor clamp and adapter for mounting to the muffler exhaust pipe TRAILER K953 1 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 amp a light package Ball Hitch K958 1 Lunette Eye Hitch K958 2 Fender amp Light Kit K959 1 Cable Rack K965 1 Service Indicator Kit K1858 1 Provides a GO NO GO visual indication of air clean er element useful service life Filter service based on restriction readings allows the longest life possible from the filter and best engine protection STICK OPTIONS ACCESSORY SET K704 Includes 35 feet 10 m of electrode cable and 30 feet 9 m of work cable headshield work clamp and elec trode holder Cable is rated at 500 amps 60 duty cycle Remote Control Kit K924 5 Contains remote control rheostat and 100 ft 30 5 m cable for adjusting the O
35. ed 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 300 MIG Gun for LN 25 K1802 1 With 15 ft 4 5m cable For 035 045 0 9 1 2mm gas shielded Includes Connector Kit 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 LN 23P to any Lincoln power source Makes 14 pin connection 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 62 gun tube for PipeWelding 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 Magnum Spool Gun K487 25 Hand held semiautomatic wire fee
36. em with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source 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 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiaut
37. emoving voltage from the out put of the receptacle If a GFCI module is tripped see the MAINTENANCE section for detailed information on testing and resetting it A GFCI module should be properly tested at least once every month The 120 V auxiliary power receptacle should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle Welder Enclosure The complete welder is rubber mount ed on a rugged steel 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 temper ature 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 Oil Drain Valve A ball valve hose and clamp are stan dard Remote Control The Remote Local Switch and Receptacle are standard CLASSIC 300D PERKINS LINCOLN 8 A 3 INSTALLATION A 3
38. he 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 SURFACES Where there is a combustible surface directly under sta tionary 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 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 grou
39. 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 A 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 cloth or paper for this purpose CLASSIC 300D PERKINS LINCOLN D 2 MAINTENANCE D 2 Replace brushes when they wear within 1 4 of the pigtail 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 th
40. iter brushes current may be loose or missing Exciter may not be operating If all recommended possible areas Field circuit of generator or of misadjustment have been exciter may be open checked and the problem persists Exciter may have lost excita Contact your local Lincoln tion Authorized Field Service Facility Series field and armature cir cuit may be open circuited Welding arc is loud and spatters Current setting may be too excessively high Polarity may be wrong Welding current too great or too Exciter output low causing low small compared to indication on output compared to dial indica the dial tion Operating speed too low or too high Arc continuously pops out Current Range Selector switch may be set at an inter mediate position 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 PERKINS LINCOLN 8 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 S
41. kins 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 SELECTOR WHILE WELDING because the current may arc between the contacts and damage the switch The Current Range Selector provides five overlapping cur rent ranges The Fine Current Adjustment adjusts the cur rent 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 butter ing 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 maxi mum 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 voltage For example to obtain 175 amps and a forceful arc set the
42. ld weather starting The control panel also contains an engine temperature gauge a battery charging ammeter an oil pressure gauge for auxiliary power consists of one 20 amp 120VAC 5 20R duplex receptacle with GFCI protection and one 15 amp 250VAC 6 15R receptacle protected by 2 pole 15 Amp breaker All Copper Windings For long life and dependable operation Engine Idler The Classic 300D Perkins 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 Section C for Power Plug Kit GFCI Module Protects the 20 amp 120V duplex recepta cle See the Maintenance Section for detailed information on testing and resetting of the GFCI Module 120 V DUPLEX RECEPTACLE AND GFCI MODULE A GFCI Module protects the 120V auxiliary power receptacle A GFCI Ground Fault Circuit Interrupter is a device to protect against electric shock should a piece of defective equipment connected to it develop a ground fault If this situation should occur the GFCI module will trip r
43. me delay cannot be adjusted If the welding or power load is not re started before the end of the time delay the idler sole noid activates and reduces the engine to low idle speed AUXILIARY POWER If a GFCI Module is tripped See the MAINTENANCE section for detailed information on testing and reset ting the GFCI Module 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 120V duplex protected by GFCI module and one 230V duplex grounding type receptacle with 2 pole 15 amp circuit breaker The rating of 3 0 KVA permits a maximum continuous current of 13 amps to be drawn from the 230 volt duplex receptacle 15 amps can be drawn from the 120 volt duplex receptacle 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 CLASSIC 300D PERKINS WITH PERKINS 1040 22 DIESEL ENGINE TYPICAL FUEL CONSUMPTION DATA Low Idle 1375 RPM No Load 45 Volts High Idle 1800 RPM No Load 96 6 Volts 3000 Watts 250 Amps 30 Volts 0 28 gal hr 1 06 Itrs hr 0 42 gal hr 1 59 Itrs hr 0 59 gal hr 2 23 Itrs hr 1 03 gal hr 3 90 Itrs hr 300 Amps 32 Volts 1 37 galhr 5 19 Itrs hr CLASSIC 300D PERKINS LINCOLN C 1 ACCESSORIES C 1 OPTIONAL FEATURES Field Install
44. mpressed 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 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
45. n 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 starting may require longer glow plug operation WARNING Under NO conditions should ether or other starting fluids be used HIGH ALTITUDE OPERATION The engine will run correctly up to an altitude of 600m 2000ft If the engine is to be operated permanently at an altitude above this the fuel consumption and exhaust emissions may be excessive Contact the Perkins Application Department for any engine adjustments that may be required STOPPING THE ENGINE 1 Turn the IGNITION switch to OFF At the end of each day s welding check the crank
46. nd 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 WARNING Have qualified personnel do the troubleshooting 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 CAUTION CLASSIC 300D PERKINS LINCOLN 8 E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Machine fails to hold the output Rough or dirty commutator heat consistently Brushes may be worn down to Limit Field circuit may have variable resistance connection or inter mittent 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 gener ator Field rheostat may be making poor contact and overheating Welder starts but fails to generate Generator or exc
47. nded 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 Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder Do not lift machine if lift bail is damaged Do not operate machine while suspended from lift bail FALLING EQUIPMENT can cause injury 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 weld ing equipment Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equip ment and likely additional attachments CLASSIC 300D PERKINS LINCOLN 8 A 4 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 operat ed environmental conditions likely maintenance 5 Conformance with federal
48. nnot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information 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
49. odule if neces sary or replace the device CLASSIC 300D PERKINS LINCOLN E TROUBLESHOOTING 1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility If for any reason you do not understa
50. olenoid Coil Control Switch 0 VDC 12 VDC Check Continuity of Check for Jamming Reed Switch in Weld Circuit of the Idler Solenoid Mechanism 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 PERKINS LINCOLN 8 E 4 TROUBLESHOOTING 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 Reed Switch in Weld Circuit Defective Will Not Close To Check Short the Red Lead on P C Board to Welder Frame Engine Picks Up Speed Engine Does Not Pick Up Speed 1 Check for Break in Red Lead and Repair 1 Check for Jamming of the Idler Solenoid Mechanism or broken return spring 2 Replace Reed Switch in Weld Circuit 2 Check Idler Circuit Wiring and Repair as Required 3 Replace Idler P C Board The Auxiliary Power Load is Turned ON Power Load Too Small Try Load Above 150 Watts Engine Does Not Pick Up Speed 1 Check for Jamming of the Idler Solenoid Mechanism or broken return spring 2 Check for Continuity of Current Transformer Toroid Replace as Required 3
51. omatic 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 EZ 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 287 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 ma
52. or Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico e toque as partes el tricas nuas e e e SHA UH Thy ab db juil ahii e Do not operate with panel open or guards off No operar con panel abierto 0 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 e Mantenha se afastado das partes moventes Na0 opere com os paineis abertos ou guardas removidas CRRBTES OARRA RE ERE ezido sel HAE zia Abeyi is la Qai ye Cut Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Chinese LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR
53. oudage 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 s PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER TRANSFORMATEUR 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 l arc et des projections quand on soude ou quand on regarde l arc 1 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 8 Relier la terre le chassis du poste conformement au code de l lectricit et a
54. per coils rated at 300 amps 32 Volts and provides other Classic features such as improved door latches and stainless hinges With the addi tion of the optional K623 1 Wire Feed Module the Classic 300D Perkins 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 8 The optional K924 5 Remote Control Kit provides a remote con trol rheostat for remote fine current and open circuit voltage adjustment See Section C for description The Classic 300D Perkins has an Electronic Engine Protection System In the event of sudden low oil pressure or high coolant temperature the engine immediately shuts down The Classic 300D Perkins has a current range of 40 850 DC amps with output ratings as follows These units are also capable of providing 3 KVA of 115 230 volts of 60 cycle AC auxiliary power The Classic 300D Perkins uses the Perkins 404D 22 industrial water cooled diesel engine RATED OUTPUT DUTY CYCLE 250A 30V 300A 32V 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 Glow Plug button for easier co
55. r 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 manufacturer s instructions for this 5f LINCOLN 8 equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY WELDING and CUTTING 7 7 SPARKS 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 to
56. tion If necessary use shorter periods 526657 VM CLASSIC 300D PERKINS LINCOLN D 4 MAINTENANCE GFCI MODULE TESTING AND RESETTING PROCEDURE The GFCI module should be properly tested at least once every month or whenever it is tripped To proper ly test and reset the GFCI module If the module 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 mod ule This will assure normal operation Plug a night light with an ON OFF switch or other product such as a lamp into the Duplex receptacle and turn the product ON Push the Test button located on the GFCI module 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 module is not work ing properly or has been incorrectly installed mis wired If your GFCI module is not working properly contact a qualified certified electrician who can assess the situation rewire the GFCI m
57. ux 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 o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr 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 s
58. ux 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 V V for selecting a QUALITY product by Lincoln Electric We want you J hank OU to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also ca
59. xic 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 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 Also see item 1 c 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 Do not use a welding power source for pipe thawing LINCOLN 8 CYLINDER may explode if damaged 7 a Use only co
60. y from moving parts See additional warning information at front of this operator s manual GENERAL INSTRUCTIONS 1 Blow out the welder and controls with an air hose at least once every two months In particularly dirty locations this cleaning may be necessary once a week Use low pressure air to avoid driving dirt into the insulation 2 Current Range Selector contacts should not be greased To keep the contacts clean rotate the cur rent control through its entire range frequently Good practice is to turn the handle from maximum to minimum setting twice each morning before start ing to weld 3 Put a drop of oil on the Current Range Selector shaft at least once every month 4 Follow the engine service schedule in this manual and the detailed maintenance and troubleshooting in the engine manufacturer s manual COOLING SYSTEM The Classic 300D Perkins is equipped with a pres sure radiator Keep the radiator cap tight to prevent loss of coolant Clean and flush the cooling system periodically to prevent clogging the passage and over heating the engine When antifreeze is needed always use the permanent type 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
61. y 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 circum stances 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 spe cific 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 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 prod ucts 5 d Shielding gases used for arc welding can displace ai

Lincoln Electric 11572 Welder User Manual

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