im631

CLASSIC ® 300 D

OPERATOR’S MANUAL

For Machines with Code Numbers 10545, 10546, 10657, 10658, 10911 and 10927

IM631-BMay, 2006

Safety Depends on YouLincoln arc welding equipmentis designed and built with safetyin mind. However, your overallsafety can be increased byproper instal lat ion ... andthoughtful operation on yourpart. DO NOT INSTALL,OPERATE OR REPAIR THISEQUIPMENT WITHOUTREADING THIS MANUAL ANDTHE SAFETY PRECAUTIONSCONTAINED THROUGHOUT.And, most importantly, thinkbefore you act and be careful.

R

• 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

• World's Leader in Welding and Cutting Products •

Copyright © 2006 Lincoln Global Inc.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes outdoors.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem 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 andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.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 bareskin 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 fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating products.

5.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b. Mar ‘95

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

ivSAFETYiv

Mar. ‘93

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

vv

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy 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:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound 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 youhave 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 packetaccompanying 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.

vivi TABLE OF CONTENTSPage

Installation .......................................................................................................Section ATechnical Specifications ........................................................................................A-1General Description ...............................................................................................A-2Design Features ....................................................................................................A-2Pre-Operation Installation ......................................................................................A-3

Safety Precautions ..........................................................................................A-3Exhaust Spark Arrester ...................................................................................A-3Location/Ventilation.........................................................................................A-3Machine Grounding.........................................................................................A-3Lift Bail ............................................................................................................A-3Trailers ............................................................................................................A-4Polarity Control and Cable Sizes ....................................................................A-4

Pre-Operation Service ...........................................................................................A-4Oil ....................................................................................................................A-4Fuel .................................................................................................................A-4Cooling System ...............................................................................................A-4Engine Break-in, Battery Charging..................................................................A-5

________________________________________________________________________Operation .........................................................................................................Section B

Engine Operation...................................................................................................B-1Starting The Perkins 104-22 Engine ...............................................................B-1Stopping the engine ........................................................................................B-1

Welder Operation...................................................................................................B-2Duty Cycle.......................................................................................................B-2Control of Welding Current..............................................................................B-2Idler Operation ................................................................................................B-2Auxiliary Power ...............................................................................................B-3

________________________________________________________________________Accessories .....................................................................................................Section C

Optional Features (Field Installed) ........................................................................C-1________________________________________________________________________

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1General Instructions ..............................................................................................D-1Cooling System .....................................................................................................D-1Bearings ................................................................................................................D-1Commutator and Brushes .....................................................................................D-1Idler Maintenance..................................................................................................D-2Nameplates ...........................................................................................................D-2Purging Air from Fuel System................................................................................D-2Engine Service Chart ....................................................................................D-3, D-4GFCI Receptacle Testing and Reseting Procedure (Optional)..............................D-5

________________________________________________________________________Troubleshooting ..............................................................................................Section E

Safety Precautions.................................................................................................E-1Welder Troubleshooting ........................................................................................E-2Electronic Idler Troubleshooting Guide...........................................................E-3,E-4Engine Troubleshooting Guide .....................................................................E-5, E-6

________________________________________________________________________Diagrams ..........................................................................................................Section F

Wiring Diagram (Classic 300 D) ......................................................................F-1,F-2Connection Diagram ..............................................................................................F-3Dimension Print......................................................................................................F-4

________________________________________________________________________Parts List ......................................................................................................P337 Series

A-1INSTALLATION

CLASSIC 300D

A-1

* Based on a 10 min. period.(1) 115V will operate either 60 Hz. or 50/60 Hz. power tools, lights etc.(2) Height to top of exhaust elbow.

PERKINS 104-22 DIESEL ENGINE TYPICAL FUEL CONSUMPTION DATALow Idle (1375 RPM)-No Load @ 45 Volts

High Idle (1800 RPM)-No Load @ 96.6 Volts

50 Amps @ 22 Volts

100 Amps @ 24 Volts

150 Amps @ 26 Volts

200 Amps @ 28 Volts

250 Amps @ 30 Volts

300 Amps @ 32 Volts

350 Amps @ 34 Volts

0.28 gal/hr ( 1.06 ltrs/hr)









TECHNICAL SPECIFICATIONS - CLASSIC 300D

Make/Model Description Speed (RPM) Displacement Starting CapacitiesSystem

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) & Starter 57 L

Engine 32.7 HP @ Full Load 1725(Water Cooled) 1800 RPM Bore x Stroke Oil: 8.7 Qts.

8.2 L3.875” x 5.00”(98.4 mm x 127.0mm) Coolant: 7.9 gal.

7.5 L

INPUT - DIESEL ENGINE

RATED OUTPUT - WELDER

HEIGHT WIDTH DEPTH

45.50 in. 24.00 in. 65.00 in.

1156 mm 610 mm 1651 mm

PHYSICAL DIMENSIONS(2)

WELDING OUTPUT*Current/Voltage/Duty Cycle

250A / 30V / 100%

300A / 32V / 60%

OUTPUT RANGEAMPS

40-350A

220A-MAX.160-240A120-240A120-190A80-130AMin.-90A

OPEN CIRCUITVOLTAGE

98 Max.@ 1800 RPM

AUXILIARY POWER(1)

115/230 VAC3000 Watts, 60 Hz.26 Amps @ 115V13 Amps @ 230V

WEIGHT

1354 lbs.(616 kg)

1354 lbs.(616 kg)

K1643-1

K1643-2

A-2INSTALLATION

CLASSIC 300D

A-2

GENERAL DESCRIPTION

The Classic® 300 D is a heavy duty, engine driven,DC arc welding power source, capable of providingconstant current output for stick welding or DC TIGwelding. This welder is wound with all copper coils,rated at 300 amps/32 Volts, and provides otherClassic features such as improved door latches andstainless hinges. With the addition of the optional

K623-1 Wire Feed Module™, the Classic 300 D willprovide constant voltage output for running the LN-7,LN-23P, or LN-25 wire feeders. (The Wire FeedModule is factory installed on the K1643-2). Theoptional K924-4 or K924-5 Remote Control Kit (Bothfield installed) See Section C for description.

The Classic 300 D has Diesel Engine Protection. Inthe event of sudden low oil pressure or high coolanttemperature, the engine immediately shuts down.The Classic 300 D has a current range of 40-350 DCamps with output ratings as follows:

These units are also capable of providing 3 kVA of115/230 volts of 60 cycle AC auxiliary power.

The Classic 300 D uses the Perkins 104-22 industrialwater-cooled diesel engine.

DESIGN FEATURES

Control Panel

Both the engine and the welder controls are locatedon one recessed panel at the exciter end of themachine. The welder controls consist of a five step“Current Range Selector” switch and a “Fine CurrentAdjustment” rheostat. The welder is equipped with a“Start” button, an “Ignition” switch, an “Idler” controlswitch, and a “Glow Plug” button for easier coldweather 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 dependableoperation.

Engine Idler - The Classic 300 D is equipped with anelectronic automatic engine idler. It automaticallyincreases and decreases engine speed when start-ing and stopping welding or using auxiliarypower. 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 idlerin 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 OptionalFeatures for Power Plug Kit.)

Welder Enclosure - The complete welder is rubbermounted on a rugged steel “C” channel base.

The output terminals are placed at the side of themachines so that they are protected by the door. Theoutput terminals are labeled (+) and (-).

Cranking System - A 12 volt electric starter is stan-dard.

Air Cleaner - Heavy duty two stage dry type.

Muffler - A muffler and stainless steel exhaust outletelbow are standard.

Engine Hour Meter - A meter to record hours of oper-ation.

Engine Protection - The system shuts the enginedown in the event of sudden low oil pressure or highcoolant temperature. A warning light on the controlpanel will indicate such a fault. To reset the engine forrestarting, turn the ignition switch off then on.

250A @ 30V300A @ 32V

100%60%

RATED OUTPUT DUTY CYCLE

A-3INSTALLATION

CLASSIC 300D

A-3

PRE-OPERATION INSTALLATION

Exhaust Spark ArresterSome federal, state or local laws may require thatengines be equipped with exhaust spark arresterswhen they are operated in certain locations whereunarrested sparks may present a fire hazard. Thestandard muffler included with this welder does notqualify as a spark arrester. When required by localregulations, a suitable spark arrester must be installedand properly maintained.

Use of an incorrect arrester may lead to engine damageor performance loss. Contact the engine manufacturerfor specific recommendations.------------------------------------------------------------------------Location / Ventilation

Always operate the welder with the doors closed.Leaving the doors open changes the designed air flowand may cause overheating.

The welder should be located to provide an unrestrict-ed flow of clean, cool air. Also, locate the welder sothat engine exhaust fumes are properly vented to anoutside area.

Machine Grounding

According to the United States National ElectricalCode, the frame of this portable generator is notrequired to be grounded and is permitted to serve asthe grounding means for cord connected equipmentplugged into its receptacle.

Some state, local, or other codes or unusual operatingcircumstances may require the machine frame to begrounded. It is recommended that you determine theextent to which such requirements may apply to yourparticular situation and follow them explicitly. Amachine grounding stud marked with the symbol isprovided on the welding generator frame foot. In gen-eral, if the machine is to be grounded, it should beconnected with a #8 or larger copper wire to a solidearth ground such as a metal water pipe going intothe ground for at least ten feet and having no insulat-ed joints, or to the metal framework of a buildingwhich has been effectively grounded. The U.S.National Code lists a number of alternate means ofgrounding electrical equipment.

Lift Bail

A lift bail is provided for lifting with a hoist.

Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.------------------------------------------------------------------------

ELECTRIC SHOCK can kill.• Do not touch electrically live parts or

electrode with skin or wet clothing.• Insulate yourself from work and

ground• Always wear dry insulating gloves.

------------------------------------------------------------------------ENGINE EXHAUST can kill.• Use in open, well ventilated areas or

vent exhaust outside.

------------------------------------------------------------------------MOVING PARTS can injure.• Do not operate with doors open or

guards off.• Stop engine before servicing.• Keep away from moving parts.

------------------------------------------------------------------------See additional warning information at thefront of this operator’s manual.

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

WARNING

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SUR-FACES.Where there is a combustible surface directly understationary or fixed electrical equipment, the surfaceshall be covered with a steel plate at least.06”(1.6mm) thick, which shall extend not more than5.90”(150mm) beyond the equipment on all side.s.----------------------------------------------------------------------

CAUTION

• Lift only with equipment ofadequate lifting capacity.

• Be sure machine is stablewhen lifting.

• Do not lift this machine usinglift bale if it is equipped with aheavy accessory such as trail-er or gas cylinder.

FALLING • Do not lift machine if lift bale isdamaged.

EQUIPMENT can • Do not operate machine while

cause injury. suspended from lift bale.

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

WARNING

PRE-OPERATION SERVICE

READ the engine operating and maintenance instruc-tions supplied with this machine.-----------------------------------------------------------------------

Oil

This unit is supplied from the factory with the enginecrankcase filled with a high quality SAE 10W/30 oil.This oil should be acceptable for most typical ambienttemperatures. Consult the engine operation manualfor specific engine manufacturer’s recommendations.Upon receipt of the welder, check the engine dipstickto be sure the oil is at the “full” mark. DO NOT overfill.

Fuel

Fill the fuel tank with the grade of fuel recommendedin the Engine Operator’s manual. Make sure the fuelvalves on the sediment bowl and the water separatorare in the open positions.

Cooling System

The radiator has been filled at the factory with a 50-50mixture of ethylene glycol antifreeze and water.Check the radiator level and add a 50-50 solution asneeded (see engine manual or antifreeze container foralternate antifreeze recommendations).

CAUTION

A-4INSTALLATION

CLASSIC 300D

A-4

TRAILER (See Optional Features) If the user adapts a non-Lincoln trailer, he mustassume responsibility that the method of attachmentand usage does not result in a safety hazard nor dam-age the welding equipment. Some of the factors to beconsidered are as follows:

1. Design capacity of trailer vs. weight of Lincolnequipment and likely additional attachments.

2. Proper support of, and attachment to, the base ofthe welding equipment so there will be no unduestress to the framework.

3. Proper placement of the equipment on the trailer toensure stability side to side and front to back whenbeing moved and when standing by itself while beingoperated 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 specificrequirements for use on public highways.

VEHICLE MOUNTING

Improperly mounted concentrated loads may causeunstable 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 workcables through the strain relief bracket on the baseand connect to the studs located below the fuel tankmounting rail. (See size recommendations below.)For positive polarity, connect the electrode cable tothe terminal marked “+”. For Negative polarity, con-nect the electrode cable to the “-” stud. These con-nections should be checked periodically and tightenedif necessary.

When welding at a considerable distance from thewelder, be sure you use ample sized welding cables.

RECOMMENDED COPPER CABLE SIZESCables Sizes for Combined Lengthof Electrode Plus Work Cable

Amps Duty Cycle Up to 200ft.(61m) 200 to 250ft.(61 to 76m)

250 100% 1 1/0

300 60% 1/0 2/0

• Stop engine while fueling.• Do not smoke when fueling.• Keep sparks and flame away

from tank.• Do not leave unattended while

fueling.• Wipe up spilled fuel and allow

fumes to clear before startingengine.

• Do not overfil l tank, fuelexpansion may cause over-flow.DIESEL FUEL ONLY

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

WARNING

DIESEL FUELcan cause fire.

A-5INSTALLATION

CLASSIC 300D

A-5

Battery Charging

The Classic 300 D is equipped with a wet chargedbattery. 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 thebattery to the battery cables, the proper polarity mustbe observed. This system is NEGATIVE GROUND.

GASES FROM BATTERY can explode.• Keep sparks, flame and cigarettesaway.

BATTERY ACID can burn eyes andskin.• Wear gloves and eye protection andbe careful when boosting, charging orworking 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 andbattery clamp. When reinstalling, connect the negative cable last.

c) Using a booster - connect the positive lead to the battery first, then connect the negative lead to the ground lead on the base.

To prevent ELECTRICAL DAMAGE when:a) Installing a new battery.b) Using a booster.

Use correct polarity - Negative Ground.

To prevent BATTERY DISCHARGE, if you have an ignition switch, turn it off when engine is notrunning.

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

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

WARNINGENGINE BREAK-IN

Lincoln Electric selects high quality, heavy-duty indus-trial engines for the portable welding machines weoffer. While it is normal to see a small amount ofcrankcase oil consumption during initial operation,excessive oil use, wetstacking (oil or tar like sub-stance at the exhaust port), or excessive smoke is notnormal.

Larger machines with a capacity of 350 amperes andhigher, which are operated at low or no-load condi-tions for extended periods of time are especially sus-ceptible to the conditions described above. Toaccomplish 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 forsome period of time during the engine’s early life.However, if the welder is subjected to extensive lightloading, occasional moderate to heavy loading of theengine may sometimes be necessary. Caution mustbe observed in correctly loading a diesel/generatorunit.

1. Connect the welder output studs to a suit-able resistive load bank. Note that anyattempt to short the output studs by con-necting the welding leads together, directshorting of the output studs, or connectingthe output leads to a length of steel willresult 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 ratingand duty cycle. Note that any attempt toexceed the welder rating or duty cycle forany period of time will result in catastrophicdamage to the generator and voids thewarranty.

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

B-1OPERATIONB-1

ENGINE OPERATION

Operate the welder with the doors closed. Leavingthe doors open changes the designed air flow and cancause overheating.

Starting the Classic 300 D Perkins 104-22Diesel Engine

1. Turn the “IDLER” switch to “HIGH”.2. Turn the “IGNITION” switch to “ON”.3. Press the Glow Plug button for 20 to 30 seconds.

(maximum 60 seconds).4. Press the Start button. When the engine starts

running, release both buttons. If the engine fails tostart in 20 seconds, wait 30 seconds and repeatthe above procedure.

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

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

CLASSIC 300D

Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.------------------------------------------------------------------------

ELECTRIC SHOCK can kill.• Do not touch electrically live parts orelectrode with skin or wet clothing.• Insulate yourself from work andground• Always wear dry insulating gloves.

------------------------------------------------------------------------ENGINE EXHAUST can kill.• Use in open, well ventilated areas orvent exhaust outside.

------------------------------------------------------------------------MOVING PARTS can injure.• Do not operate with doors open orguards off.• Stop engine before servicing.• Keep away from moving parts.

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

See additional warning information at thefront of this operator’s manual.

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

WARNING

7. Allow the engine to run at high idle speed for sev-eral minutes to warm the engine. Stop the engineand recheck the oil level, after allowing sufficienttime for the oil to drain into the pan. If the level isdown, fill it to the full mark again. The engine con-trols were properly set at the factory and shouldrequire no adjusting when received.

COLD WEATHER STARTING:

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

Note: Extreme cold weather staring may requirelonger glow plug operation.

Under NO conditions should ether or otherstarting fluids be used!------------------------------------------------------------------------

Stopping the Engine

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

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

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

If the fuel supply is cut off or runs out while the fuelpump is operating, air may be entrapped in the fueldistribution system. If this happens, bleeding of thefuel system may be necessary. Use qualified person-nel to do this per the instructions in the MAINTE-NANCE section of this manual.

WARNING

B-2OPERATIONB-2

CLASSIC 300D

WELDER OPERATION

Duty Cycle

The NEMA output rating of the Classic 300 D is 300amperes at 32 arc volts on a 60% duty cycle (consultSpecifications in this manual for alternate ratings).Duty cycle is based on a ten minute period; thus, thewelder can be loaded at rated output for six minutesout of every ten minute period.

Control of Welding Current

DO NOT TURN THE “CURRENT RANGE SELEC-TOR” WHILE WELDING because the current mayarc 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 withineach range. Open circuit voltage is also controlled bythe “Fine Current Adjustment” permitting control of thearc 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, setthe “Current Range Selector” to the lowest setting thatstill provides the current you need and set the “FineCurrent Adjustment” near maximum. For example: toobtain 175 amps and a soft arc, set the “Current

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

When a forceful “digging” arc is required, usually forvertical and overhead welding, use a higher “CurrentRange Selector” setting and lower open circuit volt-age. For example: to obtain 175 amps and a forcefularc, set the “Current Range Selector” to the 240-160position and the “Fine Current Adjustment” setting toget 175 amps.

Some arc instability may be experienced with EXX10electrodes when trying to operate with long arc tech-niques at settings at the lower end of the open circuitvoltage range.

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

These switches have a spring loaded cam whichalmost eliminates the possibility of setting this switchbetween 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 severalminutes to warm the engine. See Specifications foroperating speeds.

The idler is controlled by the “Idler” toggle switch onthe 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. Thespeed is controlled by the governor.

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

a. When welding or drawing power for lights or tools(approximately 100-150 watts minimum) from thereceptacles, the idler solenoid activates and theengine operates at high idle speed.

b. When welding ceases or the power load is turnedoff, a preset time delay of about 15 secondsstarts. This time delay cannot be adjusted.

c. If the welding or power load is not re-startedbefore the end of the time delay, the idler sole-noid deactivates and reduces the engine to lowidle speed.


electrode with skin or wet clothing.• Insulate yourself from work and ground.

FUMES & GASES can be dangerous.• Keep your head out of the fumes.• Use ventilation or exhaust to remove

fumes from breathing zone.

WELDING SPARKS can cause fire orexplosion.• Keep flammable material away.

ARC RAYS can burn.• Wear eye, ear, and body protection.

WARNING

CAUTION

CAUTION

B-3OPERATIONB-3

CLASSIC 300D

Auxiliary Power

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

With the 3.0 kVA, 115/230 VAC auxiliary power, one115V duplex and one 230V duplex, grounding typereceptacle are provided. The circuit is protected withcircuit breakers.

The rating of 3.0 kVA permits a maximum continuouscurrent of 13 amps to be drawn from the 230 voltduplex receptacle. Or a total of 26 amps can be drawnfrom the 115 volt duplex receptacle. The 115 voltduplex receptacle has a configuration which permits20 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 isspecified, the customer is supplied with a plug foreach receptacle.

C-1ACCESSORIESC-1

CLASSIC 300D

OPTIONAL FEATURES (Field Installed)

GENERAL OPTIONS

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

Power Plug Kit (K802D) - A power plug kit for theauxiliary power receptacles is available. (Provides aplug for each receptacle.)

GFCI Receptacle Kit (K1690-1) - Includes one ULapproved 115V ground fault circuit interrupter duplextype receptacle with cover and installation instruc-tions. Replaces the factory installed 115V duplexreceptacle. Each receptacle of the GFCI duplex israted at 20 amps. Maximum total current from theGFCI duplex is limited to 20 amps. See the MAINTE-NANCE section for detailed information on testing andresetting the GFCI receptacle.

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

K953-1 TRAILER - Two-wheeled trailer with optional fenderand 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 & a light pack-age.K953-1 TrailerK958-1 Ball HitchK958-2 Lunette Eye Hitch K959-1 Fender & Light KitK965-1 Cable Rack

OIL DRAIN KIT K1586-1 - Includes ball valve, hoseand clamp.

STICK OPTIONS

K704 ACCESSORY SET - Includes 35 feet (10 m) ofelectrode cable and 30 feet (9 m) of work cable, head-shield, work clamp and electrode holder. Cable israted 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 weldingsite.(For Codes below 10911.)

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

Remote Control Kit (K2464-1) - Contains remotecontrol 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 andshielding gas control for AC and DC GTAW (TIG)welding applications. Its compact case is designed foreasy carrying, complete with a handle. High frequen-cy bypass is built in.The K938-1 Contactor Kit mustbe field installed in the TIG Module when used with aZR-10. Additionally, the K936-3 control cable isrequired if remote control is used. If remote control isnot 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 forconnecting the K930-2 TIG Module to a ZR-10 notequipped with a K892-1 Remote Kit. 9-Socket to agrounded 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. inlength.

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

WARNING

C-2ACCESSORIESC-2

Wire Feed Module (K623-1) - Provides constantvoltage (CV) output with improved arc stability forInnershield welding. Excellent for MIG welding.Recommended wire feeders are the LN-7, LN-23Pand LN-25. (Factory installed on the K1643-2).

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

Remote Voltage Control Kit for LN-25 K444-2Provides 25 ft. (7.5m) of remote output voltage controland output jumper (2 and 4) for machines having 14pin MS-type connector.

Magnum® 350 Innershield Gun (for LN-25)K126-2-For self-shielded wire with 15 ft. (4.5m) cable. For.062-3/32” (1.6-2.8mm) wire.

Magnum® 200 MIG Gun (for LN-25)K497-3-With15 ft. (4.5m) cable. For .025 (0.6m) wire.

Magnum Gun Connector KiT-Connects Magnum200 MIG gun to LN-25 Wire Feeder.

LN-23P Wire Feeder K316L-1-Portable CV unit forInnershield pipe welding. Control cable operates con-tactor inside Wire Feed Module for “cold” electrode.Requires LN-23P Adapter Kit (K350-1) and Gun andCable 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 250amps, 60% duty cycle. For .068 through 5/64” (1.7through 2.0 mm) Innershield wire and includesreduced speed switch. For pipewelding, an M1147662° gun tube is recommended.

62° gun tube for Pipe Welding KP1909-1-Recommended modification for K355-X or K345-xguns 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 thepower source and the spool gun. Provides control ofwire speed and gas flow.

Input Cable K691-10.-For Lincoln engine drives with14-pin MS-type connection, separate 115V NEMAreceptacle and output stud connections. 10 ft.length.

CLASSIC 300D

D-1MAINTENANCED-1

MAINTENANCE

General Instructions

1. Blow out the welder and controls with an air hose atleast 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 begreased. To keep the contacts clean, rotate the cur-rent control through its entire range frequently. Goodpractice is to turn the handle from maximum to mini-mum setting twice each morning before starting toweld.

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 soequipped, from beneath the fuel tank and clean outany accumulated dirt and water.

5. Follow the engine service schedule in this manualand the detailed maintenance and troubleshooting inthe 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 ofcoolant. Clean and flush the cooling system periodi-cally to prevent clogging the passage and overheatingthe engine. When antifreeze is needed, always usethe permanent type. Capacity = 9.5 qts (9.0 Ltrs.).

Bearings

This welder is equipped with a double-shielded ballbearing having sufficient grease to last indefinitelyunder 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. Apad of grease one inch wide, one inch long, and oneinch high weighs approximately one half ounce. Over-greasing is far worse than insufficient greasing.

When greasing the bearings, keep all dirt out of thearea. Wipe the fittings completely clean and use cleanequipment. More bearing failures are caused by dirtintroduced during greasing than from insufficientgrease.

Commutator and Brushes

Uncovered rotating equipment can be dangerous.Use care so your hands, hair, clothing or tools donot catch in the rotating parts. Protect yourselffrom 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, andbrushes by removing the covers. DO NOT remove orreplace these covers while the machine is running.Commutators and slip rings require little attention.However, if they are black or appear uneven, havethem cleaned by an experienced maintenance man using fine sandpaper or a commutator stone. Neveruse emery cloth or paper for this purpose.

CLASSIC 300D

Have qualified personnel do the maintenancework. Turn the engine off before working insidethe machine. In some cases, it may be neces-sary to remove safety guards to performrequired maintenance. Remove guards onlywhen necessary and replace them when themaintenance 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 coolingblower fan. If a problem cannot be corrected byfollowing the instructions, take the machine tothe nearest Lincoln Field Service Shop.

-----------------------------------------------------------------------ELECTRIC SHOCK can kill.• Do not touch electrically live parts or







------------------------------------------------------------------------See additional warning information atfront of this operator’s manual.

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

WARNING

WARNING

D-2MAINTENANCED-2

Replace brushes when they wear within 1/4” of thepigtail. A complete set of replacement brushes shouldbe kept on hand. Lincoln brushes have a curved faceto fit the commutator. Have an experienced mainte-nance man seat these brushes by lightly stoning thecommutator as the armature rotates at full speed untilcontact 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 inplace. Then slide one end of a piece of fine sandpaperbetween slip rings and brushes with the coarse sideagainst the brushes. With slight additional finger pres-sure on top of the brushes, pull the sandpaper aroundthe circumference of the rings - in direction of rotationonly - until brushes seat properly. In addition, stoneslip ring with a fine stone. Brushes must be seated100%.

Arcing or excessive exciter brush wear indicates apossible misaligned shaft. Have an authorized FieldService Shop check and realign the shaft.

Idler Maintenance

Before doing electrical work on the idler printedcircuit board, disconnect the battery.------------------------------------------------------------------------When installing a new battery or using a jumper bat-tery to start the engine, be sure the battery polarity isconnected properly. The correct polarity is negativeground. Damage to the engine alternator and theprinted circuit board can result from incorrect connec-tion.

1. The solenoid plunger must work freely and notbind. Dust the plunger about once a year withgraphite powder.

2. Proper operation of the idler requires good ground-ing of the printed circuit board, reed switch, andbattery.

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 thismachine - or at least yearly - inspect all nameplatesand labels for legibility. Replace those which are nolonger clear. Refer to the parts list for the replace-ment item number.

Purging Air from Fuel System (Perkins104-22 Engine)

Keep fuel clear of open flames or arcs, allowengine to cool before working on the fuel system.Wipe up any spilled fuel and do not start engineuntil fumes clear.------------------------------------------------------------------------If the engine is running rough and you suspect air hasbeen trapped in the fuel system, (e.g. the engine wasallowed to run out of fuel) perform the following stepsusing 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 untilfuel, free of air, flows from the vent point. Tightenthe vent screw. If the pump is at the point of maxi-mum lift, it will not be possible to operate the prim-ing lever. If this occurs, turn the crankshaft onerevolution.

For Engines Equipped with an electric fuel pump:Operate the electric fuel pump by turning the“Ignition” switch “ON” until fuel, free of air, flowsfrom the vent point. Tighten the vent screw.

3. Contact your Perkins Engine repair facility if prob-lems persist.

CLASSIC 300D

CAUTION

WARNING

Vent Screw

PrimingLever

D-3D-3

CLASSIC 300D

MAINTENANCE

I

EVERY 400 HOURS OR 12 MONTHSEVERY 200 HOURS OR 6 MONTHS

EVERY 100 HOURS OR 3 MONTHSFIRST SERVICE-(20 / 50 HOURS)

EVERY DAY OR EVERY 8 HOURS

If necessary use shorter periods.These preventive maintenance periods apply to average conditions of operation.

Perkins #1300366120

TYPE OR QUANTITY

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

Perkins #140517000

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

8.7qrts, (8.2L) (including filter)

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

9.5qrts, (9.0L)

(1) Consult Engine Operators Manual for oil recommendations.NOTES:

Alternator drive belt Perkins # 080109080Alternator drive belt wear

R

Tension of alternator drive beltI

Drain water separator & fuel strainer

Engine oil (NOTE 1 & 3)

R

Engine oil level (NOTE 1)Coolant (NOTE 3)

MAINTENANCE ITEM

Concentration of antifreeze 50/50 Water/Ethylene Glycol

C

I

R

Coolant level

RC

RR

I

R

ENGINE SERVICE

I

EVERY 600 HOURS OR 18 MONTHS

Fuel filter canister

5/06S20919-2

BCI Group 24

Contact Perkins

Intake .008", exhaust .008"

Donaldson #P181050 or Nelson #70206N

R = ReplaceC = Clean

BatteryLeaks or engine damage

I

Injector performanceAll nuts and bolts for tightness

I = Inspect

Electrical systems

II

Valve clearancesI

Tighten cylinder head

I

I

Check and adjust idle speedI

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

RI

CC

Engine oil filter

ENGINE SERVICE (NOTE 2)

FOR CODES 10658 AND BELOW

D-4MAINTENANCED-4

CLASSIC 300D

I

EVERY 400 HOURS OR 12 MONTHSEVERY 200 HOURS OR 6 MONTHS

EVERY 100 HOURS OR 3 MONTHSFIRST SERVICE-(20 / 50 HOURS)

EVERY DAY OR EVERY 8 HOURS

Perkins #140517000

If necessary use shorter periods.These preventive maintenance periods apply to average conditions of operation.

Perkins #26560017

TYPE OR QUANTITY

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

9.5qrts., 9.0L

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

8.7qrts, 8.2L (including filter)

(2) Consult Engine Operators Manual for additional maintenance schedule information.(1) Consult Engine Operators Manual for oil recommendations.

Notes:

Alternator drive beltAlternator drive belt wear

R

Tension of alternator drive beltFuel filter canister

I

Drain water separator & fuel strainer

Engine oil (NOTE 1 & 3)

R

Engine oil level (NOTE 1)Coolant (NOTE 3)

MAINTENANCE ITEM

Concentration of antifreeze

C

I

R

Coolant level

RC

RR

I

R

ENGINE SERVICE

I

EVERY 600 HOURS OR 18 MONTHS

S25557

Contact Perkins

Intake .008", exhaust .008"

Donaldson #P181050, Nelson #70206N

R = ReplaceC = CleanBatteryLeaks or engine damage

I

Injector performanceAll nuts and bolts for tightness

I = Inspect

Electrical systems

II

Valve clearancesI

Tighten cylinder head

I

I

Check and adjust idle speedI

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

RI

CC

Engine oil filter

ENGINE SERVICE (NOTE 2)

50/50 Water/Ethylene Glycol

Perkins #080109080

FOR CODES 10911 AND ABOVE

D-5MAINTENANCED-5

GFCI RECEPTACLE TESTING AND RESET-TING PROCEDURE

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

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

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

• The equipment needs to be operating at high idlespeed and any necessary adjustments made on thecontrol panel so that the equipment is providing atleast 80 volts to the receptacle input terminals.

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

• 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 otherproduct (such as a lamp) into the GFCI receptacleand 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 otherproduct should go "ON" again.

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

CLASSIC 300D

E-1TROUBLESHOOTING

CLASSIC 300D

E-1

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

TROUBLESHOOTING

Have qualified personnel do the troubleshootingwork. Turn the engine off before working insidethe machine. In some cases, it may be neces-sary to remove safety guards to performrequired maintenance. Remove guards onlywhen necessary and replace them when themaintenance 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 coolingblower fan. If a problem cannot be corrected byfollowing the instructions, take the machine tothe nearest Lincoln Field Service Shop.

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








------------------------------------------------------------------------See additional warning information at thefront of this operator’s manual

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

WARNING

E-2TROUBLESHOOTING

CLASSIC 300D

E-2

WELDER TROUBLESHOOTINGTROUBLE CAUSES WHAT TO DO

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

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

c. Field circuit may have variable c. Check field current with ammeter toresistance connection or discover varying current. Thisintermittent open circuit due to applies to both the main generatorloose connection or broken wire. and exciter.

d. Electrode lead or work lead d. Tighten all connections.connection may be poor.

e. Wrong grade of brushes may e. Use Lincoln brushes.have been installed on generator.

f. Field rheostat may be making f. Inspect and clean the rheostat.poor contact and overheating.

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

tension.

b. Exciter may not be operating. b. Check exciter output voltage withvoltmeter or lamp.

c. Field circuit of generator or c. Check for open circuits in rheostat,exciter may be open. field leads, and field coils. Check

rectifier bridge.

d. Exciter may have lost excitation. d. Flash fields. (1) Check flashingdiode at 5 o’clock brushholder ingenerator.

e. Series field and armature circuit e. Check circuit with ringer or voltmeter.may be open-circuited.

(1) FLASHING THE FIELDS:

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

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

3. Using a 12 volt automotive battery, connect it’s negative terminal to the negative brushholder. The

negative brushholder is the one nearest to the rotor lamination. See the wiring diagram. With the

engine NOT running, touch the positive battery terminal to the positive brushholder. Remove the

battery from the circuit.

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

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

b. Polarity may be wrong. b. Check polarity. Try reversing polarity or try anelectrode of the opposite polarity.

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

b. Operating speed too low or too high. b. Adjust speed with screw stops at throttle linkage.(High idle - 1800 RPM, Low idle - 1375 RPM)

5. Arc continuously pops out. a. “Current Range Selector” switch may be a. Set the switch at the center of the current rangeset at an intermediate position. desired.

E-3TROUBLESHOOTING

CLASSIC 300D

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 Switchto the Auto Position

Check for Continuity through IdlerControl Switch

Open Closed

Measure DC Voltage on Replace IdlerIdler Solenoid Coil Control Switch

12 VDC 0 VDC

Check Continuity of Check for JammingReed Switch in Weld Circuit of the Idler Solenoid

Mechanism or a brokenReturn Spring

Open Closed

1. Check Wiring in Replace ReedIdler Solenoid SwitchCircuit

2. Replace IdlerP.C. Board


CAUTION

E-4TROUBLESHOOTING

CLASSIC 300D

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 CircuitDefective -- Will Not Close

To Check: Short the Red Leadon P.C. Board to Welder Frame.

The Auxiliary Power Load is Turned ON

Power Load Too Small Try Load Above 150 Watts

Engine Does Not Pick Up Speed

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

2. Check for Jamming of the IdlerSolenoid Mechanism.

3. Check for Continuity of CurrentTransformer (Toroid). Replace asRequired.

4. Check Idler Circuit Wiring and Repairas Required.

5. Replace Idler P.C. Board.

Engine Picks Up Speed

1. Check for Break inRed Lead and Repair

2. Replace Reed Switchin Weld Circuit.

Engine Does Not Pick UpSpeed

1. Check Continuity of IdlerSolenoid Coil (8.5-9.0ohms) and Replace asRequired.

2. Check for Jamming ofthe Idler SolenoidMechanism.

3. Check Idler CircuitWiring and Repair asRequired.

4. Replace Idler P.C.Board.


CAUTION

E-5TROUBLESHOOTING

CLASSIC 300D

E-5ENGINE TROUBLESHOOTING


CAUTION

TROUBLE CAUSES WHAT TO DO1. Engine does not start Faulty Ignition switch and or Injector pump solenoid Correct the connection and contact.

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

OFF & ON - See #4 Below.2. Irregular running of the engine Air mixed in the fuel system Bleed air (To be done by qualified personnel only)

Uneven fuel injection (Faulty fuel injector pump) Repair in an authorized service shop.Clogged fuel filter Replace.Defective governor Check and correct.Engine itself defective Repair in an authorized service shop.

3. Engine stops during operation Lack of fuel in the fuel tank Supply fuel and bleed air (To be done by qualified personnel only)and the Engine Protection light Clogged fuel filter Replace.does not turn on. Air mixed in the fuel system Bleed air (To be done by qualified personnel only)

Faulty function of the engine Repair in a service shop.4. Engine stops during operation a. Overheat of the Engine

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

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

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

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

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

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

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

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

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WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• 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

• World's Leader in Welding and Cutting Products •

im631

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