Lincoln Electric CLASSIC 300 D Operator's Manual
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Lincoln Electric CLASSIC 300 D Operator's Manual

Lincoln electric portable generator user manual
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RETURN TO MAIN MENU
IM631-B
CLASSIC
300 D
®
May, 2006
For Machines with Code Numbers 10545, 10546, 10657, 10658, 10911 and 10927
Safety Depends on You
Lincoln arc welding equipment
is designed and built with safety
in mind. However, your overall
safety can be increased by
proper installation ... and
thoughtful operation on your
part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT
WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
R
OPERATOR'S MANUAL
Copyright © 2006 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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  • Page 1 RETURN TO MAIN MENU IM631-B CLASSIC 300 D ® May, 2006 For Machines with Code Numbers 10545, 10546, 10657, 10658, 10911 and 10927 Safety Depends on You Lincoln arc welding equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...

  • Page 2: California Proposition 65 Warnings

    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.

  • Page 3: Fumes And Gases

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 The code number is especially important when identifying the correct replacement parts. - 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.

  • Page 7: Table Of Contents

    Troubleshooting ...Section E Safety Precautions...E-1 Welder Troubleshooting ...E-2 Electronic Idler Troubleshooting Guide...E-3,E-4 Engine Troubleshooting Guide ...E-5, E-6 ________________________________________________________________________ Diagrams ...Section F Wiring Diagram (Classic 300 D) ...F-1,F-2 Connection Diagram ...F-3 Dimension Print...F-4 ________________________________________________________________________ Parts List ...P337 Series TABLE OF CONTENTS Page...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS - CLASSIC 300D Make/Model Description Perkins 4 cylinder 104-22 Diesel 4 Cycle Engine 32.7 HP @ (Water Cooled) 1800 RPM WELDING OUTPUT* Current/Voltage/Duty Cycle 250A / 30V / 100% 300A / 32V / 60% HEIGHT WIDTH 45.50 in. 24.00 in.

  • Page 9: General Description

    Classic features such as improved door latches and stainless hinges. With the addition of the optional K623-1 Wire Feed Module ™ , the Classic 300 D will provide constant voltage output for running the LN-7, LN-23P, or LN-25 wire feeders. (The Wire Feed Module is factory installed on the K1643-2).

  • Page 10: Safety Precautions

    ---------------------------------------------------------------------- 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.

  • Page 11: Trailers

    TRAILER (See Optional Features) If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor dam- age the welding equipment. Some of the factors to be considered are as follows: 1.

  • Page 12: Battery Charging

    • To prevent BATTERY BUCKLING, tighten nuts on battery clamp until snug. ------------------------------------------------------------------------ The Classic 300 D is equipped with a wet charged battery. The charging current is automatically regulat- ed when the battery is low (after starting the engine) to a trickle current when the battery is fully charged.

  • Page 13: Engine Operation

    Operate the welder with the doors closed. Leaving the doors open changes the designed air flow and can cause overheating. Starting the Classic 300 D Perkins 104-22 Diesel Engine Turn the “IDLER” switch to “HIGH”. Turn the “IGNITION” switch to “ON”.

  • Page 14: Welder Operation

    ARC RAYS can burn. • Wear eye, ear, and body protection. Duty Cycle The NEMA output rating of the Classic 300 D is 300 amperes at 32 arc volts on a 60% duty cycle (consult Specifications in this manual for alternate ratings).

  • Page 15: Auxiliary Power

    OPERATION Auxiliary Power The AC auxiliary power, supplied as a standard, has a rating of 3.0 kVA of 115/230 VAC (60 hertz). With the 3.0 kVA, 115/230 VAC auxiliary power, one 115V duplex and one 230V duplex, grounding type receptacle are provided. The circuit is protected with circuit breakers.

  • Page 16: Optional Features (Field Installed

    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.
  • Page 17 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 installed on the K1643-2). LN-25 Wire Feeder K449-Portable CC/CV unit for flux-cored and MIG welding.

  • Page 18: Maintenance

    Cooling System The Classic 300 D is equipped with a pressure radia- tor. Keep the radiator cap tight to prevent loss of coolant. Clean and flush the cooling system periodi- cally to prevent clogging the passage and overheating the engine.

  • Page 19: Idler Maintenance

    Replace brushes when they wear within 1/4” of the pigtail. A complete set of replacement brushes should be kept on hand. Lincoln brushes have a curved face to fit the commutator. Have an experienced mainte- nance man seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact is made across the full face of the brushes.

  • Page 20: Engine Service Chart

    EVERY DAY OR EVERY 8 HOURS FIRST SERVICE-(20 / 50 HOURS) EVERY 100 HOURS OR 3 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 400 HOURS OR 12 MONTHS EVERY 600 HOURS OR 18 MONTHS ENGINE SERVICE (NOTE 2) MAINTENANCE ITEM Coolant level Concentration of antifreeze Coolant (NOTE 3)
  • Page 21 EVERY DAY OR EVERY 8 HOURS FIRST SERVICE-(20 / 50 HOURS) EVERY 100 HOURS OR 3 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 400 HOURS OR 12 MONTHS EVERY 600 HOURS OR 18 MONTHS ENGINE SERVICE (NOTE 2) MAINTENANCE ITEM Coolant level Concentration of antifreeze Coolant (NOTE 3)

  • Page 22: Gfci Receptacle Testing And Resetting Procedure

    GFCI RECEPTACLE TESTING AND RESET- TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage.

  • Page 23: Troubleshooting

    TROUBLESHOOTING 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.

  • Page 24: Welder Troubleshooting

    WELDER TROUBLESHOOTING TROUBLE Machine fails to hold the output (heat) consistently. Welder starts but fails to generate current. FLASHING THE FIELDS: Stop the engine welder and remove the cover from the exciter. Turn the “Fine Current Adjustment” (rheostat) to “100” on the dial. Using a 12 volt automotive battery, connect it’s negative terminal to the negative brushholder.

  • Page 25: Electronic Idler Troubleshooting Guide

    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 Open Measure DC Voltage on Idler Solenoid Coil 12 VDC Check Continuity of Reed Switch in Weld Circuit Mechanism or a broken...
  • Page 26 ELECTRONIC IDLER TROUBLESHOOTING GUIDE With Idler Control Switch in the AUTO Position, 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 1.

  • Page 27: Engine Troubleshooting Guide

    TROUBLE Engine does not start Faulty Ignition switch and or Injector pump solenoid Insufficient charging or complete discharge of the battery Lack of fuel Air mixed in the fuel system Clogged fuel filter Irregular and faulty fuel supply (Injector pump trouble) Glow plug not heated Improper viscosity of the lubricating oil Clogged air cleaner...

  • Page 28: Wiring Diagram

    DIAGRAMS CLASSIC 300D...
  • Page 29 DIAGRAMS CLASSIC 300D...

  • Page 30: K2464-1 Remote Control Wiring/Connection Diagram

    K2464-1 REMOTE CONTROL WIRING / CONNECTION DIAGRAM RESISTORS REMOTE CONTROL BOX DIAGRAMS CV "WIRE" CONTROL POT CC "STICK CONTROL BLUE ORANGE CONNECT TO CASE CLASSIC 300D CABLE CONNEC TION TABLE LEAD COLOR ORANGE BLUE WHITE JUMPER WHITE JUMPER S26097...

  • Page 31: Diagrams

    DIAGRAMS CLASSIC 300D...
  • Page 32 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 33 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 34 • 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...

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