Lincoln Electric CLASSIC 300 D manual

CLA SSIC ® 300 D OPERA TOR’S MANUAL For Machines with Code Numbers 10545, 10546, 10657, 10658, 10911 and 10927 IM631-B May, 2006 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 INST[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

iv SAFETY iv Mar. ‘93 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. Les[...]

v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to 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 it handy for quick reference. Pay[...]

vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 General Description .........................................................[...]

A-1 INST ALLA TION 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 DA T A Low Idle (1375 RPM)-No Load @ 45 Volts High Idle (1800 RPM)-No Load @ 96.6 Volts 50 Amps @ 22 Volts 100 Amps @ 24 [...]

A-2 INST ALLA TION CLASSIC 300D A-2 GENERAL DESCRIPTION The Classic ® 300 D is a heavy duty, engine driven, DC arc welding power source, capable of providing constant current output for stick welding or DC TIG welding. This welder is wound with all copper coils, rated at 300 amps/32 Volts, and provides other Classic features such as improved door [...]

A-3 INST ALLA TION CLASSIC 300D A-3 PRE-OPERA TION INST ALLA TION 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[...]

PRE-OPERA TION SER VICE READ the engine operating and maintenance instruc- tions supplied with this machine. ----------------------------------------------------------------------- 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 te[...]

A-5 INST ALLA TION CLASSIC 300D A-5 Battery Charging The Classic 300 D is equipped with a wet charged battery. The charging current is automatically regulat- ed when the battery is low (after starting the engine) to a trickle current when the battery is fully charged. When replacing, jumping or otherwise connecting the battery to the battery cables[...]

B-1 OPERA TION B-1 ENGINE OPERA TION 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 1. Turn the “IDLER” switch to “HIGH”. 2. Turn the “IGNITION” switch to “ON”. 3. Press the Glow Plug button for 20 to 30[...]

B-2 OPERA TION B-2 CLASSIC 300D WELDER OPERA TION 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). 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 [...]

B-3 OPERA TION B-3 CLASSIC 300D Auxiliary Power The AC auxiliary power, supplied as a standard, has a rating of 3.0 kVA of 115/230 VAC (60 hertz). With the 3.0 kVA, 115/230 VAC auxiliary power, one 115V duplex and one 230V duplex, grounding type receptacle are provided. The circuit is protected with circuit breakers. The rating of 3.0 kVA permits a[...]

C-1 ACCESSORIES C-1 CLASSIC 300D OPTIONAL FEA TURES (Field Installed) GENERAL OPTIONS 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. ------------[...]

C-2 ACCESSORIES C-2 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. Includes Gas So[...]

D-1 MAINTENANCE D-1 MAINTENANCE General Instructions 1. Blow out the welder and controls with an air hose at least once every two months. In particularly dirty loca- tions, this cleaning may be necessary once a week. Use low pressure air to avoid driving dirt into the insu- lation. 2. “Current Range Selector” contacts should not be greased. To [...]

D-2 MAINTENANCE D-2 Replace brushes when they wear within 1/4” of the pigtail. A complete set of replacement brushes should be kept on hand. Lincoln brushes have a curved face to fit the commutator. Have an experienced mainte- nance man seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact is mad[...]

D-3 D-3 CLASSIC 300D MAINTENANCE I EVERY 400 HOURS OR 12 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 100 HOURS OR 3 MONTHS FIRST 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 [...]

D-4 MAINTENANCE D-4 CLASSIC 300D I EVERY 400 HOURS OR 12 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 100 HOURS OR 3 MONTHS FIRST SERVICE-(20 / 50 HOURS) EVERY DAY OR EVERY 8 HOURS Perkins #140517000 If necessary use shorter periods. These preventive maintenance periods apply to av erage conditions of operation. Perkins #26560017 TYPE OR QUANTITY Above[...]

D-5 MAINTENANCE D-5 GFCI RECEPT ACLE 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. • If the equipment has been shut down,[...]

E-1 TROUBLESHOOTING 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 your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION TROUBLESHOOTING Have qualified personnel do the troubleshooting work. Tu[...]

E-2 TROUBLESHOOTING CLASSIC 300D E-2 WELDER TROUBLESHOOTING TROUBLE CAUSES WHA T TO DO 1. Machine fails to hold a. Rough or dirty commutator. a. Commutator should be turned or the 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 to r[...]

E-3 TROUBLESHOOTING 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 Switch to the Auto Position Check for Continuity through Idler Control Switch Open Closed Measure D[...]

E-4 TROUBLESHOOTING 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 Circuit Defective -- Will Not Close To Check: Short the Red Lead on P.C. Board to Welder Frame. The Auxiliary Power Load is Turned ON Power Load Too Sma[...]

E-5 TROUBLESHOOTING CLASSIC 300D E-5 ENGINE TROUBLESHOOTING 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. CAUTION TROUBLE CAUSES WHA T TO DO 1. Engine does not sta[...]

F-1 DIAGRAMS F-1 CLASSIC 300D CONTROL PANEL COMPON ENTS LEAD COLOR CODE B R + - + - Y R W B B SLIP RINGS TO IRON R N A 54 32 1 ALTERNATOR AUXILIAR Y POWER WINDINGS CURRENT TRANSFORMER CB3 CB1 115 VOLT RECEPTACLE 230 VOLT RECEPTACLE Y NEGATIVE SELECTOR SW ITCH WE LDER LEAD BLOCK AC AC CR2 REED RELAY 42 602A G U CB2 CB4 FUSE 15A. 1 2 3 4 5 6 7 8 9 10[...]

F-2 DIAGRAMS F-2 CLASSIC 300D NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number[...]

F-3 DIAGRAMS F-3 CLASSIC 300D S26097 A RESIST ORS Y X B G W F G ORANGE WHITE JUMPER WHITE JUMPER PIN CA BLE CONNEC TION TABLE C D E LEAD COLOR RED BLUE CV "WIRE" CONTROL POT CCW BLUE RED ORANGE REMOTE CONTROL BOX C ONNECT TO CASE K2 46 4 -1 REMOTE CONT ROL WIRI NG / CONNECT I ON DI AGRAM CC "STICK CONTROL[...]

F-4 DIAGRAMS F-4 CLASSIC 300D A A A A 18.50 20.62 A A 40.94 A A 24.00 A A 37.12 A A F A A G A A B A H A A D A A A A 23.00 A A A A A A C 4.00 4.00 .56 SKID O MOUNT ING HOLE O .56 SKID MOUNTI NG HOLE N.A. N.B. NOTES: OIL AND W ATER IN ENGINE, BUT NO FUEL. N.A. CENTER OF GRAVITY W IT H O N.B. .56 T RAILER MO UNTING HOLES. J A A K S10766 S107 66- 6, - [...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE PARA EL U[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes fro[...]

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