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Lincoln Electric IM843-C manual

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Table of contents for the manual

  • Page 1

    CLA SSIC ® 300D KUBO T A OPERA TOR’S MANUAL For Machines with Code Numbers 11112, 11113, 11243, 11244, 11413, 11414, 11474, 11475 IM843-C November, 2008 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 o[...]

  • Page 2

    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. ________________________________________________[...]

  • Page 3

    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 sk[...]

  • Page 4

    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 manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical[...]

  • Page 5

    iv SAFETY iv Mar. ʻ93 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 LʼArc 1. Protegez-vous contre la secousse électrique: a. Les c[...]

  • Page 6

    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[...]

  • Page 7

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

  • Page 8

    INST ALLA TION CLASSIC 300D KUBOTA A-1 A-1 TECHNICAL SPECIFICA TIONS - CLASSIC 300D KUBOT A Make/Model Description Speed (RPM) Displacement Starting Capacities System 4 Cylinder 4 Cycle 134.1 cu. in 12VDC battery Fuel: 15 gal. Naturally Aspirated (2.2 ltrs) (Group 24, 650 57 L Kubota Water-Cooled High Idle 1800 cold crank amps) V2203M Diesel Engine[...]

  • Page 9

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

  • Page 10

    A-3 INST ALLA TION CLASSIC 300D KUBOTA A-3 PRE-OPERA TION INST ALLA TION EXHAUST SP ARK 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 qu[...]

  • Page 11

    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 t[...]

  • Page 12

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

  • Page 13

    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 300D KUBOTA V2203M 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 [...]

  • Page 14

    B-2 OPERA TION B-2 CLASSIC 300D KUBOTA WELDER OPERA TION ------------------------------------------------------------------------ DUTY CYCLE The NEMA output rating of the CLASSIC 300D KUB- OTA is 300 amperes at 32 arc volts on a 60% duty cycle (consult Specifications in this manual for alter- nate ratings). Duty cycle is based on a ten minute perio[...]

  • Page 15

    B-3 OPERA TION B-3 CLASSIC 300D KUBOTA IDLER OPERATION Start the engine with the “Idler” switch in the “High” position. Allow it to run at high idle speed for several minutes to warm the engine. See Specifications for operating speeds. The idler is controlled by the “Idler” toggle switch on the welder control panel. The switch has two p[...]

  • Page 16

    C-1 ACCESSORIES C-1 CLASSIC 300D KUBOTA 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. -----[...]

  • Page 17

    C-2 ACCESSORIES C-2 WIRE FEED OPTIONS Wire Feed Module (K623-1) - Provides constant voltage (CV) output with improved arc stability for Innershield welding. Excellent for MIG welding. Recommended wire feeders are the LN-7, LN-23P and LN-25. (Factory installed on the K1643-6). LN-25 Wire Feeder (K449)- Portable CC/CV unit for flux-cored and MIG weld[...]

  • Page 18

    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 locations, this cleaning may be necessary once a week. Use low pressure air to avoid driving dirt into the insulation. 2. “Current Range Selector” contacts should not be greased. To keep[...]

  • Page 19

    D-2 MAINTENANCE D-2 Replace brushes when they wear within 1/4”(3.5mm) 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 experi- enced maintenance man seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact[...]

  • Page 20

    D-3 D-3 CLASSIC 300D KUBOTA MAINTENANCE If necessary use shorter periods. These prevent ive maintenance perio ds apply t o average conditions of operat ion. Above operat ions to be carried out by t rained personnel wit h reference to the w orkshop manual where necess ary. (3) Fill slowly! Ensure correct quantity is used. (2) Consult Engine Op erato[...]

  • Page 21

    D-4 MAINTENANCE D-4 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,[...]

  • Page 22

    E-1 TROUBLESHOOTING CLASSIC 300D KUBOTA 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 This Troubleshooting Guide is provided to help you locate and rep[...]

  • Page 23

    E-2 TROUBLESHOOTING E-2 CLASSIC 300D KUBOTA Observe all Safety Guidelines detailed throughout this manual 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 PRO[...]

  • Page 24

    E-3 TROUBLESHOOTING CLASSIC 300D KUBOTA 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 Ch[...]

  • Page 25

    With Idler Control Switch in the AUTO Position, Engine Will Not Pick Up Speed When: The Arc is Struck Both Auxiliary Load 1 . Check Idler circuit wiring. Possible Problems are wires from Current Sensing Board reversed at idler switch or wires connected incorrectly at Current Sensor Molex plug. 2. Check voltage across idler control switch. 12V 0V Re[...]

  • Page 26

    E-5 TROUBLESHOOTING E-5 CLASSIC 300D KUBOTA Observe all Safety Guidelines detailed throughout this manual 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 PRO[...]

  • Page 27

    E-6 TROUBLESHOOTING E-6 CLASSIC 300D KUBOTA Observe all Safety Guidelines detailed throughout this manual 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 LIG[...]

  • Page 28

    E-7 TROUBLESHOOTING E-7 CLASSIC 300D KUBOTA Observe all Safety Guidelines detailed throughout this manual 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 PRO[...]

  • Page 29

    F-1 DIAGRAMS F-1 CLASSIC 300D KUBOTA 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[...]

  • Page 30

    F-2 DIAGRAMS F-2 CLASSIC 300D KUBOTA 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[...]

  • Page 31

    F-3 DIAGRAMS F-3 CLASSIC 300D KUBOTA 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[...]

  • Page 32

    CLASSIC 300D KUBOTA F-4 DIAGRAMS F-4 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[...]

  • Page 33

    F-5 DIAGRAMS F-5 CLASSIC 300D KUBOTA[...]

  • Page 34

    F-6 DIAGRAMS F-6 CLASSIC 300D KUBOTA 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[...]

  • Page 35

    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 P ARA EL [...]

  • Page 36

    W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO 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 [...]

  • Page 37

    • 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 •[...]