Instruction/ maintenance manual of the product CLASSIC SVM194-A Lincoln Electric
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SVM194-A October , 2009 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by proper installation .
CLASSIC® 300D & 300G SAFETY i i FOR ENGINE powered equipment. 1.a. T urn 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.
CLASSIC® 300D & 300G SAFETY ii ii FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone.
CLASSIC® 300D & 300G SAFETY iii iii Jan ʻ09 FOR ELECTRICALL Y powered equipment. 8.a. T urn 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 ʼs recommendations.
CLASSIC® 300D & 300G SAFETY iv 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 L ʼArc 1.
SAFETY v v CLASSIC® 300D & 300G Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC).
SAFETY vi vi CLASSIC® 300D & 300G Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
- MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - I I CLASSIC® 300D & 300G Page S a f e t y ........................................................................... i - i v I n s t a l l a t i o n .................................................
T ABLE OF CONTENTS - INST ALLA TION SECTION A1.1 A1.1 CLASSIC® 300D & 300G I n s t a l l a t i o n ............................................................................. A 1 T e c h n i c a l S p e c i f i c a t i o n s ...................
INST ALLA TION A1.2 A1.2 CLASSIC® 300D & 300G * Based on a 10 min. period. (1) 1 15V 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 V olts High Idle (1800 RPM)-No Load @ 96.
INST ALLA TION A1.3 A1.3 CLASSIC® 300D & 300G GENERAL DESCRIPTION The Classic ® 300 D is a heavy duty , engine driven, DC arc welding power source, capable of providing con- stant current output for stick welding or DC TIG weld- ing.
INST ALLA TION A1.4 A1.4 CLASSIC® 300D & 300G 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.
INST ALLA TION A1.5 A1.5 CLASSIC® 300D & 300G PRE-OPERA TION SERVICE 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.
INST ALLA TION A1.6 A1.6 CLASSIC® 300D & 300G ENGINE BREAK-IN Lincoln Electric selects high quality , heavy-duty indus- trial engines for the portable welding machines we offer .
T ABLE OF CONTENTS - OPERA TION SECTION B1.1 B1.1 CLASSIC® 300D & 300G O p e r a t i o n .............................................................................. B 1 E n g i n e O p e r a t i o n ............................................
OPERA TION B1.2 B1.2 CLASSIC® 300D & 300G 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 Perkins 104-22 Diesel Engine 1. T urn the “IDLER” switch to “HIGH”.
OPERA TION B1.3 B1.3 CLASSIC® 300D & 300G 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).
OPERA TION B1.4 B1.4 CLASSIC® 300D & 300G AUXILIAR Y POWER The AC auxiliary power , supplied as a standard, has a rating of 3.0 kV A of 1 15/230 V AC (60 hertz). With the 3.0 kV A, 1 15/230 V AC auxiliary power , one 1 15V duplex and one 230V duplex, grounding type receptacle are provided.
T ABLE OF CONTENTS - ACCESSORIES SECTION C1.1 C1.1 CLASSIC® 300D & 300G A c c e s s o r i e s ............................................................................ C 1 O p t i o n s .........................................................
ACCESSORIES C1.2 C1.2 CLASSIC® 300D & 300G 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 .
ACCESSORIES C1.3 C1.3 CLASSIC® 300D & 300G Wire Feed Module (K623-1) - Provides constant volt- age (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.
NOTES C1.4 C1.4 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
T ABLE OF CONTENTS - MAINTENANCE SECTION D1.1 D1.1 CLASSIC® 300D & 300G Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1 Maintenance .
MAINTENANCE D1.2 D1.2 CLASSIC® 300D & 300G 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.
MAINTENANCE D1.3 D1.3 CLASSIC® 300D & 300G Replace brushes when they wear within 1/4” of the pig- tail. A complete set of replacement brushes should be kept on hand.
MAINTENANCE D1.4 D1.4 CLASSIC® 300D & 300G I EVERY 400 HOURS OR 12 MONTHS EVERY 200 HOURS OR 6 MONTHS E VERY 100 HOURS OR 3 MONTHS F IRST 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.
MAINTENANCE D1.5 D1.5 CLASSIC® 300D & 300G I EVERY 400 HOURS OR 12 MONTHS E VERY 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.
MAINTENANCE D1.6 D1.6 CLASSIC® 300D & 300G GFCI RECEPT ACLE TESTING AND RESETTING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. T o proper- ly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage.
MAINTENANCE D1.7 D1.7 CLASSIC® 300D & 300G FIGURE D1.7 - MAJOR COMPONENT LOCA TION 1. Case Front Assembly 2. Engine Assembly 3. Radiator Assembly 4. Fuel T ank & Mounting 5. Base & Lift Bale Assembly 6. Welding Generator & Coupling (1 of 2) 7.
NOTES D1.8 D1.8 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
T ABLE OF CONTENTS - INST ALLA TION SECTION A2.1 A2.1 CLASSIC® 300D & 300G Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2 T echnical Specifications .
INST ALLA TION A2.2 A2.2 CLASSIC® 300D & 300G TECHNICAL SPECIFICA TIONS - CLASSIC® 300D PERKINS Make/Model Description Speed (RPM) Displacement Starting Capacities System 4 Cylinder 135.6 cu. in 12VDC battery Fuel: 15 gal. 4 Cycle (2.2 ltrs) (Group 24, 650 57 L.
INST ALLA TION A2.3 A2.3 CLASSIC® 300D & 300G GENERAL DESCRIPTION The Classic® 300D Perkins is a heavy duty , engine dri- ven, DC arc welding power source, capable of provid- ing constant current output for stick welding or DC TIG welding.
INST ALLA TION A2.4 A2.4 CLASSIC® 300D & 300G 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.
INST ALLA TION A2.5 A2.5 CLASSIC® 300D & 300G PRE-OPERA TION SERVICE 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.
INST ALLA TION A2.6 A2.6 CLASSIC® 300D & 300G BA TTER Y CHARGING The Classic® 300D Perkins is equipped with a wet charged battery . The charging current is automatically regulated when the battery is low (after starting the engine) to a trickle current when the battery is fully charged.
T ABLE OF CONTENTS - OPERA TION SECTION B2.1 B2.1 CLASSIC® 300D & 300G Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2 Engine Operation .
OPERA TION B2.2 B2.2 CLASSIC® 300D & 300G ENGINE OPERA TION Operate the welder with the doors closed. Leaving the doors open changes the designed air flow and can cause overheating. ST ARTING THE CLASSIC® 300D PERKINS 404C-22 DIESEL ENGINE 1. T urn the “IDLER” switch to “HIGH”.
OPERA TION B2.3 B2.3 CLASSIC® 300D & 300G ENGINE BREAK-IN Lincoln Electric selects high quality , heavy-duty industrial engines for the portable welding machines we offer .
OPERA TION B2.4 B2.4 CLASSIC® 300D & 300G AUXILIAR Y POWER If a GFCI receptacle is tripped, See the MAINTE- NANCE section for detailed information on testing and resetting the GFCI receptacle. The AC auxiliary power , supplied as a standard, has a rating of 3.
T ABLE OF CONTENTS - ACCESSORIES SECTION C2.1 C2.1 CLASSIC® 300D & 300G Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2 Options .
ACCESSORIES C2.2 C2.2 CLASSIC® 300D & 300G 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 .
ACCESSORIES C2.3 C2.3 CLASSIC® 300D & 300G WIRE FEEDER OPTIONS Wire Feed Module K623-1 Provides constant voltage (CV) output with improved arc stability for Innershield welding. Excellent for MIG welding. Recommended wire feeders are the LN-7, LN-23P and LN-25.
NOTES C2.4 C2.4 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
T ABLE OF CONTENTS - MAINTENANCE SECTION D2.1 D2.1 CLASSIC® 300D & 300G Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2 Safety Precautions .
MAINTENANCE D2.2 D2.2 CLASSIC® 300D & 300G SAFETY PRECAUTIONS 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.
MAINTENANCE D2.3 D2.3 CLASSIC® 300D & 300G Replace brushes when they wear within 1/4” of the pig- tail. A complete set of replacement brushes should be kept on hand.
MAINTENANCE D2.4 D2.4 CLASSIC® 300D & 300G I EVERY 500 HOURS OR 12 MON THS EVERY 250 HOURS OR 6 MONTHS EVERY 100 HOURS OR 3 MONTHS FIRST SERVICE-(20 / 50 H OURS) EVERY DAY OR EVERY 8 HOURS Perkins #140517050 If necessary use s h orter p eriods. These preventive m aintenance periods apply t o av erage conditions of operatio n.
MAINTENANCE D2.5 D2.5 CLASSIC® 300D & 300G SERVICE DECAL FOR CODES 1 1250 AND ABOVE Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Re.
MAINTENANCE D2.6 D2.6 CLASSIC® 300D & 300G 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. T o proper- ly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage.
MAINTENANCE D2.7 D2.7 CLASSIC® 300D & 300G FIGURE D2.7 - MAJOR COMPONENT LOCA TION 1. Case Front Assembly 2. Engine Assembly 3. Radiator Assembly 4. Fuel T ank & Mounting 5. Base & Lift Bale Assembly 6. Exciter & Stator 7. Welding Generator & Coupling 8.
NOTES D2.8 D2.8 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
T ABLE OF CONTENTS - INST ALLA TION SECTION A3.1 A3.1 CLASSIC® 300D & 300G Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3 T echnical Specifications .
INST ALLA TION A3.2 A3.2 CLASSIC® 300D & 300G 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.
INST ALLA TION A3.3 A3.3 CLASSIC® 300D & 300G GENERAL DESCRIPTION The CLASSIC ® 300D KUBOT A is a heavy duty , engine driven, DC arc welding power source, capable of pro- viding constant current output for stick welding or DC TIG welding.
INST ALLA TION A3.4 A3.4 CLASSIC® 300D & 300G 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 oper- ated in certain locations where unarrested sparks may pre- sent a fire hazard.
INST ALLA TION A3.5 A3.5 CLASSIC® 300D & 300G PRE-OPERA TION SERVICE 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.
INST ALLA TION A3.6 A3.6 CLASSIC® 300D & 300G Battery Charging The CLASSIC® 300D KUBOT A is equipped with a wet charged battery . The charging current is automatically regulated when the battery is low (after starting the engine) to a trickle current when the battery is fully charged.
T ABLE OF CONTENTS - OPERA TION SECTION B3.1 B3.1 CLASSIC® 300D & 300G Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3 Engine Operation .
OPERA TION B3.2 B3.2 CLASSIC® 300D & 300G ENGINE OPERA TION Operate the welder with the doors closed. Leaving the doors open changes the designed air flow and can cause overheating. ST ARTING THE CLASSIC® 300D KUBOT A V2203M DIESEL ENGINE 1. T urn the “IDLER” switch to “HIGH”.
OPERA TION B3.3 B3.3 CLASSIC® 300D & 300G WELDER OPERA TION ------------------------------------------------------------------------ DUTY CYCLE The NEMA output rating of the CLASSIC® 300D KUB- OT A is 300 amperes at 32 arc volts on a 60% duty cycle (consult Specifications in this manual for alternate ratings).
OPERA TION B3.4 B3.4 CLASSIC® 300D & 300G IDLER OPERA TION 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.
T ABLE OF CONTENTS - ACCESSORIES SECTION C3.1 C3.1 CLASSIC® 300D & 300G Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3 Options .
ACCESSORIES C3.2 C3.2 CLASSIC® 300D & 300G 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 .
ACCESSORIES C3.3 C3.3 CLASSIC® 300D & 300G WIRE FEED OPTIONS Wire Feed Module (K623-1) - Provides constant volt- age (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.
NOTES C3.4 C3.4 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
T ABLE OF CONTENTS - MAINTENANCE SECTION D3.1 D3.1 CLASSIC® 300D & 300G Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3 Maintenance .
MAINTENANCE D3.2 D3.2 CLASSIC® 300D & 300G 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.
MAINTENANCE D3.3 D3.3 CLASSIC® 300D & 300G Replace brushes when they wear within 1/4”(3.5mm) of the pigtail. A complete set of replacement brushes should be kept on hand.
MAINTENANCE D3.4 D3.4 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC If ne ce ss ary use s ho rter period s.
MAINTENANCE D3.5 D3.5 CLASSIC® 300D & 300G 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. T o proper- ly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage.
MAINTENANCE D3.6 D3.6 CLASSIC® 300D & 300G FIGURE D3.6 - MAJOR COMPONENT LOCA TION 1. Case Front Assembly 2. Engine Assembly 3. Radiator Assembly 4. Fuel T ank & Mounting 5. Base & Lift Bale Assembly 6. Exciter and Stator 7. Welding Generator & Coupling (2 of 2) 8.
T ABLE OF CONTENTS - INST ALLA TION SECTION A4.1 A4.1 CLASSIC® 300D & 300G Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4 T echnical Specifications .
INST ALLA TION A4.2 A4.2 CLASSIC® 300D & 300G TECHNICAL SPECIFICA TIONS - CLASSIC® 300D PERKINS Make/Model Description Speed (RPM) Displacement Starting Capacities System 4 Cylinder 135 cu. in 12VDC battery Fuel: 15 gal. 4 Cycle (2.2 ltrs) (Group 24, 650 57 L.
INST ALLA TION A4.3 A4.3 CLASSIC® 300D & 300G GENERAL DESCRIPTION The Classic® 300D Perkins is a heavy duty , engine dri- ven, DC arc welding power source, capable of provid- ing constant current output for stick welding or DC TIG welding.
INST ALLA TION A4.4 A4.4 CLASSIC® 300D & 300G 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.
INST ALLA TION A4.5 A4.5 CLASSIC® 300D & 300G PRE-OPERA TION SERVICE READ the engine operating and maintenance instructions 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.
INST ALLA TION A4.6 A4.6 CLASSIC® 300D & 300G BA TTER Y CHARGING The Classic® 300D Perkins is equipped with a wet charged battery . The charging current is automatically regulated when the battery is low (after starting the engine) to a trickle current when the battery is fully charged.
T ABLE OF CONTENTS - OPERA TION SECTION B4.1 B4.1 CLASSIC® 300D & 300G Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4 Engine Operation .
OPERA TION B4.2 B4.2 CLASSIC® 300D & 300G ENGINE OPERA TION Operate the welder with the doors closed. Leaving the doors open changes the designed air flow and can cause overheating. ST ARTING THE CLASSIC® 300D PERKINS 404D-22 DIESEL ENGINE 1. T urn the “IDLER” switch to “HIGH”.
OPERA TION B4.3 B4.3 CLASSIC® 300D & 300G ENGINE BREAK-IN Lincoln Electric selects high quality , heavy-duty industrial engines for the portable welding machines we offer .
OPERA TION B4.4 B4.4 CLASSIC® 300D & 300G AUXILIAR Y POWER If a GFCI receptacle is tripped, See the MAINTE- NANCE section for detailed information on testing and resetting the GFCI receptacle. The AC auxiliary power , supplied as a standard, has a rating of 3.
T ABLE OF CONTENTS - ACCESSORIES SECTION C4.1 C4.1 CLASSIC® 300D & 300G Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4 Optional Features .
ACCESSORIES C4.2 C4.2 CLASSIC® 300D & 300G 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 .
ACCESSORIES C4.3 C4.3 CLASSIC® 300D & 300G WIRE FEEDER OPTIONS Wire Feed Module K623-1 Provides constant voltage (CV) output with improved arc stability for Innershield welding. Excellent for MIG welding. Recommended wire feeders are the LN-7, LN-23P and LN-25.
NOTES C4.4 C4.4 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
T ABLE OF CONTENTS - MAINTENANCE SECTION D4.1 D4.1 CLASSIC® 300D & 300G Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4 Safety Precautions .
MAINTENANCE D4.2 D4.2 CLASSIC® 300D & 300G SAFETY PRECAUTIONS 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.
MAINTENANCE D4.3 D4.3 CLASSIC® 300D & 300G Replace brushes when they wear within 1/4” of the pig- tail. A complete set of replacement brushes should be kept on hand.
MAINTENANCE D4.4 D4.4 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC R.
MAINTENANCE D4.5 D4.5 CLASSIC® 300D & 300G 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. T o proper- ly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage.
MAINTENANCE D4.6 D4.6 CLASSIC® 300D & 300G FIGURE D4.6 - MAJOR COMPONENT LOCA TION 1. Case Front Assembly 2. Engine Assembly 3. Radiator Assembly 4. Fuel T ank & Mounting 5. Base & Lift Bale Assembly 6. Exciter & Stator 7. Welding Generator & Coupling 8.
T ABLE OF CONTENTS - INST ALLA TION SECTION A5.1 A5.1 CLASSIC® 300D & 300G Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5 T echnical Specifications .
INST ALLA TION A5.2 A5.2 CLASSIC® 300D & 300G TECHNICAL SPECIFICA TIONS – CLASSIC® 300G (K1754-1) DC CURRENT RANGE Fine Adjustment in each Range 40-350 Amps DUTY CYCLE 100% 60% RA TED DC OUTPUT* VOL TS @ RA TED AMPS 30V @ 250A NEMA Rating 32V @ 300A (1) 115V will operate either 60 Hz.
INST ALLA TION A5.3 A5.3 CLASSIC® 300D & 300G 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.
INST ALLA TION A5.4 A5.4 CLASSIC® 300D & 300G PRE-OPERA TION SERVICE 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.
INST ALLA TION A5.5 A5.5 CLASSIC® 300D & 300G BA TTER Y CHARGING The Classic® 300G is equipped with a wet charged battery . The charging current is automatically regulated when the battery is low (after starting the engine) to a trickle current when the battery is fully charged.
NOTES A5.6 A5.6 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
T ABLE OF CONTENTS - OPERA TION SECTION B5.1 B5.1 CLASSIC® 300D & 300G Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5 Safety Precautions .
OPERA TION B5.2 B5.2 CLASSIC® 300D & 300G SAFETY PRECAUTIONS Operate the welder with the doors closed. Leaving the doors open changes the designed air flow and can cause overheating.
OPERA TION B5.3 B5.3 CLASSIC® 300D & 300G • When hauling the welder between job sites, close the fuel feed valve beneath the fuel tank. • If the fuel supply is cut off or runs out while the fuel pump is operating, air may be entrapped in the fuel distribution system.
AUXILIAR Y POWER The AC auxiliary power , supplied as a standard, has a rating of 3.0 kV A of 1 15/230 V AC (60 hertz). With the 3.0 kV A, 1 15/230 V AC auxiliary power , one 1 15V duplex and one 230V duplex, grounding type receptacle are provided. The circuit is protected with circuit breakers.
T ABLE OF CONTENTS - ACCESSORIES SECTION C5.1 C5.1 CLASSIC® 300D & 300G Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C5 Optional Equipment .
ACCESSORIES C5.2 C5.2 CLASSIC® 300D & 300G OPTIONAL EQUIPMENT (Field Installed) Accessory Set (K704) - Includes 35 ft. (10.7m) elec- trode and 30 ft. (9.1m) work cables, headshield, work clamp and electrode holder . Pipe Thawing with an arc welder can cause fire, explosion, damage to electric wiring or to the arc welder i f done improperly .
T ABLE OF CONTENTS - MAINTENANCE SECTION D5.1 D5.1 CLASSIC® 300D & 300G Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5 Safety Precautions .
MAINTENANCE D5.2 D5.2 CLASSIC® 300D & 300G SAFETY PRECAUTIONS GENERAL INSTRUCTIONS • 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.
MAINTENANCE D5.3 D5.3 CLASSIC® 300D & 300G Replace brushes when they wear within 1/4” of the pig- tail. A complete set of replacement brushes should be kept on hand.
MAINTENANCE D5.4 D5.4 CLASSIC® 300D & 300G EN GINE S ERVICE E V ER Y D A Y O R E V E RY 8 H O U RS FIR ST S E R VICE - (50 H O U R S ) E V E R Y 1 0 0 H O U R S O R 3 M O N T H S E V E R Y 2 0 0 .
MAINTENANCE D5.5 D5.5 CLASSIC® 300D & 300G FIGURE D5.5 - MAJOR COMPONENT LOCA TION 1. Case Front Assembly 2. Engine Assembly 3. Radiator Assembly 4. Fuel T ank & Mounting 5. Base & Lift Bale Assembly 6. Exciter and Stator 7. Welding Generator & Coupling (2 of 2) 8.
NOTES D5.6 D5.6 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 CLASSIC® 300D & 300G Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 General Description .
THEOR Y OF OPERA TION E-2 E-2 CLASSIC® 300D & 300G GENERAL DESCRIPTION The Classic® 300 welding machines are heavy duty , engine driven DC arc welding power sources capable of providing con stant current output for stick welding or DC TIG welding.
THEOR Y OF OPERA TION E-3 E-3 CLASSIC® 300D & 300G NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion FIGURE E.2 - GENERAL DESCRIPTION (Classic® 300D, Perkins Engine) + - .
THEOR Y OF OPERA TION E-4 E-4 CLASSIC® 300D & 300G BA TTER Y , ST ARTER, ENGINE, AL TERNA TOR & PROTECTION CIRCUITS The 12VDC battery powers the starter motor and, through the ignition switch, the engine protection cir- cuitry .
THEOR Y OF OPERA TION E-5 E-5 CLASSIC® 300D & 300G + - N EGA TIVE O UTPUT T ERMINAL P OSITIVE OUTPUT TERMINAL S ELECTOR S WITCH G ENERA TOR FRAME A L TERNA TOR ST AT OR R OT AT OR F IELD R ECTIFI.
THEOR Y OF OPERA TION E-6 E-6 CLASSIC® 300D & 300G ENGINE, GENERA TOR ARMA TURE AND FRAME, AL TERNA TOR ST A- T OR AND ROTOR EXCIT A TION (FLASHING) When the engine is started and running, voltag.
THEOR Y OF OPERA TION E-7 E-7 CLASSIC® 300D & 300G FIGURE E.8 - CLASSIC® 300D, PERKINS ENGINE + - N EGA TIVE O UTPUT T ERMINAL P OSITIVE OUTPUT T ERMINAL SELECTOR SWITCH G ENERA TOR FRAME AL TER.
THEOR Y OF OPERA TION E-8 E-8 CLASSIC® 300D & 300G FIGURE E.7 - CLASSIC® 300G, ZENITH FUEL SYSTEM / GM ENGINE NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion Classic® .
THEOR Y OF OPERA TION E-9 E-9 CLASSIC® 300D & 300G ENGINE IDLER CIRCUIT Classic® 300G (Codes 10659, 10912, and 1 1 135) The Zenith ECU used in the Classic® 300G con- trols whether the engine operates at high idle or low idle.
THEOR Y OF OPERA TION E-10 E-10 CLASSIC® 300D & 300G When the idle switch is in the auto position, and welding current is being drawn, the reed switch CR2 is closed. This signals the idler PC board to deactivate the idle solenoid, allowing t he governor to increase the engine speed to high RPM.
THEOR Y OF OPERA TION E-11 E-11 CLASSIC® 300D & 300G DC GENERA TOR MACHINES The armature winding of a DC generator is located on the rotating member . Current is conducted from it by means of carbon brushes. The field winding is located in the stator , which is stationary , and is excited by direct current.
NOTES E-12 E-12 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
TROUBLESHOOTING AND REP AIR F-1 F-1 CLASSIC® 300D & 300G T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1 How to Use T roubleshooting Guide .
TROUBLESHOOTING AND REP AIR F-2 F-2 CLASSIC® 300D & 300G This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”.
TROUBLESHOOTING AND REP AIR F-3 F-3 CLASSIC® 300D & 300G Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
WELDING PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not un.
WELDING PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not un.
WELDING PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not un.
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not u.
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not u.
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not u.
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not u.
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not u.
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not u.
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not u.
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not u.
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not u.
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not u.
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not u.
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
BRUSH & SLIP RING SERVICE PROCEDURE (continued) (Exciter/Auxiliary Power Alternator) TROUBLESHOOTING AND REP AIR F-24 F-24 CLASSIC® 300D & 300G PROCEDURE 1. Remove the round end cover from the exciter . 2. Examine brushes, slip rings and brush holder .
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
ENGINE AL TERNA TOR TEST PROCEDURE (continued) PROCEDURE 1. Locate the engine alternator . NOTE: Secure the door in the open position using the door restraint system. If the machine does not have a door restraint system, remove the door(s) or securely restrain them to prevent them from falling closed.
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
ENGINE FUEL SYSTEM VOL T AGE TEST PROCEDURE (continued) PROCEDURE 1. Open and secure the side door . NOTE: Secure the doors in the open position using the door restraint system. If the machine does not have a door restraint system, remove the doors or securely restrain them to prevent them from falling closed.
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
ENGINE PROTECTION SYSTEM TEST PROCEDURE (continued) PROCEDURE 1. Open the side doors on the Classic® 300 machine. NOTE: Secure the doors in the open position using the door restraint system. If the machine does not have a door restraint system, remove the doors or securely restrain them to prevent them from falling closed.
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
ENGINE RPM ADJUSTMENT TEST PROCEDURE (continued) PROCEDURE 1. T urn the engine off. 2. Place the RPM adjustment potentiometer or "Custom Arc" control to maximum (Classic® 300G and Classic® 300D Kubota models only .) 3. Open the side door .
ENGINE RPM ADJUSTMENT TEST PROCEDURE (continued) ENGINE RPM ADJUSTMENT PROCEDURE Classic® 300G and Classic® 300D (Kubota) have electronic engine RPM control. Both high and low RPM are programmed into the engine control mod- ule and cannot be adjusted.
NOTES F-34 F-34 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
FLASHING VOL T AGE TEST PROCEDURE (continued) PROCEDURE 1. Remove the cover from the exciter / auxiliary power alternator . 2. Connect the volt meter probes to the brush ter- minals. See the wiring diagram. 3. Remove one of the AC input leads from the field bridge rectifier .
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
ROCKER DRILL MARKS EX CITER BR ACKET FIGURE F .1 – F ACTOR Y SET POINT DRILL MARK LOCA TIONS ROCKER ADJUSTMENT PROCEDURE (continued) PROCEDURE When the rocker is set for the first time at the fac- tory , a 1/8" drill is used to mark the position of both the rocker and the exciter bracket.
Check that the brush holders are properly installed and positioned correctly . See the Welding Generator Brush and Commutator Inspection and Service procedure. Start the engine, place the idle switch in the high idle position, and seat the brushes using a com- mutator stone.
NOTES F-40 F-40 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
FIGURE F .2 – LEAD LOCA TION EXCITER ROTOR RESIST ANCE AND GROUND TESTS PROCEDURE (Exciter / Auxiliary Power Alternator) (continued) PROCEDURE "Static" T ests: 1. Turn the engine off. 2. Remove the round cover from the exciter / aux- iliary power alternator .
EXCITER ROTOR RESIST ANCE AND GROUND TESTS PROCEDURE (Exciter / Auxiliary Power Alternator) (continued) 7. Insulate the lead wires that had been discon- nected from the brushes during the static rotor resistance test. Position and secure them so they cannot become damaged by the spinning rotor .
NOTES F-44 F-44 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
SHUNT FIELD COIL RESIST ANCE AND GROUND TEST PROCEDURE (continued) PROCEDURE 1. Turn the engine off. 2. Open either or both of the doors on the machine.
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
SHUNT FIELD CIRCUIT VOL T AGE TEST PROCEDURE (continued) PROCEDURE 1. Turn the engine off. 2. Open either or both of the side doors. NOTE: Secure the doors in the open position using the door restraint system. If the machine does not have a door restraint system, remove the doors or securely restrain them to prevent them from falling closed.
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
EXCITER ST A TOR SHORT CIRCUIT & GROUND TEST PROCEDURE (continued) PROCEDURE 1. Open either , or both of the side doors. Note: Secure the doors in the open position using the door restraint system. If the machine does not have a door restraint system, remove the doors or securely restrain them to prevent them from falling closed.
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST PROCEDURE (continued) PROCEDURE 1. Turn the engine off. Weld circuit ground test: 2. Measure the resistance between either of the two weld output terminals and a clean chassis ground connection. The resistance measurement should be very high 500,000 (500k) Ohms minimum.
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
WELDING GENERA TOR BRUSH AND COMMUT A TOR INSPECTION AND SER VICE PROCEDURE (continued) PROCEDURE 1. Shut off the engine. 2. Open either , or both of the side doors of the Classic® 300 machine. NOTE: Secure the doors in the open position using the door restraint system.
WELDING GENERA TOR BRUSH AND COMMUT A TOR INSPECTION AND SER VICE PROCEDURE (continued) Pitted and Are Damaged Commutator: If pitting and arc damage to the commutator is evi- dent, the machine may have been used with badly worn brushes. The brush spring tension may have been too low , or the brushes may have been stick- ing in the holders.
NOTES F-56 F-56 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
SERIES COIL SHORT CIRCUIT TEST PROCEDURE (continued) PROCEDURE 1. Place the current range switch in the Max posi- tion, connect the Classic® 300 to a load bank and start the engine. 2. Apply a load of 250 amps and allow the machine to reach normal operating tempera- ture, (about 30 minutes) 3.
TROUBLESHOOTING AND REP AIR F-59 F-59 CLASSIC® 300D & 300G This is the typical auxiliary output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division rep- resents 5 milliseconds in time.
TROUBLESHOOTING AND REP AIR F-60 F-60 CLASSIC® 300D & 300G This is the typical DC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 50 volts and that each horizontal division represents 5 milliseconds in time.
This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time. The machine was loaded with a resistance grid bank.
NOTES F-62 F-62 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
AL TERNA TOR ROTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-64 F-64 CLASSIC® 300D & 300G FIGURE F .4 – BA TTERY P ANEL REMOV AL NEGA TIVE BATTERY CABLE BA TTER Y MOUNTING PANEL PROCEDURE 1. T urn the engine off.
AL TERNA TOR ROTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-65 F-65 CLASSIC® 300D & 300G FIGURE F .5 – AL TERNA TOR COVER AND WRAP AROUND REMOV AL AL TERNA T OR CO VER BR USHES WRAP AROUND SLIP RINGS See Figure F .
TROUBLESHOOTING AND REP AIR F-66 F-66 CLASSIC® 300D & 300G AL TERNA TOR ROTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) FIGURE F .6 – ROTOR REMOV AL STATOR FRAME NUT SLEEVE COLLAR "BENT" WASHER BRUSH HOLDER ASSEMBLY See Figure F .
AL TERNA TOR ROTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-67 F-67 CLASSIC® 300D & 300G Replacement 9. Carefully mount the rotor onto the generator shaft. Install a new sleeve collar (part num- ber T14337), washer , and rotor locking nut.
NOTES F-68 F-68 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
AL TERNA TOR ST A TOR REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING AND REP AIR F-70 F-70 CLASSIC® 300D & 300G FIGURE F .7 – COMMUT A TOR WRAP-AROUND REMOV AL PROCEDURE 1. T urn the engine OFF . 2. Perform the Alternato r Rotor Removal procedure.
AL TERNA TOR ST A TOR REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING AND REP AIR F-71 F-71 CLASSIC® 300D & 300G FIGURE F .8 - LEAD DISCONNECTION POINTS YELLO W AND WHITE WIRE IN-LINE CONNECT ORS; YELLO W LEADS; BLACK CURRENT TRANSFORMER LEAD ALL LOCA TED BEHIND CASE FRONT FIGURE F .
AL TERNA TOR ST A TOR REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING AND REP AIR F-72 F-72 CLASSIC® 300D & 300G 13. Clear the leads in preparation for remov- ing the stator/end bracket. 14. Lift the eight brushes from the commuta- tor . Note the position of the brushes for reassembly .
AL TERNA TOR ST A TOR REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING AND REP AIR F-73 F-73 CLASSIC® 300D & 300G FIGURE F .11 - DRILL SPOT LOCA TIONS BRUSH HOLDER DRILL SPOT LOCATION STATOR/END BRACKET MOUNTING BOLT STATOR END BRACKET DRILL SPOT 16.
NOTES F-74 F-74 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
GENERA TOR FRAME REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING AND REP AIR F-76 F-76 CLASSIC® 300D & 300G FIGURE F .12 – FUEL T ANK / OUTPUT CABLE REMOV AL FUEL BOWL COPPER STRAP POSITIVE CABLE FUEL LINE FUEL T ANK MOUNTING HARDW ARE FUEL T ANK RETURN LINE (DIESEL ONL Y) PROCEDURE 1.
GENERA TOR FRAME REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING AND REP AIR F-77 F-77 CLASSIC® 300D & 300G See Figure F .13 for steps 10 - 13. 10. Cut all necessary cable ties. 1 1. Disconnect the blue and the brown wires at the in- line connectors.
GENERA TOR FRAME REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING AND REP AIR F-78 F-78 CLASSIC® 300D & 300G See Figure F .14 for steps 14 - 16. 14. With the 9/16" wrench, remove the four bolts and lock washers holding the case front to the welder frame.
GENERA TOR FRAME REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING AND REP AIR F-79 F-79 CLASSIC® 300D & 300G FIGURE F .15 – FRAME MOUNTING DET AILS ENGINE/GENERATOR MOUNTING HOLES ROPE SLING See Figure F .
GENERA TOR FRAME REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING AND REP AIR F-80 F-80 CLASSIC® 300D & 300G 27. Re-attach the positive output terminal cable. 28. Set the fuel tank into position on the rails and secure it with the four bolts, washers, and nuts.
Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
PROCEDURE 1. T urn the engine OFF . 2. Perform the Alternator Rotor Removal pro- cedure. 3. Perform the Alternator Stator Removal pro- cedure. 4. Perform the Generator Frame Removal pro- cedure. 5. Using the rope sling, support the armature. 6. Make sure the engine is supported with the wood or steel blocks.
TROUBLESHOOTING AND REP AIR F-83 F-83 CLASSIC® 300D & 300G RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machineʼs electrical characteristics.
NOTES F-84 F-84 CLASSIC® 300D & 300G Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return .
T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 CLASSIC® 300D & 300G Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram (Codes 10545, 10546, 10657, 10658) (L10877) .
ELECTRICAL DIAGRAMS G-2 CLASSIC® 300D & 300G WIRING DIAGRAM - CODES 10545, 10546, 10657, 10658) (L10877) CONTRO L PANE L COMPONENT S LEAD C OLO R CODE B R + - + - Y R W B B S LI P R INGS T O I RO.
ELECTRICAL DIAGRAMS G-3 CLASSIC® 300D & 300G WIRING DIAGRAM - (CODE 10659) (L1 1 194) CO NTROL P AN EL COM P ON E NTS B R + - + - Y R W B B SLI P RIN GS TO IR ON A 54 3 2 1 ALTE RN ATO R AUX ILI .
ELECTRICAL DIAGRAMS G-4 CLASSIC® 300D & 300G WIRING DIAGRAM - (CODES 1091 1, 10927) (L1 1865) C L11865 CON TRO L P ANE L COM PON EN TS L EA D C OL OR C OD E 6 10A 60 0C + - + - 8 10 820 1 1B B SL.
ELECTRICAL DIAGRAMS G-5 CLASSIC® 300D & 300G WIRING DIAGRAM - (CODES 10912, 1 1 135) (L1 1866) L11866 CLAS SI C 30 0G WI RI NG DI AGRAM B CONTROL PAN EL COMPONENT S B R + - + - Y R W B B SLIP RIN.
ELECTRICAL DIAGRAMS G-6 CLASSIC® 300D & 300G WIRING DIAGRAM - (CODES 1 1 1 10, 1 1 1 11) (M20499) WI RE F EED MOD ULE ( OPTIONAL) 608 609 CLAS SIC 300D PERKINS W I RING DIAGRA M B M204 99 PLUG P5 INLINE CONNECTORS W .F .M. CONTROL PANEL CONNEC T TO POS .
ELECTRICAL DIAGRAMS G-7 CLASSIC® 300D & 300G WIRING DIAGRAM - (CODES 1 1 1 12, 1 1 1 13) (M20432) S B WI RE F EED MOD ULE ( OPTIONAL) 608 609 + CLAS SIC 300D KUBOTA W IRING DIAGRA M NEGA TI VE (CC -) 67B A M204 32 PLUG P5 INLINE CONNECTORS W .F .
ELECTRICAL DIAGRAMS G-8 CLASSIC® 300D & 300G WIRING DIAGRAM - (CODES 1 1243, 1 1244) (M20432-1) S B WI RE F EED MOD ULE ( OPTIONAL) 608 609 + CLAS SIC 300D KUBOTA W IRING DIAGRA M NEGA TI VE (CC -) 67B B M204 32-1 PLUG P5 INLINE CONNECTORS W .F .
ELECTRICAL DIAGRAMS G-9 CLASSIC® 300D & 300G WIRING DIAGRAM - (CODES 1 1248, 1 1249, 1 1280, 1 1281) (M20616) WI RE F EED MOD ULE ( OPTIONAL) 608 609 CLAS SIC 300D PERKINS W I RING DIAGRA M B M206 16 PLUG P5 INLINE CONNECTORS W .F .M. CONTROL PANEL CONNEC T TO POS .
ELECTRICAL DIAGRAMS G-10 CLASSIC® 300D & 300G WIRING DIAGRAM - (CODES 1 141 1, 1 1412) (M21292) WI RE F EED MOD ULE ( OPTIONAL) 608 609 CLAS SIC 300D PERKINS W I RING DIAGRA M A M212 92 PLUG P5 INLINE CONNECTORS W .F .M. CONTROL PANEL CONNEC T TO POS .
ELECTRICAL DIAGRAMS G-11 CLASSIC® 300D & 300G WIRING DIAGRAM - (CODES 1 1413, 1 1414) (M21293) S B WI RE F EED MOD ULE ( OPTIONAL) 608 609 + CLAS SIC 300D KUBOTA W IRING DIAGRA M NEGA TI VE (CC -) 67B A M212 93 PLUG P5 INLINE CONNECTORS W .F .M. CONTROL PANEL CONNEC T TO POS .
ELECTRICAL DIAGRAMS G-12 CLASSIC® 300D & 300G WIRING DIAGRAM - (CODES 1 1472, 1 1473) (M21684) WI RE F EED MOD ULE ( OPTIONAL) 608 609 CLAS SIC 300D PERKINS W I RING DIAGRA M A M216 84 PLUG P5 INLINE CONNECTORS W .F .M. CONTROL PANEL CONNEC T TO POS .
ELECTRICAL DIAGRAMS G-13 CLASSIC® 300D & 300G WIRING DIAGRAM - (CODES 1 1474, 1 1475) (M21563) S B WI RE F EED MOD ULE ( OPTIONAL) 608 609 + CLAS SIC 300D KUBOTA W IRING DIAGRA M NEGA TI VE (CC -) 67B A M215 63 PLUG P5 INLINE CONNECTORS W .F .M. CONTROL PANEL CONNEC T TO POS .
ELECTRICAL DIAGRAMS G-14 CLASSIC® 300D & 300G SCHEMA TIC - COMPLETE MACHINE - (CODES 11 1 10, 1 1 1 1 1) (L12412) L12412 CLASSIC 300D PE RKINS 404C-22 MACHINE SCHEMATI C NA L12020 DM / DFM J. STAPP U NLESS OTHERW ISE SPE C IF IE D TOLERA N CE MANUFACTURIN G TOLERANCE PER E2056 ON 2 PLACE DECIMA LS IS ± .
ELECTRICAL DIAGRAMS G-15 CLASSIC® 300D & 300G SCHEMA TIC - COMPLETE MACHINE - (CODES 11 1 12, 1 1 1 13) (L12265) OIL PRESSURE SWI TCH / SENDER TEMPERATURE SWITCH / SENDER W G TEMPERATURE G AUGE S.
ELECTRICAL DIAGRAMS G-16 CLASSIC® 300D & 300G SCHEMA TIC - COMPLETE MACHINE - (CODES 11243, 1 1244) (L12265-1) OIL PRESSURE SWI TCH / SENDER TEMPERATURE SWITCH / SENDER AMMETER + - ENGINE CONTROL.
ELECTRICAL DIAGRAMS G-17 CLASSIC® 300D & 300G SCHEMA TIC - COMPLETE MACHINE - (CODES 11248, 1 1249, 1 1280, 1 1281) (L12561) L12561 CLASSIC 300D PE RKINS 404C-22 MACHINE SCHEMATI C NA L12412 DFM N. T AYLOR U NLESS OTHERW ISE SPE C IF IE D TOLERA N CE MANUFACTURIN G TOLERANCE PER E2056 ON 2 PLACE DECIMA LS IS ± .
ELECTRICAL DIAGRAMS G-18 CLASSIC® 300D & 300G SCHEMA TIC - COMPLETE MACHINE - (CODES 1141 1, 1 1412) (L13096) L13096 CLASSIC 300D PE RKINS 404C-22 MACHINE SCHEMATI C NA L12561 Ma gl ietta D. BENDER U NLESS OTHERW ISE SPE C IF IE D TOLERA N CE MANUFACTURIN G TOLERANCE PER E2056 ON 2 PLACE DECIMA LS IS ± .
ELECTRICAL DIAGRAMS G-19 CLASSIC® 300D & 300G SCHEMA TIC - COMPLETE MACHINE - (CODES 11413, 1 1414) (L13097) OIL PRESSURE SWI TCH / SENDER TEMPERATURE SWITCH / SENDER W G TEMPERATURE GAUGE S I G .
ELECTRICAL DIAGRAMS G-20 CLASSIC® 300D & 300G SCHEMA TIC - COMPLETE MACHINE - (CODES 11472, 1 1473) (L13672) L13672 C LASS IC 300 D( PE R KI NS MACHIN E SCHEM ATI C NO NE L13096 DO N OT S CA LE T.
ELECTRICAL DIAGRAMS G-21 CLASSIC® 300D & 300G SCHEMA TIC - COMPLETE MACHINE - (CODES 11474, 1 1475) (L13351) L13351 C LASS IC 300 D K UB OTA MACHIN E SCHEM ATI C NO NE L13097 DO N OT S CA LE TH I.
ELECTRICAL DIAGRAMS G-22 CLASSIC® 300D & 300G WIRING DIAGRAM - WIRE FEED MODULE OPTION - (L9259) L 9259 AM PHENOL 1 A D F 510 602 610A 503A 609 501 CO NTA CT OR CO NTA CT OR ++ + 622 666 633 75A .
ELECTRICAL DIAGRAMS G-23 CLASSIC® 300D & 300G SCHEMA TIC - WIRE FEED MODULE OPTION - (G2562) G-23 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS G-24 CLASSIC® 300D & 300G SCHEMA TIC - IDLER (CODES 10545, 10546, 10657, 10658, 10911, 10927) - (L10826) G-24 NOTE: This diagram is for reference only .
ELECTRICAL DIAGRAMS G-25 CLASSIC® 300D & 300G SCHEMA TIC - IDLER (CODES 11 110 THRU 1 1475 PERKINS ENGINE ONL Y) - (G4828) G-25 NOTE: This diagram is for reference only .
ELECTRICAL DIAGRAMS G-26 CLASSIC® 300D & 300G SCHEMA TIC - CURRENT SENSOR PC BD (KUBOTA ENGINE ONL Y) - (S25973) G-26 NOTE: This diagram is for reference only .
An important point after buying a device Lincoln Electric CLASSIC SVM194-A (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lincoln Electric CLASSIC SVM194-A yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lincoln Electric CLASSIC SVM194-A - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric CLASSIC SVM194-A you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric CLASSIC SVM194-A will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric CLASSIC SVM194-A, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric CLASSIC SVM194-A.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric CLASSIC SVM194-A. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric CLASSIC SVM194-A along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
