Lincoln-electric CLASSIC SVM194-A User Manual

SVM194-AOctober, 2009Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However,your overall safe

INSTALLATIONA1.2 A1.2CLASSIC® 300D & 300G* Based on a 10 min. period.(1) 115V will operate either 60 Hz. or 50/60 Hz. power tools, lights etc.(2)

OPERATIONB5.2 B5.2CLASSIC® 300D & 300GSAFETY PRECAUTIONSOperate the welder with the doors closed. Leaving thedoors open changes the design

OPERATIONB5.3 B5.3CLASSIC® 300D & 300G• When hauling the welder between job sites, close thefuel feed valve beneath the fuel tank. • If the fuel

AUXILIARY POWERThe AC auxiliary power, supplied as a standard, has arating of 3.0 kVA of 115/230 VAC (60 hertz).With the 3.0 kVA, 115/230 VAC au

TABLE OF CONTENTS - ACCESSORIES SECTIONC5.1 C5.1CLASSIC® 300D & 300GAccessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIESC5.2 C5.2CLASSIC® 300D & 300GOPTIONAL EQUIPMENT (Field Installed)Accessory Set (K704) - Includes 35 ft. (10.7m) elec-trode and 30 ft.

TABLE OF CONTENTS - MAINTENANCE SECTIOND5.1 D5.1CLASSIC® 300D & 300GMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCED5.2 D5.2CLASSIC® 300D & 300GSAFETY PRECAUTIONSGENERAL INSTRUCTIONS• Blow out the welder and controls with an air hose atleast once

MAINTENANCED5.3 D5.3CLASSIC® 300D & 300GReplace brushes when they wear within 1/4” of the pig-tail. A complete set of replacement brushes should

MAINTENANCED5.4 D5.4CLASSIC® 300D & 300G ENGINE SERVICEEVERY DAY OR EVERY 8 HOURSFIRST SERVICE - (50 HOURS)EVERY 100 HOURS OR 3 MONTHSEV

MAINTENANCED5.5 D5.5CLASSIC® 300D & 300GFIGURE D5.5 - MAJOR COMPONENT LOCATION1. Case Front Assembly2. Engine Assembly3. Radiator Assembly4. F

INSTALLATIONA1.3 A1.3CLASSIC® 300D & 300GGENERAL DESCRIPTIONThe Classic®300 D is a heavy duty, engine driven, DCarc welding power source, capable

NOTESD5.6 D5.6CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

TABLE OF CONTENTS-THEORY OF OPERATION SECTIONE-1 E-1CLASSIC® 300D & 300GTheory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .

THEORY OF OPERATIONE-2 E-2CLASSIC® 300D & 300GGENERAL DESCRIPTIONThe Classic® 300 welding machines are heavy duty,engine driven DC arc weld

THEORY OF OPERATIONE-3 E-3CLASSIC® 300D & 300GNOTE: Unshaded areas of Block LogicDiagram are the subject of discussionFIGURE E.2 - GENERAL DESCRIP

THEORY OF OPERATIONE-4 E-4CLASSIC® 300D & 300GBATTERY, STARTER, ENGINE,ALTERNATOR & PROTECTION CIRCUITSThe 12VDC battery powers the sta

THEORY OF OPERATIONE-5 E-5CLASSIC® 300D & 300G+-NEGATIVEOUTPUTTERMINALPOSITIVEOUTPUTTERMINALSELECTORSWITCHGENERATORFRAMEALTERNATOR STATORROTATORFI

THEORY OF OPERATIONE-6 E-6CLASSIC® 300D & 300GENGINE, GENERATOR ARMATUREAND FRAME, ALTERNATOR STA-TOR AND ROTOREXCITATION (FLASHING)When the

THEORY OF OPERATIONE-7 E-7CLASSIC® 300D & 300GFIGURE E.8 - CLASSIC® 300D, PERKINS ENGINE+-NEGATIVEOUTPUTTERMINALPOSITIVEOUTPUTTERMINALSELECTORSWIT

THEORY OF OPERATIONE-8 E-8CLASSIC® 300D & 300GFIGURE E.7 - CLASSIC® 300G, ZENITH FUEL SYSTEM / GM ENGINENOTE: Unshaded areas of Block LogicDiagram

THEORY OF OPERATIONE-9 E-9CLASSIC® 300D & 300GENGINE IDLER CIRCUITClassic® 300G (Codes 10659, 10912, and11135)The Zenith ECU used in the Clas

INSTALLATIONA1.4 A1.4CLASSIC® 300D & 300GPRE-OPERATION INSTALLATIONExhaust Spark ArresterSome federal, state or local laws may require thatengines

THEORY OF OPERATIONE-10 E-10CLASSIC® 300D & 300GWhen the idle switch is in the auto position, andwelding current is being drawn, the reed s

THEORY OF OPERATIONE-11 E-11CLASSIC® 300D & 300GDC GENERATOR MACHINESThe armature winding of a DC generator is located onthe rotating member. C

NOTESE-12 E-12CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

TROUBLESHOOTING AND REPAIRF-1 F-1CLASSIC® 300D & 300GTroubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING AND REPAIRF-2 F-2CLASSIC® 300D & 300GThis Troubleshooting Guide is provided tohelp you locate and repair possible machinemalf

TROUBLESHOOTING AND REPAIRF-3 F-3CLASSIC® 300D & 300GSometimes machine failures appear to be due to PCboard failures. These problems can so

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

INSTALLATIONA1.5 A1.5CLASSIC® 300D & 300GPRE-OPERATION SERVICEREAD the engine operating and maintenance instruc-tions supplied with this machine.-

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

WELDING PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURS

WELDING PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURS

WELDING PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURS

FUNCTION PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOUR

FUNCTION PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOUR

FUNCTION PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOUR

FUNCTION PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOUR

FUNCTION PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOUR

FUNCTION PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOUR

INSTALLATIONA1.6 A1.6CLASSIC® 300D & 300GENGINE BREAK-INLincoln Electric selects high quality, heavy-duty indus-trial engines for the portable wel

FUNCTION PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOUR

FUNCTION PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOUR

FUNCTION PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOUR

FUNCTION PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOUR

FUNCTION PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOUR

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

BRUSH & SLIP RING SERVICE PROCEDURE (continued)(Exciter/Auxiliary Power Alternator)TROUBLESHOOTING AND REPAIRF-24 F-24CLASSIC® 300D & 300GPROC

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

ENGINE ALTERNATOR TEST PROCEDURE (continued)PROCEDURE1. Locate the engine alternator.NOTE: Secure the door in the open position usingthe door restr

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

TABLE OF CONTENTS - OPERATION SECTIONB1.1 B1.1CLASSIC® 300D & 300GOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE FUEL SYSTEM VOLTAGE TEST PROCEDURE (continued)PROCEDURE1. Open and secure the side door.NOTE: Secure the doors in the open position usingthe

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

ENGINE PROTECTION SYSTEM TEST PROCEDURE (continued)PROCEDURE1. Open the side doors on the Classic® 300machine.NOTE: Secure the doors in the op

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

ENGINE RPM ADJUSTMENT TEST PROCEDURE (continued)PROCEDURE1. Turn the engine off.2. Place the RPM adjustment potentiometer or"Custom Arc&q

ENGINE RPM ADJUSTMENT TEST PROCEDURE (continued)ENGINE RPM ADJUSTMENT PROCEDUREClassic® 300G and Classic® 300D (Kubota) haveelectronic engine RPM cont

NOTESF-34 F-34CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

FLASHING VOLTAGE TEST PROCEDURE (continued)PROCEDURE1. Remove the cover from the exciter / auxiliarypower alternator.2. Connect the volt mete

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

OPERATIONB1.2 B1.2CLASSIC® 300D & 300GENGINE OPERATIONOperate the welder with the doors closed. Leaving thedoors open changes the designed air flo

ROCKERDRILL MARKSEXCITER BRACKETFIGURE F.1 – FACTORY SET POINT DRILL MARK LOCATIONSROCKER ADJUSTMENT PROCEDURE (continued)PROCEDUREWhen the rocker is

Check that the brush holders are properly installedand positioned correctly. See the WeldingGenerator Brush and Commutator Inspectionand Serv

NOTESF-40 F-40CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

FIGURE F.2 – LEAD LOCATIONEXCITER ROTOR RESISTANCE AND GROUND TESTS PROCEDURE(Exciter / Auxiliary Power Alternator) (continued)PROCEDURE"Static&q

EXCITER ROTOR RESISTANCE AND GROUND TESTS PROCEDURE(Exciter / Auxiliary Power Alternator) (continued)7. Insulate the lead wires that had been

NOTESF-44 F-44CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

SHUNT FIELD COIL RESISTANCE AND GROUND TESTPROCEDURE (continued)PROCEDURE1. Turn the engine off.2. Open either or both of the doors on thema

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

OPERATIONB1.3 B1.3CLASSIC® 300D & 300GWELDER OPERATIONDuty CycleThe NEMA output rating of the Classic® 300 D is 300amperes at 32 arc volts ona 60%

SHUNT FIELD CIRCUIT VOLTAGE TEST PROCEDURE (continued)PROCEDURE1. Turn the engine off.2. Open either or both of the side doors.NOTE: Secure the d

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

EXCITER STATOR SHORT CIRCUIT & GROUND TEST PROCEDURE(continued)PROCEDURE1. Open either, or both of the side doors.Note: Secure the doors in the o

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST PROCEDURE(continued)PROCEDURE1. Turn the engine off.Weld circuit ground test:2. Measure the resistance

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

WELDING GENERATOR BRUSH AND COMMUTATOR INSPECTION AND SERVICE PROCEDURE (continued)PROCEDURE1. Shut off the engine.2. Open either, or both of t

WELDING GENERATOR BRUSH AND COMMUTATOR INSPECTION AND SERVICE PROCEDURE (continued)Pitted and Are Damaged Commutator:If pitting and arc damage to the

NOTESF-56 F-56CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

OPERATIONB1.4 B1.4CLASSIC® 300D & 300GAUXILIARY POWERThe AC auxiliary power, supplied as a standard, has arating of 3.0 kVA of 115/230 VAC (60 her

SERIES COIL SHORT CIRCUIT TEST PROCEDURE (continued)PROCEDURE1. Place the current range switch in the Max posi-tion, connect the Classic® 300 to a

TROUBLESHOOTING AND REPAIRF-59 F-59CLASSIC® 300D & 300GThis is the typical auxiliary outputvoltage generated from a properlyoperating machine. No

TROUBLESHOOTING AND REPAIRF-60 F-60CLASSIC® 300D & 300GThis is the typical DC output voltagegenerated from a properly operatingmachine. Note that

This is the typical DC output voltagegenerated from a properly operatingmachine. Note that each verticaldivision represents 20 volts and thateach hor

NOTESF-62 F-62CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

ALTERNATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued)TROUBLESHOOTING AND REPAIRF-64 F-64CLASSIC® 300D & 300GFIGURE F.4 – BATTERY PANEL RE

ALTERNATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued)TROUBLESHOOTING AND REPAIRF-65 F-65CLASSIC® 300D & 300GFIGURE F.5 – ALTERNATOR COVER

TROUBLESHOOTING AND REPAIRF-66 F-66CLASSIC® 300D & 300GALTERNATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued)FIGURE F.6 – ROTOR REMOVALSTA

ALTERNATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued)TROUBLESHOOTING AND REPAIRF-67 F-67CLASSIC® 300D & 300GReplacement9. Carefully mount

TABLE OF CONTENTS - ACCESSORIES SECTIONC1.1 C1.1CLASSIC® 300D & 300GAccessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTESF-68 F-68CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-70 F-70CLASSIC® 300D & 300GFIGURE F.7 – COMMUTATOR WRAP-AROUND RE

ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-71 F-71CLASSIC® 300D & 300GFIGURE F.8 - LEAD DISCONNECTION POINTS

ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-72 F-72CLASSIC® 300D & 300G13. Clear the leads in preparation fo

ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-73 F-73CLASSIC® 300D & 300GFIGURE F.11 - DRILL SPOT LOCATIONSBRUS

NOTESF-74 F-74CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

GENERATOR FRAME REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-76 F-76CLASSIC® 300D & 300GFIGURE F.12 – FUEL TANK / OUTPUT CABLE R

GENERATOR FRAME REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-77 F-77CLASSIC® 300D & 300GSee Figure F.13 for steps 10 - 13.10. C

CLASSIC® 300D & 300GSAFETYi iFOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenanc

ACCESSORIESC1.2 C1.2CLASSIC® 300D & 300GOPTIONAL FEATURES (Field Installed)GENERAL OPTIONSPipe Thawing with an arc welder can cause fire,explosion

GENERATOR FRAME REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-78 F-78CLASSIC® 300D & 300GSee Figure F.14 for steps 14 - 16.14. W

GENERATOR FRAME REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-79 F-79CLASSIC® 300D & 300GFIGURE F.15 – FRAME MOUNTING DETAILSENGI

GENERATOR FRAME REMOVAL AND REPLACEMENT (continued)TROUBLESHOOTING AND REPAIRF-80 F-80CLASSIC® 300D & 300G27. Re-attach the positive output termi

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

PROCEDURE1. Turn the engine OFF.2. Perform the Alternator Rotor Removal pro-cedure.3. Perform the Alternator Stator Removal pro-cedure.4. Perform

TROUBLESHOOTING AND REPAIRF-83 F-83CLASSIC® 300D & 300GRETEST AFTER REPAIRRetest a machine:• If it is rejected under test for any reason that req

NOTESF-84 F-84CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

TABLE OF CONTENTS - DIAGRAM SECTIONG-1 G-1CLASSIC® 300D & 300GElectrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL DIAGRAMSG-2CLASSIC® 300D & 300GWIRING DIAGRAM - CODES 10545, 10546, 10657, 10658) (L10877)CONTROLPANELCOMPONENTSLEADCOLORCODEBR+-+-YRWB

ELECTRICAL DIAGRAMSG-3CLASSIC® 300D & 300GWIRING DIAGRAM - (CODE 10659) (L11194)CONTROLPANELCOMPONENTSBR+-+-YRWBBSLIPRINGSTO IRONA54 321ALTERNATOR

ACCESSORIESC1.3 C1.3CLASSIC® 300D & 300GWire Feed Module (K623-1) - Provides constant volt-age (CV) output with improved arc stability forInnershi

ELECTRICAL DIAGRAMSG-4CLASSIC® 300D & 300GWIRING DIAGRAM - (CODES 10911, 10927) (L11865)CL11865CONTROL PANEL COMPONENTSLEAD COLORCODE610A600C+-+-8

ELECTRICAL DIAGRAMSG-5CLASSIC® 300D & 300GWIRING DIAGRAM - (CODES 10912, 11135) (L11866)L11866CLASSIC 300G WIRING DIAGRAMBCONTROL PANEL COMPONENTS

ELECTRICAL DIAGRAMSG-6CLASSIC® 300D & 300GWIRING DIAGRAM - (CODES 11110, 11111) (M20499)WIREFEEDMODULE(OPTIONAL)608609CLA SS IC 300D PERKINS W IRI

ELECTRICAL DIAGRAMSG-7CLASSIC® 300D & 300GWIRING DIAGRAM - (CODES 11112, 11113) (M20432)SBWIREFEEDMODULE(OPTIONAL)608609+CLA SS IC 300D KUBOTA W I

ELECTRICAL DIAGRAMSG-8CLASSIC® 300D & 300GWIRING DIAGRAM - (CODES 11243, 11244) (M20432-1)SBWIREFEEDMODULE(OPTIONAL)608609+CLA SS IC 300D KUBOTA W

ELECTRICAL DIAGRAMSG-9CLASSIC® 300D & 300GWIRING DIAGRAM - (CODES 11248, 11249, 11280, 11281) (M20616)WIREFEEDMODULE(OPTIONAL)608609CLA SS IC 300D

ELECTRICAL DIAGRAMSG-10CLASSIC® 300D & 300GWIRING DIAGRAM - (CODES 11411, 11412) (M21292)WIREFEEDMODULE(OPTIONAL)608609CLA SS IC 300D PERKINS W IR

ELECTRICAL DIAGRAMSG-11CLASSIC® 300D & 300GWIRING DIAGRAM - (CODES 11413, 11414) (M21293)SBWIREFEEDMODULE(OPTIONAL)608609+CLA SS IC 300D KUBOTA W

ELECTRICAL DIAGRAMSG-12CLASSIC® 300D & 300GWIRING DIAGRAM - (CODES 11472, 11473) (M21684)WIREFEEDMODULE(OPTIONAL)608609CLA SS IC 300D PERKINS W IR

ELECTRICAL DIAGRAMSG-13CLASSIC® 300D & 300GWIRING DIAGRAM - (CODES 11474, 11475) (M21563)SBWIREFEEDMODULE(OPTIONAL)608609+CLA SS IC 300D KUBOTA W

NOTESC1.4 C1.4CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

ELECTRICAL DIAGRAMSG-14CLASSIC® 300D & 300GSCHEMATIC - COMPLETE MACHINE - (CODES 11110, 11111) (L12412)L12412CLASSIC 300D PERKINS 404C-22MACHINE S

ELECTRICAL DIAGRAMSG-15CLASSIC® 300D & 300GSCHEMATIC - COMPLETE MACHINE - (CODES 11112, 11113) (L12265)OIL PRESSURE SWITCH / SENDERTEMPERATURE SWI

TABLE OF CONTENTS - MAINTENANCE SECTIOND1.1 D1.1CLASSIC® 300D & 300GMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCED1.2 D1.2CLASSIC® 300D & 300GMAINTENANCEGeneral Instructions1. Blow out the welder and controls with an air hose atleast once every two

MAINTENANCED1.3 D1.3CLASSIC® 300D & 300GReplace brushes when they wear within 1/4” of the pig-tail. A complete set of replacement brushes should

MAINTENANCED1.4 D1.4CLASSIC® 300D & 300GIEVERY 400 HOURS OR 12 MONTHSEVERY 200 HOURS OR 6 MONTHSEVERY 100 HOURS OR 3 MONTHSFIRST SERVICE-(20 / 50

MAINTENANCED1.5 D1.5CLASSIC® 300D & 300GIEVERY 400 HOURS OR 12 MONTHSEVERY 200 HOURS OR 6 MONTHSEVERY 100 HOURS OR 3 MONTHSFIRST SERVICE-(20 / 50

MAINTENANCED1.6 D1.6CLASSIC® 300D & 300GGFCI RECEPTACLE TESTING AND RESETTING PROCEDUREThe GFCI receptacle should be properly tested at leastonce

MAINTENANCED1.7 D1.7CLASSIC® 300D & 300GFIGURE D1.7 - MAJOR COMPONENT LOCATION1. Case Front Assembly2. Engine Assembly3. Radiator Assembly4. F

CLASSIC® 300D & 300GSAFETYii iiFUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing thesef

NOTESD1.8 D1.8CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

TABLE OF CONTENTS - INSTALLATION SECTIONA2.1 A2.1CLASSIC® 300D & 300GInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATIONA2.2 A2.2CLASSIC® 300D & 300GTECHNICAL SPECIFICATIONS - CLASSIC® 300D PERKINS Make/Model Description Speed (RPM) Displacement Starting

INSTALLATIONA2.3 A2.3CLASSIC® 300D & 300GGENERAL DESCRIPTIONThe Classic® 300D Perkins is a heavy duty, engine dri-ven, DC arc welding power source

INSTALLATIONA2.4 A2.4CLASSIC® 300D & 300GPRE-OPERATION INSTALLATIONEXHAUST SPARK ARRESTERSome federal, state or local laws may require th

INSTALLATIONA2.5 A2.5CLASSIC® 300D & 300GPRE-OPERATION SERVICEREAD the engine operating and maintenance instruc-tions supplied with this machine.O

INSTALLATIONA2.6 A2.6CLASSIC® 300D & 300GBATTERY CHARGINGThe Classic® 300D Perkins is equipped with a wetcharged battery. The charging cu

TABLE OF CONTENTS - OPERATION SECTIONB2.1 B2.1CLASSIC® 300D & 300GOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATIONB2.2 B2.2CLASSIC® 300D & 300GENGINE OPERATIONOperate the welder with the doors closed. Leaving thedoors open changes the designed a

OPERATIONB2.3 B2.3CLASSIC® 300D & 300GENGINE BREAK-INLincoln Electric selects high quality, heavy-duty industrialengines for the portable weld

CLASSIC® 300D & 300GSAFETYiii iiiJan ʻ09FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box bef

OPERATIONB2.4 B2.4CLASSIC® 300D & 300GAUXILIARY POWERIf a GFCI receptacle is tripped, See the MAINTE-NANCE section for detailed informatio

TABLE OF CONTENTS - ACCESSORIES SECTIONC2.1 C2.1CLASSIC® 300D & 300GAccessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIESC2.2 C2.2CLASSIC® 300D & 300GOPTIONAL FEATURES (Field Installed)GENERAL OPTIONSPipe Thawing with an arc welder can cause fire,e

ACCESSORIESC2.3 C2.3CLASSIC® 300D & 300GWIRE FEEDER OPTIONSWire Feed Module K623-1Provides constant voltage (CV) output with improvedarc stabili

NOTESC2.4 C2.4CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

TABLE OF CONTENTS - MAINTENANCE SECTIOND2.1 D2.1CLASSIC® 300D & 300GMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCED2.2 D2.2CLASSIC® 300D & 300GSAFETY PRECAUTIONSGENERAL INSTRUCTIONS1. Blow out the welder and controls with an air hose atleast once

MAINTENANCED2.3 D2.3CLASSIC® 300D & 300GReplace brushes when they wear within 1/4” of the pig-tail. A complete set of replacement brushes should

MAINTENANCED2.4 D2.4CLASSIC® 300D & 300GIEVERY 500 HOURS OR 12 MONTHSEVERY 250 HOURS OR 6 MONTHSEVERY 100 HOURS OR 3 MONTHSFIRST SERVICE-(20 / 50

MAINTENANCED2.5 D2.5CLASSIC® 300D & 300GSERVICE DECAL FOR CODES 11250 AND ABOVEReturn to Section TOC Return to Section TOC Return to Section TOC R

CLASSIC® 300D & 300GSAFETYiv ivMar ʻ93PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions

MAINTENANCED2.6 D2.6CLASSIC® 300D & 300GGFCI RECEPTACLE TESTING AND RESET-TING PROCEDUREThe GFCI receptacle should be properly tested at least

MAINTENANCED2.7 D2.7CLASSIC® 300D & 300GFIGURE D2.7 - MAJOR COMPONENT LOCATION1. Case Front Assembly2. Engine Assembly3. Radiator Assembly4. F

NOTESD2.8 D2.8CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

TABLE OF CONTENTS - INSTALLATION SECTIONA3.1 A3.1CLASSIC® 300D & 300GInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATIONA3.2 A3.2CLASSIC® 300D & 300GTECHNICAL SPECIFICATIONS - CLASSIC® 300D KUBOTAMake/Model Description Speed (RPM) Displacement Starting C

INSTALLATIONA3.3 A3.3CLASSIC® 300D & 300GGENERAL DESCRIPTIONThe CLASSIC®300D KUBOTA is a heavy duty, enginedriven, DC arc welding power source, ca

INSTALLATIONA3.4 A3.4CLASSIC® 300D & 300GPRE-OPERATION INSTALLATIONEXHAUST SPARK ARRESTERSome federal, state or local laws may require that engin

INSTALLATIONA3.5 A3.5CLASSIC® 300D & 300GPRE-OPERATION SERVICEREAD the engine operating and maintenance instruc-tions supplied with this machine.-

INSTALLATIONA3.6 A3.6CLASSIC® 300D & 300GBattery ChargingThe CLASSIC® 300D KUBOTA is equipped with a wetcharged battery. The charging current is

TABLE OF CONTENTS - OPERATION SECTIONB3.1 B3.1CLASSIC® 300D & 300GOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETYv vCLASSIC® 300D & 300GElectromagnetic Compatibility (EMC)ConformanceProducts displaying the CE mark are in conformity with European Communi

OPERATIONB3.2 B3.2CLASSIC® 300D & 300GENGINE OPERATIONOperate the welder with the doors closed. Leaving thedoors open changes the designed a

OPERATIONB3.3 B3.3CLASSIC® 300D & 300GWELDER OPERATION------------------------------------------------------------------------DUTY CYCLEThe NEMA o

OPERATIONB3.4 B3.4CLASSIC® 300D & 300GIDLER OPERATIONStart the engine with the “Idler” switch in the “High”position. Allow it to run at

TABLE OF CONTENTS - ACCESSORIES SECTIONC3.1 C3.1CLASSIC® 300D & 300GAccessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIESC3.2 C3.2CLASSIC® 300D & 300GOPTIONAL FEATURES (Field Installed)GENERAL OPTIONSPipe Thawing with an arc welder can cause fire,e

ACCESSORIESC3.3 C3.3CLASSIC® 300D & 300GWIRE FEED OPTIONSWire Feed Module (K623-1) - Provides constant volt-age (CV) output with improved a

NOTESC3.4 C3.4CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

TABLE OF CONTENTS - MAINTENANCE SECTIOND3.1 D3.1CLASSIC® 300D & 300GMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCED3.2 D3.2CLASSIC® 300D & 300GMAINTENANCEGENERAL INSTRUCTIONS1. Blow out the welder and controls with an air hose atleast once every

MAINTENANCED3.3 D3.3CLASSIC® 300D & 300GReplace brushes when they wear within 1/4”(3.5mm)of the pigtail. A complete set of replacement brus

SAFETYvi viCLASSIC® 300D & 300GElectromagnetic Compatibility (EMC)The size of the surrounding area to be considered will depend on the structure o

MAINTENANCED3.4 D3.4CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TO

MAINTENANCED3.5 D3.5CLASSIC® 300D & 300GGFCI RECEPTACLE TESTING AND RESET-TING PROCEDUREThe GFCI receptacle should be properly tested at least

MAINTENANCED3.6 D3.6CLASSIC® 300D & 300GFIGURE D3.6 - MAJOR COMPONENT LOCATION1. Case Front Assembly2. Engine Assembly3. Radiator Assembly4. F

TABLE OF CONTENTS - INSTALLATION SECTIONA4.1 A4.1CLASSIC® 300D & 300GInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATIONA4.2 A4.2CLASSIC® 300D & 300GTECHNICAL SPECIFICATIONS - CLASSIC® 300D PERKINS Make/Model Description Speed (RPM) Displacement Starting

INSTALLATIONA4.3 A4.3CLASSIC® 300D & 300GGENERAL DESCRIPTIONThe Classic® 300D Perkins is a heavy duty, engine dri-ven, DC arc welding power source

INSTALLATIONA4.4 A4.4CLASSIC® 300D & 300GPRE-OPERATION INSTALLATIONEXHAUST SPARK ARRESTERSome federal, state or local laws may require th

INSTALLATIONA4.5 A4.5CLASSIC® 300D & 300GPRE-OPERATION SERVICEREAD the engine operating and maintenanceinstructions supplied with this machine

INSTALLATIONA4.6 A4.6CLASSIC® 300D & 300GBATTERY CHARGINGThe Classic® 300D Perkins is equipped with a wetcharged battery. The charging cu

TABLE OF CONTENTS - OPERATION SECTIONB4.1 B4.1CLASSIC® 300D & 300GOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -I ICLASSIC® 300D & 300GPageSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATIONB4.2 B4.2CLASSIC® 300D & 300GENGINE OPERATIONOperate the welder with the doors closed. Leaving thedoors open changes the designed a

OPERATIONB4.3 B4.3CLASSIC® 300D & 300GENGINE BREAK-INLincoln Electric selects high quality, heavy-duty industrialengines for the portable weld

OPERATIONB4.4 B4.4CLASSIC® 300D & 300GAUXILIARY POWERIf a GFCI receptacle is tripped, See the MAINTE-NANCE section for detailed informatio

TABLE OF CONTENTS - ACCESSORIES SECTIONC4.1 C4.1CLASSIC® 300D & 300GAccessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIESC4.2 C4.2CLASSIC® 300D & 300GOPTIONAL FEATURES (Field Installed)GENERAL OPTIONSPipe Thawing with an arc welder can cause fire,e

ACCESSORIESC4.3 C4.3CLASSIC® 300D & 300GWIRE FEEDER OPTIONSWire Feed Module K623-1Provides constant voltage (CV) output with improvedarc stabili

NOTESC4.4 C4.4CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

TABLE OF CONTENTS - MAINTENANCE SECTIOND4.1 D4.1CLASSIC® 300D & 300GMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCED4.2 D4.2CLASSIC® 300D & 300GSAFETY PRECAUTIONSGENERAL INSTRUCTIONS1. Blow out the welder and controls with an air hose atleast once

MAINTENANCED4.3 D4.3CLASSIC® 300D & 300GReplace brushes when they wear within 1/4” of the pig-tail. A complete set of replacement brushes should

TABLE OF CONTENTS - INSTALLATION SECTIONA1.1 A1.1CLASSIC® 300D & 300GInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCED4.4 D4.4CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TO

MAINTENANCED4.5 D4.5CLASSIC® 300D & 300GGFCI RECEPTACLE TESTING AND RESET-TING PROCEDUREThe GFCI receptacle should be properly tested at least

MAINTENANCED4.6 D4.6CLASSIC® 300D & 300GFIGURE D4.6 - MAJOR COMPONENT LOCATION1. Case Front Assembly2. Engine Assembly3. Radiator Assembly4. F

TABLE OF CONTENTS - INSTALLATION SECTIONA5.1 A5.1CLASSIC® 300D & 300GInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATIONA5.2 A5.2CLASSIC® 300D & 300GTECHNICAL SPECIFICATIONS – CLASSIC® 300G (K1754-1)DC CURRENT RANGEFine Adjustment in each Range40-350 Am

INSTALLATIONA5.3 A5.3CLASSIC® 300D & 300GPRE-OPERATION INSTALLATIONEXHAUST SPARK ARRESTERSome federal, state or local laws may require tha

INSTALLATIONA5.4 A5.4CLASSIC® 300D & 300GPRE-OPERATION SERVICEREAD the engine operating and maintenance instruc-tions supplied with this machine.O

INSTALLATIONA5.5 A5.5CLASSIC® 300D & 300GBATTERY CHARGINGThe Classic® 300G is equipped with a wet chargedbattery. The charging current is

NOTESA5.6 A5.6CLASSIC® 300D & 300GReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Retu

TABLE OF CONTENTS - OPERATION SECTIONB5.1 B5.1CLASSIC® 300D & 300GOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .