Lincoln Electric Svm194-A Classic 300d and 300g PDF

SVM194-A
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October, 2009
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CLASSIC® 300 D & 300 G

For use with machine code number: 10545, 10546, 10657, 10658,10911, 10927,11110
11111, 11112, 11113, 11243, 11244, 11248, 11249,
11280, 11281, 11411, 11412, 11413, 11414, 11472,
11473, 11474, 11475
Classic® 300G: 10659, 10912, 11135
Safety Depends on You

Lincoln arc welding and cutting

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equipment is designed and built

with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
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SERVICE MANUAL
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Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i SAFETY i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE
1.h. To avoid scalding, do not remove the
powered equipment.
radiator pressure cap when the engine is
hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes

have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan. 2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or work cables. If the electrode cable is on your right
idler by pushing on the throttle control rods side, the work cable should also be on your right side.
while the engine is running.
2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar ʻ95
CLASSIC® 300D & 300G

ii SAFETY ii
ELECTRIC SHOCK can kill. ARC RAYS can burn.

3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot” when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot” parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
clothing; on metal structures such as floors, gratings or
FUMES AND GASES

scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
can be dangerous.
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases
• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these
• AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough

3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot”. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
3.e. Ground the work or metal to be welded to a good electrical ACGIH TLV limits using local exhaust or mechanical ven-
(earth) ground. tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
3.f. Maintain the electrode holder, work clamp, welding cable and cautions are also required when welding on galvanized
welding machine in good, safe operating condition. Replace steel.
damaged insulation.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
3.g. Never dip the electrode in water for cooling.
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo-
3.h. Never simultaneously touch electrically “hot” parts of
sure level should be checked upon installation and periodi-
electrode holders connected to two welders because voltage

cally thereafter to be certain it is within applicable OSHA PEL
between the two can be the total of the open circuit voltage
and ACGIH TLV limits.
of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
3.i. When working above floor level, use a safety belt to protect
coming from degreasing, cleaning or spraying operations.
yourself from a fall should you get a shock.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.j. Also see Items 6.c. and 8.
ucts.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturerʼs instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Jan ʻ09

iii SAFETY iii
WELDING and CUTTING CYLINDER may explode

SPARKS can cause fire or if damaged.
explosion. 7.a. Use only compressed gas cylinders

containing the correct shielding gas for the
6.a. Remove fire hazards from the welding area.If process used and properly operating
this is not possible, cover them to prevent the welding sparks regulators designed for the gas and
from starting a fire. Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjcent areas. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to “Safety in Welding and Cutting” (ANSI • Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
• A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances”, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
FOR ELECTRICALLY
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
powered equipment.
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.

framework or other locations away from the welding area
increase the possibility of the welding current passing through 8.b. Install equipment in accordance with the U.S. National
lifting chains, crane cables or other alternate circuits. This can Electrical Code, all local codes and the manufacturerʼs
create fire hazards or overheat lifting chains or cables until recommendations.
they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. Electrical Code and the manufacturerʼs recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.

Jan ʻ09

iv SAFETY iv
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque dʼincendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions

et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un
antes: échauffement et un risque dʼincendie.
Sûreté Pour Soudage A LʼArc 8. Sʼassurer que la masse est connectée le plus prés possible de
1. Protegez-vous contre la secousse électrique: la zone de travail quʼil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dʼautres endroits
a. Les circuits à lʼélectrode et à la piéce sont sous tension éloignés de la zone de travail, on augmente le risque de voir
quand la machine à souder est en marche. Eviter toujours passer le courant de soudage par les chaines de levage,
tout contact entre les parties sous tension et la peau nue câbles de grue, ou autres circuits. Cela peut provoquer des
ou les vétements mouillés. Porter des gants secs et sans risques dʼincendie ou dʼechauffement des chaines et des
trous pour isoler les mains. câbles jusquʼà ce quʼils se rompent.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met- 9. Assurer une ventilation suffisante dans la zone de soudage.
allique ou des grilles metalliques, principalement dans Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse. produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc- 10. Ne pas souder en présence de vapeurs de chlore provenant
tionnement. dʼopérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans lʼeau pour le chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
refroidir. du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension ou autres produits irritants.
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total 11. Pour obtenir de plus amples renseignements sur la sûreté, voir
de la tension à vide des deux machines. le code “Code for safety in welding and cutting” CSA Standard
f. Si on utilise la machine à souder comme une source de W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
TRANSFORMATEUR ET À
enrouler le câble-électrode autour de nʼimporte quelle partie du
REDRESSEUR
corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi 1. Relier à la terre le chassis du poste conformement au code de
quʼun verre blanc afin de se protéger les yeux du rayon- lʼélectricité et aux recommendations du fabricant. Le dispositif
nement de lʼarc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde lʼarc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de lʻarc. 2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
c. Protéger lʼautre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à lʼaide dʼécrans appropriés et non-inflammables.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de lʼarc de er à lʼinterrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur place.
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
Mar ʻ93

Return to Master TOC v SAFETY v
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). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturerʼs
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work com-
plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equip-
ment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
L10093 3-1-96H

Return to Master TOC vi SAFETY vi
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.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturerʼs recommen-
dations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturerʼs recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturerʼs recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con-
nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capaci-
tance, selected according to national regulations.
Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
tions. 1
_________________________
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”
L10093 3-1-96H

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Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Aʼs

Classic® 300D Perkins 104-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.1
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.2
Classic® 300D Kubota V2203M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.3
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.4
Classic® 300G GM 3.0 Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Bʼs

Classic® 300D Perkins 104-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.1
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.2
Classic® 300D Kubota V2203M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.3
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.4
Classic® 300G GM 3.0 Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.5
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Cʼs

Classic® 300D Perkins 104-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.1
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.2
Classic® 300D Kubota V2203M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.3
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.4
Classic® 300G GM 3.0 Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Dʼs

Classic® 300D Perkins 104-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D.1
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D.2
Classic® 300D Kubota V2203M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D.3
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D.4
Classic® 300G GM 3.0 Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D.5
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-337, P-379, P-498, P-507

Classic® 300D Perkins 104-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-337
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-507
Classic® 300D Kubota V2203M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-498
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-507
Classic® 300G GM 3.0 Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-379

Return to Master TOC A1.1 TABLE OF CONTENTS - INSTALLATION SECTION A1.1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.3
Pre-Operation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.4
Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5
Polarity Control & Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6

Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6


A1.2 INSTALLATION A1.2
TECHNICAL SPECIFICATIONS - CLASSIC® 300D

INPUT - DIESEL ENGINE
Return to Section TOC
Make/Model Description Speed (RPM) Displacement Starting Capacities

System
Perkins 4 cylinder High Idle 1800 135.6 cu. in 12VDC batteries Fuel: 15 gal.
104-22 Diesel 4 Cycle Low Idle 1350 (2.2 L) (2) & Starter 57 L
Engine 32.7 HP @ Full Load 1725
(Water Cooled) 1800 RPM Bore x Stroke Oil: 8.7 Qts.
8.2 L
3.875” x 5.00”
(98.4 mm x 127.0mm) Coolant: 7.9 gal.
7.5 L
RATED OUTPUT - WELDER

WELDING OUTPUT* OPEN CIRCUIT OUTPUT RANGE AUXILIARY POWER(1)
Current/Voltage/Duty Cycle VOLTAGE AMPS
40-350A
115/230 VAC
250A / 30V / 100% 98 Max. 220A-MAX. 3000 Watts, 60 Hz.
@ 1800 RPM 160-240A 26 Amps @ 115V
300A / 32V / 60% 120-240A 13 Amps @ 230V
120-190A
80-130A
Min.-90A
PHYSICAL DIMENSIONS(2)
HEIGHT WIDTH DEPTH WEIGHT
K1643-1 1354 lbs.

45.50 in. 24.00 in. 65.00 in. (616 kg)
1156 mm 610 mm 1651 mm K1643-2 1354 lbs.

(616 kg)
* Based on a 10 min. period.
(1) 115V will operate either 60 Hz. or 50/60 Hz. power tools, lights etc.
(2) Height to top of exhaust elbow.
PERKINS 104-22 DIESEL ENGINE TYPICAL FUEL CONSUMPTION DATA
Low Idle (1375 RPM)-No Load @ 45 Volts 0.28 gal/hr ( 1.06 ltrs/hr)
High Idle (1800 RPM)-No Load @ 96.6 Volts 0.45 gal/hr ( 1.70 ltrs/hr)
50 Amps @ 22 Volts 0.51 gal/hr ( 1.93 ltrs/hr)


GENERAL DESCRIPTION DESIGN FEATURES

Control Panel
The Classic® 300 D is a heavy duty, engine driven, DC

arc welding power source, capable of providing con- Both the engine and the welder controls are located on
stant current output for stick welding or DC TIG weld- one recessed panel at the exciter end of the machine.
ing. This welder is wound with all copper coils, rated at The welder controls consist of a five step “Current
300 amps/32 Volts, and provides other Classic® fea- Range Selector” switch and a “Fine Current
tures such as improved door latches and stainless Adjustment” rheostat. The welder is equipped with a
hinges. With the addition of the optional K623-1 Wire “Start” button, an “Ignition” switch, an “Idler” control
Feed Module™, the Classic® 300 D will provide con- switch, and a “Glow Plug” button for easier cold weath-
stant voltage output for running the LN-7, LN-23P, or er starting.
LN-25 wire feeders. (The Wire Feed Module is factory
installed on the K1643-2). The optional K924-4 or The control panel also contains an engine temperature
K924-5 Remote Control Kit (Both field installed) See gauge, a battery charging ammeter, an oil pressure
Section C for description. gauge, two three prong grounding type receptacles
and four circuit breakers for auxiliary power.
The Classic® 300 D has Diesel Engine Protection. In
All Copper Windings - For long life and dependable
the event of sudden low oil pressure or high coolant
operation.
temperature, the engine immediately shuts down. The

Classic® 300 D has a current range of 40-350 DC Engine Idler - The Classic® 300 D is equipped with
amps with output ratings as follows: an electronic automatic engine idler. It automatically
increases and decreases engine speed when starting
and stopping welding or using auxiliary power. A
built-in time delay permits changing electrodes before
the engine slows to its low idle speed. The “Idler” con-
RATED OUTPUT DUTY CYCLE
trol switch on the panel locks the idler in high idle posi-
250A @ 30V 100% tion when desired.
300A @ 32V 60%
Auxiliary Power - 3.0 kVA of nominal 115/230V, 60Hz,
AC. Output voltage is maintained within ± 10% at all
These units are also capable of providing 3 kVA of loads up to rated capacity. (See Optional Features
115/230 volts of 60 cycle AC auxiliary power. in Section C for Power Plug Kit.)
Welder Enclosure - The complete welder is rubber

The Classic® 300 D uses the Perkins 104-22 industri-
mounted on a rugged steel “C” channel base.
al water-cooled diesel engine.
The output terminals are placed at the side of the

machines so that they are protected by the door. The
output terminals are labeled (+) and (-).
Cranking System - A 12 volt electric starter is stan-

dard.
Air Cleaner - Heavy duty two stage dry type.
Muffler - A muffler and stainless steel exhaust outlet

elbow are standard.
Engine Hour Meter - A meter to record hours of oper-

ation.
Engine Protection - The system shuts the engine

down in the event of sudden low oil pressure or high
coolant temperature. A warning light on the control

panel will indicate such a fault. To reset the engine for
restarting, turn the ignition switch off then on.

PRE-OPERATION INSTALLATION CAUTION

WARNING DO NOT MOUNT OVER COMBUSTIBLE SUR-
FACES.
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs Where there is a combustible surface directly under
manual supplied with your welder. It includes stationary or fixed electrical equipment, the surface
important safety precautions, detailed engine shall be covered with a steel plate at least .06”(1.6mm)
starting, operating and maintenance instructions, thick, which shall extend not more than 5.90”(150mm)
and parts lists. beyond the equipment on all sides.
------------------------------------------------------------------------ ----------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or Machine Grounding
electrode with skin or wet clothing.
• Insulate yourself from work and According to the United States National Electrical
ground Code, the frame of this portable generator is not
• Always wear dry insulating gloves. required to be grounded and is permitted to serve as
------------------------------------------------------------------------ the grounding means for cord connected equipment
ENGINE EXHAUST can kill.
plugged into its receptacle.
• Use in open, well ventilated areas or
vent exhaust outside.
Some state, local, or other codes or unusual operating
circumstances may require the machine frame to be

------------------------------------------------------------------------ grounded. It is recommended that you determine the
MOVING PARTS can injure. extent to which such requirements may apply to your
• Do not operate with doors open or particular situation and follow them explicitly. A
guards off.
machine grounding stud marked with the symbol is
• Stop engine before servicing.
• Keep away from moving parts. provided on the welding generator frame foot. In gen-
eral, if the machine is to be grounded, it should be con-
------------------------------------------------------------------------ nected with a #8 or larger copper wire to a solid earth
See additional warning information at the ground such as a metal water pipe going into the
front of this operatorʼs manual. ground for at least ten feet and having no insulated
----------------------------------------------------------- joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
Code lists a number of alternate means of grounding
Exhaust Spark Arrester
electrical equipment.
Some federal, state or local laws may require that
engines be equipped with exhaust spark arresters
when they are operated in certain locations where
Lift Bail
unarrested sparks may present a fire hazard. The

standard muffler included with this welder does not A lift bail is provided for lifting with a hoist.
WARNING
qualify as a spark arrester. When required by local reg-
ulations, a suitable spark arrester must be installed
and properly maintained. FALLING EQUIPMENT can cause injury.
• Lift only with equipment of
CAUTION adequate lifting capacity.
Use of an incorrect arrester may lead to engine damage • Be sure machine is stable
or performance loss. Contact the engine manufacturer for when lifting.
specific recommendations. • Do not lift this machine using
------------------------------------------------------------------------ lift bale if it is equipped with a
heavy accessory such as trail-
Location / Ventilation
er or gas cylinder.
Always operate the welder with the doors closed. • Do not lift machine if lift bale is damaged.
Leaving the doors open changes the designed air flow • Do not operate machine while suspended from
and may cause overheating. lift bale.

------------------------------------------------------------------------
The welder should be located to provide an unrestrict-
ed flow of clean, cool air. Also, locate the welder so
that engine exhaust fumes are properly vented to an
outside area.

TRAILER (See Optional Features) RECOMMENDED COPPER CABLE SIZES

If the user adapts a non-Lincoln trailer, he must
Cables Sizes for Combined Length
of Electrode Plus Work Cable
assume responsibility that the method of attachment

and usage does not result in a safety hazard nor dam- Amps Duty Cycle Up to 200ft.(61m) 200 to 250ft.
(61 to 76m)
age the welding equipment. Some of the factors to be 250 100% 1 1/0
considered are as follows:
300 60% 1/0 2/0
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
PRE-OPERATION SERVICE
CAUTION
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue READ the engine operating and maintenance instruc-
stress to the framework. tions supplied with this machine.
-----------------------------------------------------------------------
3. Proper placement of the equipment on the trailer to
ensure stability side to side and front to back when WARNING
being moved and when standing by itself while
being operated or serviced.
• Stop engine while fueling.
• Do not smoke when fueling.
4. Typical conditions of use, i.e., travel speed, rough-

• Keep sparks and flame away
ness of surface on which the trailer will be operated;

from tank.
environmental conditions, likely maintenance.
• Do not leave unattended while
DIESEL FUEL • Wipe up spilled fuel and allow

fueling.
5. Conformance with federal, state and local laws. (1)
(1) Consult your federal, state and local laws regarding specific can cause fire. fumes to clear before starting
requirements for use on public highways. engine.
VEHICLE MOUNTING
• Do not overfill tank, fuel
expansion may cause over-
Improperly mounted concentrated loads may cause

flow.
unstable vehicle handling and tires or other compo- ------------------------------------------------------------------------

DIESEL FUEL ONLY
nents to fail.
• Only transport this equipment on serviceable vehi-
cles which are rated and designed for such loads. Oil
• Distribute, balance and secure loads so vehicle is
stable under conditions of use. This unit is supplied from the factory with the engine
• Do not exceed maximum rated loads for compo- crankcase filled with a high quality SAE 10W/30 oil.
nents such as suspension, axles and tires. This oil should be acceptable for most typical ambient
• Mount equipment base to metal bed or frame of temperatures. Consult the engine operation manual
vehicle. for specific engine manufacturerʼs recommendations.
• Follow vehicle manufacturerʼs instruction. Upon receipt of the welder, check the engine dipstick to
---------------------------------------------------------------------------- be sure the oil is at the “full” mark. DO NOT overfill.
POLARITY CONTROL AND CABLE SIZES Fuel
With the engine off, route the electrode and work Fill the fuel tank with the grade of fuel recommended in
cables through the strain relief bracket on the base and the Engine Operatorʼs manual. Make sure the fuel
connect to the studs located below the fuel tank mount- valves on the sediment bowl and the water separator
ing rail. (See size recommendations below.) For pos- are in the open positions.
itive polarity, connect the electrode cable to the termi-
nal marked “+”. For Negative polarity, connect the
electrode cable to the “-” stud. These connections Cooling System
should be checked periodically and tightened if neces-

sary. The radiator has been filled at the factory with a 50-50
mixture of ethylene glycol antifreeze and water. Check
When welding at a considerable distance from the the radiator level and add a 50-50 solution as needed
welder, be sure you use ample sized welding cables. (see engine manual or antifreeze container for alter-
nate antifreeze recommendations).

ENGINE BREAK-IN Battery Charging

WARNING
Lincoln Electric selects high quality, heavy-duty indus-

trial engines for the portable welding machines we GASES FROM BATTERY can explode.
offer. While it is normal to see a small amount of • Keep sparks, flame and cigarettes
crankcase oil consumption during initial operation, away.
excessive oil use, wetstacking (oil or tar like substance
at the exhaust port), or excessive smoke is not normal.
BATTERY ACID can burn eyes and
Larger machines with a capacity of 350 amperes and skin.
• Wear gloves and eye protection and be
higher, which are operated at low or no-load conditions careful when boosting, charging or work-
for extended periods of time are especially susceptible ing near battery.
to the conditions described above. To accomplish suc-
cessful engine break-in, most diesel-powered equip- To prevent EXPLOSION when:
ment needs only to be run at a reasonably heavy load a) Installing a new battery - disconnect the
within the rating of the welder for some period of time negative cable from the old battery first and
during the engineʼs early life. However, if the welder is connect the negative cable to the new battery
subjected to extensive light loading, occasional moder- last.
ate to heavy loading of the engine may sometimes be b) Connecting a battery charger - remove the
necessary. Caution must be observed in correctly battery from the welder by disconnecting the
loading a diesel/generator unit. negative cable first, then the positive cable and
battery clamp. When reinstalling, connect the
negative cable last.
1. Connect the welder output studs to a suitable resis- c) Using a booster - connect the positive lead to
tive load bank. Note that any attempt to short the the battery first, then connect the negative lead to
output studs by connecting the welding leads the ground lead on the base.
together, direct shorting of the output studs, or con-
necting the output leads to a length of steel will To prevent ELECTRICAL DAMAGE when:
result in catastrophic damage to the generator and a) Installing a new battery.
voids the warranty. b) Using a booster.
Use correct polarity - Negative Ground.

2. Set the welder controls for an output current and
voltage within the welder rating and duty cycle. To prevent BATTERY DISCHARGE, if you have an
Note that any attempt to exceed the welder rating or ignition switch, turn it off when engine is not
duty cycle for any period of time will result in cata- running.
strophic damage to the generator and voids the
warranty. • To prevent BATTERY BUCKLING, tighten nuts on
battery clamp until snug.
------------------------------------------------------------------------
3. Periodically shut off the engine and check the
crankcase oil level.
The Classic® 300 D is equipped with a wet charged

battery. The charging current is automatically regulat-
ed when the battery is low (after starting the engine) to
a trickle current when the battery is fully charged.
When replacing, jumping or otherwise connecting the

battery to the battery cables, the proper polarity must
be observed. This system is NEGATIVE GROUND.

Return to Master TOC B1.1 TABLE OF CONTENTS - OPERATION SECTION B1.1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.2
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.2
Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.3
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.4


B1.2 OPERATION B1.2
ENGINE OPERATION 7. Allow the engine to run at high idle speed for sev-
eral minutes to warm the engine. Stop the engine
WARNING
and recheck the oil level, after allowing sufficient

Do not attempt to use this equipment until you time for the oil to drain into the pan. If the level is
have thoroughly read the engine manufacturerʼs down, fill it to the full mark again. The engine con-
manual supplied with your welder. It includes trols were properly set at the factory and should
important safety precautions, detailed engine require no adjusting when received.
starting, operating and maintenance instructions,
and parts lists. COLD WEATHER STARTING:
------------------------------------------------------------------------
• Do not touch electrically live parts or With a fully charged battery and the proper weight oil,
electrode with skin or wet clothing. the engine should start satisfactorily even down to
• Insulate yourself from work and about -15°F (-26°C), it maybe desirable to install cold-
ground starting aides.
• Always wear dry insulating gloves.
------------------------------------------------------------------------ Note: Extreme cold weather staring may require longer
• Use in open, well ventilated areas or glow plug operation.
WARNING
------------------------------------------------------------------------
MOVING PARTS can injure. Under NO conditions should ether or other starting
• Do not operate with doors open or fluids be used!
guards off.
• Stop engine before servicing. ------------------------------------------------------------------------
• Keep away from moving parts.
------------------------------------------------------------------------ Stopping the Engine
See additional warning information at the 1. Turn the “IGNITION” switch to “OFF”
front of this operatorʼs manual.
At the end of each dayʼs welding, check the crankcase
----------------------------------------------------------- oil level, drain accumulated dirt and water from the
sediment bowl under the fuel tank and refill the fuel
Operate the welder with the doors closed. Leaving the tank to minimize moisture condensation in the tank.
doors open changes the designed air flow and can Also, running out of fuel tends to draw dirt into the fuel
cause overheating. system.
When hauling the welder between job sites, close the

Starting the Classic® 300D Perkins 104-22 fuel feed valve beneath the fuel tank.
Diesel Engine
If the fuel supply is cut off or runs out while the fuel
1. Turn the “IDLER” switch to “HIGH”. pump is operating, air may be entrapped in the fuel dis-
2. Turn the “IGNITION” switch to “ON”. tribution system. If this happens, bleeding of the fuel
3. Press the Glow Plug button for 20 to 30 seconds. system may be necessary. Use qualified personnel to
(maximum 60 seconds). do this per the instructions in the MAINTENANCE sec-
4. Press the Start button. When the engine starts tion of this manual.
running, release both buttons. If the engine fails to
start in 20 seconds, wait 30 seconds and repeat
the above procedure.
5. Observe the oil pressure. If no pressure shows
within 30 seconds, stop the engine and consult the
engine operating manual. To stop the engine, turn
the “IGNITION” switch to “OFF”.
6. If the engine protection warning light comes on

during cranking or after start up, the “IGNITION”
switch must be turned “OFF” to reset the engine
protection system.

B1.3 OPERATION B1.3
WELDER OPERATION When a forceful “digging” arc is required, usually for

vertical and overhead welding, use a higher “Current
WARNING Range Selector” setting and lower open circuit voltage.
For example: to obtain 175 amps and a forceful arc,

ELECTRIC SHOCK can kill. set the “Current Range Selector” to the 240-160 posi-
• Do not touch electrically live parts or tion and the “Fine Current Adjustment” setting to get
electrode with skin or wet clothing. 175 amps.
• Insulate yourself from work and
ground.
Some arc instability may be experienced with EXX10
FUMES & GASES can be dangerous. electrodes when trying to operate with long arc tech-
• Keep your head out of the fumes. niques at settings at the lower end of the open circuit
• Use ventilation or exhaust to remove voltage range.
fumes from breathing zone.
CAUTION
WELDING SPARKS can cause fire or DO NOT attempt to set the “Current Range Selector”
explosion. between the five points designated on the nameplate.
• Keep flammable material away. ------------------------------------------------------------------------
These switches have a spring loaded cam which

almost eliminates the possibility of setting this switch

ARC RAYS can burn.
• Wear eye, ear, and body protection.
between the designated points.
Idler Operation
Duty Cycle
Start the engine with the “Idler” switch in the “High”
The NEMA output rating of the Classic® 300 D is 300 position. Allow it to run at high idle speed for several
amperes at 32 arc volts on a 60% duty cycle (consult minutes to warm the engine. See Specifications for
Specifications in this manual for alternate ratings). operating speeds.
Duty cycle is based on a ten minute period; thus, the
welder can be loaded at rated output for six minutes The idler is controlled by the “Idler” toggle switch on the
out of every ten minute period. welder control panel. The switch has two positions as
follows:
Control of Welding Current
1. In the “High” position, the idler solenoid acti-
CAUTION
vates, and the engine goes to high idle speed. The

speed is controlled by the governor.
DO NOT TURN THE “CURRENT RANGE SELEC-
TOR” WHILE WELDING because the current may 2. In the “Auto” / position, the idler oper-
arc between the contacts and damage the switch. ates as follows:
------------------------------------------------------------------------
The “Current Range Selector” provides five overlap- a. When welding or drawing power for lights or tools
ping current ranges. The “Fine Current Adjustment” (approximately 100-150 watts minimum) from the
adjusts the current from minimum to maximum within receptacles, the idler solenoid activates and the
each range. Open circuit voltage is also controlled by engine operates at high idle speed.
the “Fine Current Adjustment” permitting control of the
arc characteristics. b. When welding ceases or the power load is turned
off, a preset time delay of about 15 seconds
A high open circuit voltage setting provides the soft starts. This time delay cannot be adjusted.
“buttering” arc with best resistance to pop-outs pre-
ferred for most welding. To get this characteristic, set c. If the welding or power load is not re-started
the “Current Range Selector” to the lowest setting that before the end of the time delay, the idler solenoid
still provides the current you need and set the “Fine deactivates and reduces the engine to low idle
Current Adjustment” near maximum. For example: to speed.
obtain 175 amps and a soft arc, set the “Current Range
Selector” to the 190-120 position and then adjust the
“Fine Current Adjustment” for 175 amps.

B1.4 OPERATION B1.4
AUXILIARY POWER
The AC auxiliary power, supplied as a standard, has a

rating of 3.0 kVA of 115/230 VAC (60 hertz).
With the 3.0 kVA, 115/230 VAC auxiliary power, one

115V duplex and one 230V duplex, grounding type
receptacle are provided. The circuit is protected with
circuit breakers.
The rating of 3.0 kVA permits a maximum continuous

current of 13 amps to be drawn from the 230 volt
duplex receptacle. Or a total of 26 amps can be drawn
from the 115 volt duplex receptacle. The 115 volt
duplex receptacle has a configuration which permits 20
amps to be drawn from either half. The total combined
load of all receptacles is not to exceed 3.0 kVA.
An optional power plug kit is available. When this kit is

specified, the customer is supplied with a plug for each

receptacle.

Return to Master TOC C1.1 TABLE OF CONTENTS - ACCESSORIES SECTION C1.1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1.2
Wire Feed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1.3


C1.2 ACCESSORIES C1.2
OPTIONAL FEATURES (Field Installed)

Remote Control Kit (K924-4) - Contains switch,
receptacle, remote control rheostat, and 100 ft (30.5m)

GENERAL OPTIONS
cable for adjusting the OCV at the welding site.(For
Codes below 10911.)
WARNING
Remote Control Kit (K924-5) - Contains remote con-
trol rheostat and 100 ft. (30.5 m) cable for adjusting
Pipe Thawing with an arc welder can cause fire, the OCV at the welding site. (For Codes 10911 and
explosion, damage to electric wiring or to the arc above.)
welder if done improperly. The use of an arc welder
for pipe thawing is not approved by the CSA, nor is Remote Control Kit (K2464-1) - Contains remote
it recommended or supported by Lincoln Electric. control rheostat (for adjusting the CC “STICK OVC),
------------------------------------------------------------------------ remote control potentiometer (for adjusting the CV
“WIRE” OCV) and 100 ft. (30.5 m) cable.
Power Plug Kit (K802D) - A power plug kit for the aux-
iliary power receptacles is available. (Provides a plug TIG OPTIONS
for each receptacle.)
TIG Module (K930-2) - Provides high frequency and
GFCI Receptacle Kit (K1690-1) - Includes one UL shielding gas control for AC and DC GTAW (TIG) weld-
approved 115V ground fault circuit interrupter duplex ing applications. Its compact case is designed for easy
type receptacle with cover and installation instructions. carrying, complete with a handle. High frequency
Replaces the factory installed 115V duplex receptacle. bypass is built in.The K938-1 Contactor Kit must be
Each receptacle of the GFCI duplex is rated at 20 field installed in the TIG Module when used with a ZR-
amps. Maximum total current from the GFCI duplex is 10. Additionally, the K936-3 control cable is required if
limited to 20 amps. See the MAINTENANCE section remote control is used. If remote control is not used the
for detailed information on testing and resetting the K936-4 control cable is required.
GFCI receptacle.
PTA-26V TIG Torch K1783-9-Air cooled 200 amptorch
Spark Arrestor Kit (K903-1) - Includes a heavy gage equipped with valve for gas flow control. 25Ft. length.
steel, approved spark arrestor, clamp and adapter for
mounting to the muffler exhaust pipe. Magnum Parts Kit For PTA-26V TIG Torch KP509
K953-1 TRAILER - Two-wheeled trailer with optional fender Remote Control Cable (K936-4) - Control cable for
and light package. For highway use, consult applicable feder- connecting the K930-2 TIG Module to a ZR-10 not
al, state, and local laws regarding possible additional require- equipped with a K892-1 Remote Kit. 9-Socket to a
ments. There is a choice of 2 hitches, a fender & a light pack- grounded 115 V plug and a 6 pin MS-connector.
age. (Contains circuits 31, 32, and ground)
K953-1 Trailer
K958-1 Ball Hitch Arc Start Switch K814
K958-2 Lunette Eye Hitch
K959-1 Fender & Light Kit Contactor Kit K938-1
K965-1 Cable Rack
Control Cable Extension K937-45-Cable is 45Ft. in
OIL DRAIN KIT K1586-1 - Includes ball valve, hose length.
and clamp.
Water Valve Kit K844-1-For use with a water-cooled
STICK OPTIONS TIG torch. Installs inside TIG Module.
K704 ACCESSORY SET - Includes 35 feet (10 m) of

electrode cable and 30 feet (9 m) of work cable, head-
shield, work clamp and electrode holder. Cable is rated

at 500 amps, 60% duty cycle.

Wire Feed Module (K623-1) - Provides constant volt- SG Control Module K488-The interface between the
age (CV) output with improved arc stability for power source and the spool gun. Provides control of
Innershield welding. Excellent for MIG welding. wire speed and gas flow.
Recommended wire feeders are the LN-7, LN-23P and
LN-25. (Factory installed on the K1643-2). Input Cable K691-10.-For Lincoln engine drives with
14-pin MS-type connection, separate 115V NEMA
receptacle and output stud connections. 10 ft.
LN-25 Wire Feeder K449-Portable CC/CV unit for length.
flux-cored and MIG welding. Includes Gas Solenoid &
Internal Contactor. Requires Wire Feed Module.
Remote Voltage Control Kit for LN-25 K444-2

Provides 25 ft. (7.5m) of remote output voltage control
and output jumper (2 and 4) for machines having 14
pin MS-type connector.
For self-shielded wire with 15 ft. (4.5m) cable. For

Magnum® 350 Innershield Gun (for LN-25)K126-2-
.062-3/32” (1.6-2.8mm) wire.

15 ft. (4.5m) cable. For .025 (0.6m) wire.

Magnum® 200 MIG Gun (for LN-25))K497-3-With
Magnum Gun Connector KiT-Connects Magnum 200

MIG gun to LN-25 Wire Feeder.
LN-23P Wire Feeder K316L-1-Portable CV unit for

Innershield pipe welding. Control cable operates con-
tactor inside Wire Feed Module for “cold” electrode.
Requires LN-23P Adapter Kit (K350-1) and Gun and
Cable Assembly.
LN-23P Adapter Kit K350-1-Required to adapt LN-

23P to any Lincoln power source. Makes 14 pin con-

nection at power source.
Magnum® 250 Innershield Gun (for LN-23P) K355-

10-For lighter weight and easier handling. Rated 250
amps, 60% duty cycle. For .068 through 5/64” (1.7
through 2.0 mm) Innershield wire and includes
reduced speed switch. For pipe welding, an M11476
62° gun tube is recommended.
62° gun tube for Pipe Welding KP1909-1-

Recommended modification for K355-X or K345-x
guns with 90° gun tubes. Compatible with K126-1,-
2,K264_8 and K355-10.
SPOOL GUN WELDER
Magnum Spool Gun K487-25-Hand held semiauto-

matic wire feeder requires SG Control Module. 25 ft.
length.

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 C1.4
NOTES

C1.4
Return to Master TOC D1.1 TABLE OF CONTENTS - MAINTENANCE SECTION D1.1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.2
Idler Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.3
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.4/D1.5
GFCI Receptacle Testing & Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.6
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.7


D1.2 MAINTENANCE D1.2
MAINTENANCE 4. When necessary, remove the sediment bowl, if so

equipped, from beneath the fuel tank and clean out
WARNING
any accumulated dirt and water.

Have qualified personnel do the maintenance
work. Turn the engine off before working inside 5. Follow the engine service schedule in this manual
the machine. In some cases, it may be necessary and the detailed maintenance and troubleshooting in
to remove safety guards to perform required the engine manufacturerʼs manual.
maintenance. Remove guards only when neces-
sary and replace them when the maintenance Cooling System
requiring their removal is complete. Always use
The Classic® 300 D is equipped with a pressure radi-
the greatest care when working near moving
ator. Keep the radiator cap tight to prevent loss of
parts.
coolant. Clean and flush the cooling system periodical-
ly to prevent clogging the passage and overheating the
Do not put your hands near the engine cooling engine. When antifreeze is needed, always use the
blower fan. If a problem cannot be corrected by permanent type. Capacity = 9.5 qts (9.0 Ltrs.).
following the instructions, take the machine to
the nearest Lincoln Field Service Shop. Bearings
-----------------------------------------------------------------------
This welder is equipped with a double-shielded ball

• Do not touch electrically live parts or bearing having sufficient grease to last indefinitely
electrode with skin or wet clothing. under normal service. Where the welder is used con-
• Insulate yourself from work and stantly or in excessively dirty locations, it may be nec-
ground
• Always wear dry insulating gloves. essary to add one half ounce of grease per year. A pad
of grease one inch wide, one inch long, and one inch
------------------------------------------------------------------------ high weighs approximately one half ounce. Over-
ENGINE EXHAUST can kill. greasing is far worse than insufficient greasing.
vent exhaust outside. When greasing the bearings, keep all dirt out of the
area. Wipe the fittings completely clean and use clean
equipment. More bearing failures are caused by dirt
------------------------------------------------------------------------ introduced during greasing than from insufficient
MOVING PARTS can injure. grease.
• Do not operate with doors open or
guards off.
• Stop engine before servicing. Commutator and Brushes
WARNING
------------------------------------------------------------------------
See additional warning information at

front of this operatorʼs manual. Uncovered rotating equipment can be dangerous.
Use care so your hands, hair, clothing or tools do
----------------------------------------------------------- not catch in the rotating parts. Protect yourself
from particles that may be thrown out by the rotat-
ing armature when stoning the commutator.
General Instructions ------------------------------------------------------------------------
Shifting of the commutator brushes may result in:
1. Blow out the welder and controls with an air hose at - Change in machine output
least once every two months. In particularly dirty loca- - Commutator damage
tions, this cleaning may be necessary once a week. - Excessive brush wear
Use low pressure air to avoid driving dirt into the insu-
lation. Periodically inspect the commutator, slip rings, and
brushes by removing the covers. DO NOT remove or
2. “Current Range Selector” contacts should not be replace these covers while the machine is running.
greased. To keep the contacts clean, rotate the current Commutators and slip rings require little attention.
control through its entire range frequently. Good prac- However, if they are black or appear uneven, have
tice is to turn the handle from maximum to minimum them cleaned by an experienced maintenance man
setting twice each morning before starting to weld. using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
3. Put a drop of oil on the “Current Range Selector”
shaft at least once every month.

Replace brushes when they wear within 1/4” of the pig- Purging Air from Fuel System (Perkins
tail. A complete set of replacement brushes should be 104-22 Engine)
kept on hand. Lincoln brushes have a curved face to

fit the commutator. Have an experienced maintenance

man seat these brushes by lightly stoning the commu-
WARNING
tator as the armature rotates at full speed until contact Keep fuel clear of open flames or arcs, allow
is made across the full face of the brushes. After ston- engine to cool before working on the fuel system.
ing, blow out the dust with low pressure air. Wipe up any spilled fuel and do not start engine
To seat slip ring brushes, position the brushes in place. until fumes clear.
Then slide one end of a piece of fine sandpaper ------------------------------------------------------------------------
between slip rings and brushes with the coarse side If the engine is running rough and you suspect air has
against the brushes. With slight additional finger pres- been trapped in the fuel system, (e.g. the engine was
sure on top of the brushes, pull the sandpaper around allowed to run out of fuel) perform the following steps
the circumference of the rings - in direction of rotation using qualified personnel:
only - until brushes seat properly. In addition, stone slip
ring with a fine stone. Brushes must be seated 100%. 1. Loosen by two or three turns, the vent screw
(Figure D1.3) on the fuel inlet connection.
Arcing or excessive exciter brush wear indicates a pos-
sible misaligned shaft. Have an authorized Field

Service Shop check and realign the shaft.
Idler Maintenance Vent Screw
CAUTION
Before doing electrical work on the idler printed Priming
circuit board, disconnect the battery. Lever
------------------------------------------------------------------------
FIGURE D1.3
When installing a new battery or using a jumper battery
to start the engine, be sure the battery polarity is con-
2. For Engines Equipped with a mechanical fuel pump:
nected properly. The correct polarity is negative
Operate the priming lever on the fuel lift pump until
ground. Damage to the engine alternator and the print-
fuel, free of air, flows from the vent point. Tighten
ed circuit board can result from incorrect connection.
the vent screw. If the pump is at the point of maxi-
mum lift, it will not be possible to operate the prim-
1. The solenoid plunger must work freely and not bind.
ing lever. If this occurs, turn the crankshaft one

Dust the plunger about once a year with graphite
revolution.
powder.
For Engines Equipped with an electric fuel pump:
Operate the electric fuel pump by turning the
2. Proper operation of the idler requires good ground-
“Ignition” switch “ON” until fuel, free of air, flows
ing of the printed circuit board, reed switch, and bat-
from the vent point. Tighten the vent screw.
tery.
3. Contact your Perkins Engine repair facility if prob-
3. Idler solenoid is activated for high idle.
lems persist.
4. If desired, the welder can be used without automat-
ic idling by setting the “Idler” switch to the “High”
position.
Nameplates
Whenever routine maintenance is performed on this

machine - or at least yearly - inspect all nameplates

and labels for legibility. Replace those which are no
longer clear. Refer to the parts list for the replacement
item number.

FOR CODES 10658 AND BELOW
ENGINE SERVICE
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE-(20 / 50 HOURS)
EVERY 100 HOURS OR 3 MONTHS
ENGINE SERVICE (NOTE 2)
MAINTENANCE ITEM TYPE OR QUANTITY
I Coolant level
I Concentration of antifreeze 50/50 Water/Ethylene Glycol
R Coolant (NOTE 3) 9.5qrts, (9.0L)
I Engine oil level (NOTE 1)
R R Engine oil (NOTE 1 & 3) 8.7qrts, (8.2L) (including filter)
R R Engine oil filter Perkins #140517000
C C Drain water separator & fuel strainer
R Fuel filter canister Perkins #1300366120
I Tension of alternator drive belt
I Alternator drive belt wear
R Alternator drive belt Perkins # 080109080
C C Air filter (earlier check may be req'd.)
R Air filter element Donaldson #P181050 or Nelson #70206N
I Check and adjust idle speed
I Tighten cylinder head
I Valve clearances Intake .008", exhaust .008"

I Electrical systems
I All nuts and bolts for tightness
I Injector performance Contact Perkins
I Leaks or engine damage
I Battery BCI Group 24
I = Inspect C = Clean R = Replace

NOTES:
(1) Consult Engine Operators Manual for oil recommendations.
(2) Consult Engine Operators Manual for additional maintenance schedule information.
(3) Fill slowly! Ensure correct quantity is used.
Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.
These preventive maintenance periods apply to average conditions of operation.
5/06
If necessary use shorter periods. S20919-2

FOR CODES 10911 AND ABOVE

ENGINE SERVICE

I Coolant level
R Coolant (NOTE 3) 9.5qrts., 9.0L
R R Engine oil (NOTE 1 & 3) 8.7qrts, 8.2L (including filter)


C C Drain water separator & fuel strainer
R Alternator drive belt Perkins #080109080
C C Air filter (earlier check may be req'd.)
R Air filter element Donaldson #P181050, Nelson #70206N
I Check and adjust idle speed
I Battery

Notes:
If necessary use shorter periods. S25557

GFCI RECEPTACLE TESTING AND

RESETTING PROCEDURE
The GFCI receptacle should be properly tested at least

once every month or whenever it is tripped. To proper-
ly 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, it must be
restarted.
• The equipment needs to be operating at high idle
speed and any necessary adjustments made on the
control panel so that the equipment is providing at
least 80 volts to the receptacle input terminals.
• The circuit breaker for this receptacle must not be
tripped. Reset if necessary.
• Push the "Reset" button located on the GFCI recep-
tacle. This will assure normal GFCI operation.

• Plug a night-light (with an "ON/OFF" switch) or other

product (such as a lamp) into the GFCI receptacle
and turn the product "ON".
• Push the "Test" button located on the GFCI recepta-
cle. The night-light or other product should go "OFF".
• Push the "Reset" button, again. The light or other
product should go "ON" again.
If the light or other product remains "ON" when the

"Test" button is pushed, the GFCI is not working prop-
erly or has been incorrectly installed (miswired). If your
GFCI is not working properly, contact a qualified, certi-
fied electrician who can assess the situation, rewire the
GFCI if necessary or replace the device.

1. Case Front Assembly

2. Engine Assembly
3. Radiator Assembly
4. Fuel Tank & Mounting
5. Base & Lift Bale Assembly
6. Welding Generator & Coupling (1 of 2)
8. Solenoid Assembly
9. Roof & Doors
10. Alternator Brush Holder
11. Generator Brush Holder
FIGURE D1.7 - MAJOR COMPONENT LOCATION
1 2
5
7
11
6
10

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D1.8
NOTES

D1.8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2


TECHNICAL SPECIFICATIONS - CLASSIC® 300D PERKINS


System
4 Cylinder 135.6 cu. in 12VDC battery Fuel: 15 gal.

4 Cycle (2.2 ltrs) (Group 24, 650 57 L.
Naturally Aspirated High Idle 1800 cold crank amps)
Water-Cooled Low Idle 1400 Bore x Stroke 2.0 KW Starter Oil: 8.45 Qts.
Perkins Diesel Engine Full Load 1725 55 A. Alternator 8 L.
404C-22 Cast Iron Cylinder, 3.43” x 3.64” w/ built in reg.
Block/Crankcase 32.7HP @1800 RPM (For Codes 11111 Coolant: 9.5 Qts.
and Below) 9.0 L.
65 A. Alternator
w/ built in reg.
(For Codes 11248
and Above)
RATED OUTPUT @ 104°F(40°C) - WELDER

DESCRIPTION RATED DC OUTPUT * Duty DC CURRENT RANGE
VOLTS @ RATED AMPS CYCLE Fine Adjustments in each Range
40-350 Amps
220-Max.
300 Amp DC Welder 30V @ 250A 100% 160-240
All Copper Windings 32V @ 300A 60% 120-190
Pure DC Power Generator 99V DC Max. OCV @ 1800RPM 80-130
Min.-90
RATED OUTPUT @ 104°F(40°C) - GENERATOR

Auxiliary Power (1)
3,000 Watts Continuous, 60 Hz AC
26 Amps @ 115V
13 Amps @ 230V
PHYSICAL DIMENSIONS (2)

MODEL HEIGHT WIDTH DEPTH WEIGHT
K1643-3 CSA
w/o Wire Feed Module 1354 lbs.
(Codes 11110, 11248, 45.5 in. 24.00 in. 65.0 in. (616 kg)
11280) (1156 mm) (610 mm) (1651 mm
K1643-4 CSA
w/ Wire Feed Module 1389lbs.
(Codes 11111, 11249, (630 kg)
11281)
(1) Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to
rated capacity. When welding, available auxiliary power will be reduced.

GENERAL DESCRIPTION All Copper Windings - For long life and dependable
operation.
The Classic® 300D Perkins is a heavy duty, engine dri- Engine Idler - The Classic® 300D Perkins is
ven, DC arc welding power source, capable of provid- equipped with an electronic automatic engine idler. It
ing constant current output for stick welding or DC TIG automatically increases and decreases engine speed
welding. This welder is wound with all copper coils, when starting and stopping welding or using auxil-
rated at 300 amps/32 Volts, and provides other iary power. A built-in time delay permits changing
Classic® features such as improved door latches and electrodes before the engine slows to its low idle
stainless hinges. With the addition of the optional speed. The “Idler” control switch on the panel locks the
K623-1 Wire Feed Module™, the Classic® 300D idler in high idle position when desired.
Perkins will provide constant voltage output for running
the LN-7, LN-23P, or LN-25 wire feeders. (The Wire Auxiliary Power - 3.0 KVA of nominal 115/230V, 60Hz,
Feed Module is factory installed on the K1643-4). The AC. Output voltage is maintained within ± 10% at all
optional K924-5 Remote Control Kit, provides a remote loads up to rated capacity. (See Optional Features
control rheostat for remote fine current and open circuit Section C for Power Plug Kit.)
voltage adjustment. See Section C for description.
GFCI Receptacle - One UL approved 115V ground
fault circuit interrupter duplex type receptacle is stan-
The Classic® 300D Perkins has an Electronic Engine dard. See the MAINTENANCE section for detailed
Protection System. In the event of sudden low oil pres- information on testing and resetting the GFCI recepta-
sure or high coolant temperature, the engine immedi- cle.
ately shuts down. The Classic® 300D Perkins has a
current range of 40-350 DC amps with output ratings Welder Enclosure - The complete welder is rubber
as follows: mounted on a rugged steel “C” channel base.

250A @ 30V 100% dard.
300A @ 32V 60%

These units are also capable of providing 3 KVA of
elbow are standard.
115/230 volts of 60 cycle AC auxiliary power.
Engine Hour Meter - A meter to record hours of oper-

The Classic® 300D Perkins uses the Perkins 404C-22 ation.
industrial water-cooled diesel engine.
DESIGN FEATURES down in the event of sudden low oil pressure or high
Control Panel panel will indicate such a fault. To reset the engine for
Both the engine and the welder controls are located on
one recessed panel at the exciter end of the machine.
Oil Drain Valve - A ball valve, hose and clamp are
The welder controls consist of a five step “Current
standard.
Range Selector” switch and a “Fine Current
Adjustment” rheostat. The welder is equipped with a
Remote Control - The Remote / Local Switch and
“Start” button, an “Ignition” switch, an “Idler” control
Receptacle are standard.
switch, and a “Glow Plug” button for easier cold weath-
er starting.
The control panel also contains an engine temperature

gauge, a battery charging ammeter, an oil pressure
gauge, for auxiliary power one three prong grounding
type receptacles, one GFCI receptacle and circuit
breakers for protection.


WARNING DO NOT MOUNT OVER COMBUSTIBLE SUR-
FACES.
Do not attempt to use this equipment until you Where there is a combustible surface directly under sta-
have thoroughly read the engine manufacturerʼs tionary or fixed electrical equipment, the surface shall be
manual supplied with your welder. It includes covered with a steel plate at least .06”(1.6mm) thick,
important safety precautions, detailed engine which shall extend not more than 5.90”(150mm) beyond
starting, operating and maintenance instructions, the equipment on all sides.
and parts lists.
--------------------------------------------------------------------------------
------------------------------------------------------------------------
ELECTRIC SHOCK can kill. MACHINE GROUNDING
• Do not touch electrically live parts or According to the United States National Electrical
electrode with skin or wet clothing. Code, the frame of this portable generator is not
ground required to be grounded and is permitted to serve as
• Always wear dry insulating gloves. the grounding means for cord connected equipment
------------------------------------------------------------------------ plugged into its receptacle.
• Use in open, well ventilated areas or Some state, local, or other codes or unusual operating
vent exhaust outside. circumstances may require the machine frame to be
grounded. It is recommended that you determine the

------------------------------------------------------------------------ extent to which such requirements may apply to your

MOVING PARTS can injure. particular situation and follow them explicitly. A
• Do not operate with doors open or machine grounding stud marked with the symbol is
guards off. provided on the welding generator frame foot. In gen-
• Stop engine before servicing. eral, if the machine is to be grounded, it should be con-
• Keep away from moving parts. nected with a #8 or larger copper wire to a solid earth
ground such as a metal water pipe going into the
------------------------------------------------------------------------
See additional warning information at the ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
front of this operatorʼs manual. has been effectively grounded. The U.S. National
-----------------------------------------------------------
EXHAUST SPARK ARRESTER
Some federal, state or local laws may require that LIFT BAIL
engines be equipped with exhaust spark arresters A lift bail is provided for lifting with a hoist.
WARNING

standard muffler included with this welder does not • Lift only with equipment of adequate
qualify as a spark arrester. When required by local lifting capacity.
regulations, a suitable spark arrester must be installed • Be sure machine is stable when lifting.
and properly maintained. • Do not lift this machine using lift bail if
it is equipped with a heavy accessory
CAUTION such as trailer or gas cylinder.
FALLING • Do not lift machine if lift bail is
Use of an incorrect arrester may lead to engine damage
EQUIPMENT can damaged.
or performance loss. Contact the engine manufacturer for
specific recommendations. cause injury. • Do not operate machine while
------------------------------------------------------------------------ suspended from lift bail.
LOCATION / VENTILATION ----------------------------------------------------------------------------
TRAILER (SEE OPTIONAL FEATURES)
Always operate the welder with the doors closed.
If the user adapts a non-Lincoln trailer, he must assume
Leaving the doors open changes the designed air flow
responsibility that the method of attachment and usage
and may cause overheating.

does not result in a safety hazard nor damage the weld-
ing equipment. Some of the factors to be considered are
as follows:
1. Design capacity of trailer vs. weight of Lincoln equip-
ment and likely additional attachments.
outside area.

2. Proper support of, and attachment to, the base of PRE-OPERATION SERVICE
the welding equipment so there will be no undue
CAUTION
stress to the framework.

3. Proper placement of the equipment on the trailer to READ the engine operating and maintenance instruc-
ensure stability side to side and front to back when tions supplied with this machine.
WARNING
ness of surface on which the trailer will be operat-
ed; environmental conditions, likely maintenance.


from tank.
(1) Consult your federal, state and local laws regarding specific
requirements for use on public highways.
VEHICLE MOUNTING
fueling.
DIESEL FUEL
• Wipe up spilled fuel and allow
WARNING can
fumes to clear before starting
cause fire
engine.
Improperly mounted concentrated loads may

• Do not overfill tank, fuel expan-
cause unstable vehicle handling and tires or other
sion may cause overflow.
components to fail.
------------------------------------------------------------------------
DIESEL FUEL ONLY
• Only transport this Equipment on serviceable
vehicles which are rated and designed for such OIL
loads.
• Distribute, balance and secure loads so vehicle This unit is supplied from the factory with the engine
is stable under conditions of use. crankcase filled with a high quality SAE 10W/30 oil.
• Do not exceed maximum rated loads for compo- This oil should be acceptable for most typical ambient
nents such as suspension, axles and tires. temperatures. Consult the engine operation manual
• Use appropriate nuts bolts and lockwashers to for specific engine manufacturerʼs recommendations.
attach the equipment base to the metal bed or Upon receipt of the welder, check the engine dipstick to
frame of vehicle. be sure the oil is at the “full” mark. DO NOT overfill.
• Follow vehicle manufacturerʼs instructions.
------------------------------------------------------------------------ FUEL
POLARITY CONTROL AND CABLE SIZES Fill the fuel tank with the grade of fuel recommended in
the Engine Operatorʼs manual. Make sure the fuel
With the engine off, route the electrode and work valve on the water separator is in the open position.
cables through the strain relief bracket on the base and
connect to the studs located below the fuel tank mount-
ing rail. (See size recommendations below.) For pos- COOLING SYSTEM
itive polarity, connect the electrode cable to the termi-
nal marked “+”. For Negative polarity, connect the The radiator has been filled at the factory with a 50-50
electrode cable to the “-” stud. These connections mixture of ethylene glycol antifreeze and water. Check
should be checked periodically and tightened if neces- the radiator level and add a 50-50 solution as needed
sary. (see engine manual or antifreeze container for alter-
When welding at a considerable distance from the
welder, be sure you use ample sized welding cables.
RECOMMENDED COPPER CABLE SIZES

Amps Duty Cycle Up to 200ft.(61m) 200 to 250ft.

(61 to 76m)
250 100% 1 1/0
300 60% 1/0 2/0

BATTERY CHARGING
WARNING
GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes
away.

skin.
careful when boosting, charging or
working near battery.
To prevent EXPLOSION when:

a) Installing a new battery - disconnect the
negative cable from the old battery first and
connect the negative cable to the new battery
last.
b) Connecting a battery charger - remove the

battery from the welder by disconnecting the

negative cable first, then the positive cable and
c) Using a booster - connect the positive lead to
the battery first, then connect the negative lead to
the ground lead on the base.
To prevent ELECTRICAL DAMAGE when:

a) Installing a new battery.
b) Using a booster.
• To prevent BATTERY DISCHARGE, if you have an

ignition switch, turn it off when engine is not
running.
• To prevent BATTERY BUCKLING, tighten nuts on

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


Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2.3
Idler Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2.4


B2.2 OPERATION B2.2
WARNING

------------------------------------------------------------------------
------------------------------------------------------------------------ Note: Extreme cold weather staring may require longer
• Use in open, well ventilated areas or glow plug operation.
------------------------------------------------------------------------ WARNING
guards off.
• Keep away from moving parts. HIGH ALTITUDE OPERATION:
------------------------------------------------------------------------
The engine will run correctly up to an altitude of 600m
See additional warning information at the (2000ft.). If the engine is to be operated permanently at
front of this operatorʼs manual. an altitude above this, the fuel consumption and
exhaust emissions may be excessive.
------------------------------------------------------------
Contact the Perkins Application Department for any
Operate the welder with the doors closed. Leaving the engine adjustments that may be required.
doors open changes the designed air flow and can
cause overheating. STOPPING THE ENGINE
1. Turn the “IGNITION” switch to “OFF”

STARTING THE CLASSIC® 300D PERKINS
404C-22 DIESEL ENGINE At the end of each dayʼs welding, check the crankcase
oil level, drain accumulated dirt and water from the
1. Turn the “IDLER” switch to “HIGH”. water separator located on the fuel rail. Refill the fuel
2. Turn the “IGNITION” switch to “ON”. tank to minimize moisture condensation in the tank.
3. Press the Glow Plug button for 20 to 30 seconds. Also, running out of fuel tends to draw dirt into the fuel
(maximum 60 seconds). system.
4. Press the Start button. When the engine starts
running, release both buttons. If the engine fails to When hauling the welder between job sites, close the
start in 20 seconds, wait 30 seconds and repeat fuel feed valve on the separator located on the fuel rail.
5. Observe the oil pressure. If no pressure shows If the fuel supply is cut off or runs out while the fuel
within 30 seconds, stop the engine and consult the pump is operating, air may be entrapped in the fuel dis-
engine operating manual. To stop the engine, turn tribution system. If this happens, bleeding of the fuel
the “IGNITION” switch to “OFF”. system may be necessary. Use qualified personnel to
6. If the engine protection warning light comes on do this per the instructions in the MAINTENANCE sec-
during cranking or after start up, the “IGNITION” tion of this manual.
protection system.

B2.3 OPERATION B2.3
ENGINE BREAK-IN The NEMA output rating of the Classic® 300D Perkins is 300
amperes at 32 arc volts on a 60% duty cycle (consult
Specifications in this manual for alternate ratings). Duty
Lincoln Electric selects high quality, heavy-duty industrial

engines for the portable welding machines we offer. cycle is based on a ten minute period; thus, the welder can
While it is normal to see a small amount of crankcase oil be loaded at rated output for six minutes out of every ten
consumption during initial operation, excessive oil use, minute period.
wet stacking (oil or tar like substance at the exhaust port),
or excessive smoke is not normal. CONTROL OF WELDING CURRENT
Larger machines with a capacity of 350 amperes and CAUTION

higher, which are operated at low or no-load conditions for
extended periods of time are especially susceptible to the DO NOT TURN THE “CURRENT RANGE SELECTOR”
conditions described above. To accomplish successful WHILE WELDING because the current may arc between
engine break-in, most diesel-powered equipment needs the contacts and damage the switch.
only to be run at a reasonably heavy load within the rating -------------------------------------------------------------------------------
of the welder for some period of time during the engineʼs The “Current Range Selector” provides five overlapping cur-
early life. However, if the welder is subjected to extensive rent ranges. The “Fine Current Adjustment” adjusts the cur-
light loading, occasional moderate to heavy loading of the rent from minimum to maximum within each range. Open cir-
engine may sometimes be necessary. Caution must be cuit voltage is also controlled by the “Fine Current
observed in correctly loading a diesel/generator unit. Adjustment” permitting control of the arc characteristics.
1. Connect the welder output studs to a suitable resis- A high open circuit voltage setting provides the soft “butter-
tive load bank. Note that any attempt to short the ing” arc with best resistance to pop-outs preferred for most
output studs by connecting the welding leads togeth- welding. To get this characteristic, set the “Current Range
er, direct shorting of the output studs, or connecting Selector” to the lowest setting that still provides the current
the output leads to a length of steel will result in cat- you need and set the “Fine Current Adjustment” near maxi-
astrophic damage to the generator and voids the mum.
warranty.
2. Set the welder controls for an output current and volt- For example: to obtain 175 amps and a soft arc, set the
age within the welder rating and duty cycle. Note that “Current Range Selector” to the 190-120 position and then
any attempt to exceed the welder rating or duty cycle adjust the “Fine Current Adjustment” for 175 amps.
for any period of time will result in catastrophic dam-
age to the generator and voids the warranty. When a forceful “digging” arc is required, usually for vertical
3. Periodically shut off the engine and check the and overhead welding, use a higher “Current Range
crankcase oil level. Selector” setting and lower open circuit voltage.
WELDER OPERATION For example: to obtain 175 amps and a forceful arc, set the
“Current Range Selector” to the 240-160 position and the
“Fine Current Adjustment” setting to get 175 amps.
DUTY CYCLE
WARNING
Some arc instability may be experienced with EXX10 elec-
trodes when trying to operate with long arc techniques at set-
ELECTRIC SHOCK can kill. tings at the lower end of the open circuit voltage range.
• Do not touch electrically live parts or
• Insulate yourself from work and ground.
CAUTION
DO NOT attempt to set the “Current Range Selector” between
FUMES & GASES can be dangerous.
the five points designated on the nameplate.
• Keep your head out of the fumes.
• Use ventilation or exhaust to remove --------------------------------------------------------------------------------
These switches have a spring loaded cam which almost elim-
WELDING SPARKS can cause fire or inates the possibility of setting this switch between the des-
explosion.
ignated points.
• Keep flammable material away.
ARC RAYS can burn.


B2.4 OPERATION B2.4
IDLER OPERATION AUXILIARY POWER

Start the engine with the “Idler” switch in the “High” If a GFCI receptacle is tripped, See the MAINTE-
position. Allow it to run at high idle speed for several NANCE section for detailed information on testing and
minutes to warm the engine. See Specifications for resetting the GFCI receptacle.
operating speeds.
The idler is controlled by the “Idler” toggle switch on the rating of 3.0 KVA of 115/230 VAC (60 hertz).
welder control panel. The switch has two positions as
follows: With the 3.0 KVA, 115/230 VAC auxiliary power, one
115V GFCI and one 230V duplex, grounding type
1. In the “High” position, the idler solenoid deac- receptacles are provided. The circuit is protected with
tivates, and the engine goes to high idle speed. The circuit breakers.
The rating of 3.0 KVA permits a maximum continuous
2. In the “Auto” / position, the idler oper- current of 13 amps to be drawn from the 230 volt
ates as follows: duplex receptacle. Or a total of 20 amps can be drawn
from the 115 volt GFCI receptacle. The total combined
a. When welding or drawing power for lights or tools
load of all receptacles is not to exceed 3.0 KVA.

(approximately 100 watts minimum) from the
receptacles, the idler solenoid deactivates and the An optional power plug kit is available. When this kit is
engine operates at high idle speed. specified, the customer is supplied with a plug for each
receptacle.
b. When welding ceases or the power load is turned
starts. This time delay cannot be adjusted.
c. If the welding or power load is not re-started

before the end of the time delay, the idler solenoid
activates and reduces the engine to low idle
speed.
CLASSIC® 300D PERKINS WITH PERKINS 104-22 DIESEL ENGINE

TYPICAL FUEL CONSUMPTION DATA
3000 Watts 0.59 gal/hr ( 2.23 ltrs/hr)


Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2.2


OPTIONAL FEATURES (Field Installed) TIG OPTIONS
TIG Module K930-2

GENERAL OPTIONS
Provides high frequency and shielding gas control for
AC and DC GTAW (TIG) welding applications. Its com-
pact case is designed for easy carrying, complete with
WARNING a handle. High frequency bypass is built in.
Pipe Thawing with an arc welder can cause fire, Additionally, the K936-3 control cable is required if
explosion, damage to electric wiring or to the arc remote control is used. If remote control is not used the
welder if done improperly. The use of an arc welder K936-4 control cable is required.
for pipe thawing is not approved by the CSA, nor is
it recommended or supported by Lincoln Electric. PTA-26V TIG Torch K1783-9
------------------------------------------------------------------------ Air cooled 200 amp torch equipped with valve for gas
flow control. 25Ft. length.
Power Plug Kit K802D
A power plug kit for the auxiliary power receptacles is Magnum Parts Kit For PTA-26V TIG Torch KP509
available. (Provides a plug for each receptacle.)
Control Cable K936-4 (required for TIG Module)
Spark Arrestor Kit K903-1 Control cable for connecting the K930-2 TIG Module.
Includes a heavy gage steel, approved spark arrestor,

clamp and adapter for mounting to the muffler exhaust Arc Start Switch K814 (required for TIG Module)
pipe. Comes with a 25ft.(7.6m) cable.
Attaches to the TIG torch for convenient finger control.
TRAILER K953-1
Two-wheeled trailer with optional fender and light package. Contactor Kit K938-1 (required for TIG Module)
For highway use, consult applicable federal, state, and local Provide “Cold” tungsten Tip when welding with the TIG
laws regarding possible additional requirements. There is a Module.
choice of 2 hitches, a fender & a light package.
Control Cable Extension K937-45
Ball Hitch K958-1 Allows the TIG Module to be operated at distances up
Lunette Eye Hitch K958-2 to 200 ft. from the power source.Available in 45 ft.
Fender & Light Kit K959-1 (13.7m).
Cable Rack K965-1
Water Valve Kit K844-1
Service Indicator Kit K1858-1 For use with a water-cooled TIG torch. Installs inside
TIG Module.
Provides a GO / NO-GO visual indication of air clean-

er element useful service life. Filter service based on
restriction readings allows the longest life possible
from the filter and best engine protection.
STICK OPTIONS
ACCESSORY SET K704

Includes 35 feet (10 m) of electrode cable and 30 feet
(9 m) of work cable, headshield, work clamp and elec-
trode holder. Cable is rated at 500 amps, 60% duty
cycle.
Remote Control Kit K924-5

Contains remote control rheostat and 100 ft. (30.5 m)
cable for adjusting the OCV at the welding site.

WIRE FEEDER OPTIONS

Wire Feed Module K623-1 Magnum Spool Gun K487-25

Provides constant voltage (CV) output with improved Hand held semiautomatic wire feeder requires SG
arc stability for Innershield welding. Excellent for MIG Control Module. 25 ft. length.
welding. Recommended wire feeders are the LN-7,
LN-23P and LN-25. (Factory installed on the K1643-2). SG Control Module K488 (For Magnum Spool Gun)
The interface between the power source and the
spool gun. Provides control of wire speed and gas
flow.
LN-25 Wire Feeder K449
Portable CC/CV unit for flux-cored and MIG welding.
Includes Gas Solenoid & Internal Contactor. Requires
Wire Feed Module.
Input Cable K691-10 ( For SG Control Module)
For Lincoln engine drives with 14-pin MS-type connec-
tion, separate 115V NEMA receptacle and output
stud connections. 10 ft. length.

Magnum® 350 Innershield Gun for LN-25 K126-2
.062-3/32” (1.6-2.8mm) wire.
Magnum® 300 MIG Gun for LN-25 K1802-1

With 15 ft. (4.5m) cable. For .035”-.045” (0.9-1.2mm)
gas shielded (Includes Connector Kit).
LN-23P Wire Feeder K316L-1

Portable CV unit for Innershield pipe welding. Control
cable operates contactor inside Wire Feed Module for
“cold” electrode. Requires LN-23P Adapter Kit (K350-
1) and Gun and Cable Assembly.
LN-23P Adapter Kit K350-1

Required to adapt LN-23P to any Lincoln power
source. Makes 14 pin connection at power source.
Magnum® 250 Innershield Gun for LN-23P K355-10

For lighter weight and easier handling. Rated 250
62° gun tube for pipe welding KP1909-1


guns with 90° gun tubes. Compatible with K126-1,-2,
K264-8 and K355-10.

NOTES

C2.4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.2
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.4/D2.5


SAFETY PRECAUTIONS 4. Follow the engine service schedule in this manual

WARNING
and the detailed maintenance and troubleshooting
in the engine manufacturerʼs manual.

work. Turn the engine off before working inside COOLING SYSTEM
the machine. In some cases, it may be necessary
to remove safety guards to perform required The Classic® 300D Perkins is equipped with a pres-
maintenance. Remove guards only when neces- sure radiator. Keep the radiator cap tight to prevent
sary and replace them when the maintenance loss of coolant. Clean and flush the cooling system
requiring their removal is complete. Always use periodically to prevent clogging the passage and over-
the greatest care when working near moving heating the engine. When antifreeze is needed, always
parts. use the permanent type.
BEARINGS
Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to bearing having sufficient grease to last indefinitely
the nearest Lincoln Field Service Shop. under normal service. Where the welder is used con-
----------------------------------------------------------------------- stantly or in excessively dirty locations, it may be nec-
essary to add one half ounce of grease per year. A pad

• Do not touch electrically live parts or of grease one inch wide, one inch long, and one inch
high weighs approximately one half ounce. Over-
ground greasing is far worse than insufficient greasing.
When greasing the bearings, keep all dirt out of the
------------------------------------------------------------------------ area. Wipe the fittings completely clean and use clean
ENGINE EXHAUST can kill. equipment. More bearing failures are caused by dirt
• Use in open, well ventilated areas or introduced during greasing than from insufficient
vent exhaust outside. grease.
COMMUTATOR AND BRUSHES

------------------------------------------------------------------------
WARNING
MOVING PARTS can injure.
guards off.
• Stop engine before servicing. Uncovered rotating equipment can be dangerous.
• Keep away from moving parts. Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself
------------------------------------------------------------------------
See additional warning information at from particles that may be thrown out by the rotat-
front of this operatorʼs manual. ing armature when stoning the commutator.
------------------------------------------------------------------------
----------------------------------------------------------- Shifting of the commutator brushes may result in:
- Change in machine output
- Commutator damage
GENERAL INSTRUCTIONS - Excessive brush wear
1. Blow out the welder and controls with an air hose at Periodically inspect the commutator, slip rings, and
least once every two months. In particularly dirty brushes by removing the covers. DO NOT remove or
locations, this cleaning may be necessary once a replace these covers while the machine is running.
week. Use low pressure air to avoid driving dirt into Commutators and slip rings require little attention.
the insulation. However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
2. “Current Range Selector” contacts should not be using fine sandpaper or a commutator stone. Never
greased. To keep the contacts clean, rotate the cur- use emery cloth or paper for this purpose.
rent control through its entire range frequently. Good
practice is to turn the handle from maximum to min-

imum setting twice each morning before starting to
weld.

Replace brushes when they wear within 1/4” of the pig- PURGING AIR FROM FUEL SYSTEM
tail. A complete set of replacement brushes should be (PERKINS 404C-22 ENGINE)
WARNING
tator as the armature rotates at full speed until contact
Keep fuel clear of open flames or arcs, allow
is made across the full face of the brushes. After ston-
engine to cool before working on the fuel system.
ing, blow out the dust with low pressure air.
Wipe up any spilled fuel and do not start engine

IDLER MAINTENANCE Vent Screw
CAUTION
------------------------------------------------------------------------
FIGURE D2.3
2. Operate the electric fuel pump by turning the
lems persist.
tery.
2. Idler solenoid is activated for low idle.

position.
NAMEPLATES

item number.

SERVICE DECAL FOR CODES 11249 AND BELOW
ENGINE SERVICE
EVERY 1000 HOURS

I Coolant level
R Coolant (NOTE 3) 9.5qrts., 9.0L
R R Engine oil (NOTE 1 & 3) 8.45Qrts, 8L (including filter)
C Drain water separator & fuel strainer
R Alternator drive belt Perkins #080109107
C Air filter(earlier check may be req'd.)
R Air filter element Donaldson #P821575
R Renew the engine breather
I Battery
Notes:
These preventive maintenance periods apply to average conditions of operation. C


MAINTENANCE
SERVICE DECAL FOR CODES 11250 AND ABOVE

D2.5
GFCI RECEPTACLE TESTING AND RESET-

TING PROCEDURE


restarted.





2. Engine Assembly
6. Exciter & Stator
7. Welding Generator & Coupling
8. Roof & Doors

1
4
5
7
9
6

NOTES

D2.8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3
Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.5



TECHNICAL SPECIFICATIONS - CLASSIC® 300D KUBOTA


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 Low Idle 1400 Bore x Stroke 1.4 KW Starter Oil: 8.0 Qts.
Cast Iron Cylinder, Full Load 1800 40 A. Alternator 7.6 L
Block/Crankcase 3.43” x 3.64” w/ built in reg. Coolant:
32.5HP @1800 RPM 9.5 Qts.
9.0 L

DESCRIPTION RATED DC OUTPUT* Duty DC CURRENT RANGE

40-350 Amps
220-Max.
300 Amp DC Welder 30V @ 250A 100% 160-240
Min.-90

Auxiliary Power (1)
26 Amps @ 115V
13 Amps @ 230V
K1643-5 CSA@ 1320 lbs.

With Out (599 kg)
Wire Feed Module
45.5 in. 24.00 in. 66.36 in.
K1643-6 CSA @ (1156 mm) (610 mm) (1686 mm) 1355 lbs.
With Wire Feed Module (615 kg)


GENERAL DESCRIPTION Engine Idler - The Classic® 300D is equipped with an

electronic automatic engine idler. It automatically
increases and decreases engine speed when starting
The CLASSIC® 300D KUBOTA is a heavy duty, engine

and stopping welding or using auxiliary power. A
driven, DC arc welding power source, capable of pro-
built-in time delay permits changing electrodes before
viding constant current output for stick welding or DC
the engine slows to its low idle speed. The “Idler” con-
TIG welding. This welder is wound with all copper coils,
trol switch on the panel locks the idler in high idle posi-
rated at 300 amps/32 Volts, and provides other
tion when desired.
Classic® features such as improved door latches and
stainless hinges. With the addition of the optional Auxiliary Power - 3.0 kVA of nominal 115/230V, 60Hz,
K623-1 Wire Feed Module™, the CLASSIC® 300D AC. Output voltage is maintained within ± 10% at all
KUBOTA will provide constant voltage output for run- loads up to rated capacity. (See Optional Features
ning the LN-7, LN-23P, or LN-25 wire feeders. (The in Section C for Power Plug Kit.)
Wire Feed Module is factory installed on the K1643-6).
The optional K924-5 Remote Control Kit, provides a Welder Enclosure - The complete welder is rubber
remote control rheostat for remote fine current and mounted on a rugged steel “C” channel base.
open circuit voltage adjustment. See Section C for
description.
The CLASSIC® 300D KUBOTA has an Electronic

Engine Protection System. In the event of sudden low Cranking System - A 12 volt electric starter is stan-
oil pressure or high coolant temperature, the engine dard.
immediately shuts down. The CLASSIC® 300D KUB-
OTA has a current range of 40-350 DC amps with out- Air Cleaner - Heavy duty two stage dry type.
put ratings as follows:
RATED OUTPUT DUTY CYCLE elbow are standard.
250A @ 30V 100% Engine Hour Meter - A meter to record hours of oper-
300A @ 32V 60% ation.

These units are also capable of providing 3 kVA of down in the event of sudden low oil pressure or high
115/230 volts of 60 cycle AC auxiliary power. coolant temperature. A warning light on the control
The CLASSIC® 300D KUBOTA uses the Kubota restarting, turn the ignition switch off then on.
V2203M industrial water-cooled diesel engine. Refer to Troubleshooting section for all warning light
fault codes.
DESIGN FEATURES
High Idle RPM (OCV) Adjustment - A Potentiometer
Control Panel
is mounted on the Control Panel that allows the opera-
Both the engine and the welder controls are located on tor to adjust the high idle engine speed between 1650
one recessed panel at the exciter end of the machine. and 1800 RPMʼS. This is to allow further adjustment of
The welder controls consist of a five step “Current the OCV. Total OCV adjustment range is about 15
Range Selector” switch and a “Fine Current volts.
“Start” button, an “Ignition” switch, an “Idler” control Oil Drain Valve - A ball valve, hose and clamp are
switch, and a “Glow Plug” button for easier cold weath- standard.
er starting.
Remote Control - The Remote/Local switch and
The control panel also contains an engine temperature Receptacle are standard.
gauge, two three prong grounding type receptacles GFCI Receptacle - One UL approved 115V ground
and circuit breakers for auxiliary power. fault circuit interupter duplex type receptacle is stan-
dard on codes 11243 and above. See MAINTENANCE
All Copper Windings - For long life and dependable section for detailed information on testing and resetting
operation. the GFCI receptacle.


WARNING DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Do not attempt to use this equipment until you have Where there is a combustible surface directly under sta-
thoroughly read the engine manufacturerʼs manual sup- tionary or fixed electrical equipment, the surface shall be
plied with your welder. It includes important safety pre- covered with a steel plate at least .06”(1.6mm) thick,
cautions, detailed engine starting, operating and mainte- which shall extend not more than 5.90”(150mm) beyond
nance instructions, and parts lists. the equipment on all side.
------------------------------------------------------------------------ --------------------------------------------------------------------------------
• Do not touch electrically live parts or elec-
trode with skin or wet clothing. If the engine is to be operated at an angle, provisions must be
• Insulate yourself from work and ground made for checking and maintaining the oil level at the normal
• Always wear dry insulating gloves. (FULL) oil capacity in the crankcase.
--------------------------------------------------------------------------------
ENGINE EXHAUST can kill. When operating the welder at an angle, the effective fuel
• Use in open, well ventilated areas or vent capacity will be slightly less than the amount specified.
exhaust outside.
-------------------------------------------------------------------------------- MACHINE GROUNDING

• Do not operate with doors open or guards According to the United States National Electrical Code, the
off.
frame of this portable generator is not required to be grounded
• Stop engine before servicing.
• Keep away from moving parts. and is permitted to serve as the grounding means for cord con-
-------------------------------------------------------------------------------- nected equipment plugged into its receptacle.
See additional warning information at the front
of this operatorʼs manual. Some state, local, or other codes or unusual operating circum-
----------------------------------------------------------------- stances may require the machine frame to be grounded. It is
recommended that you determine the extent to which such
EXHAUST SPARK ARRESTER requirements may apply to your particular situation and follow
Some federal, state or local laws may require that engines be them explicitly. A machine grounding stud marked with the sym-
equipped with exhaust spark arresters when they are oper- bol is provided on the welding generator frame foot. In gen-
ated in certain locations where unarrested sparks may pre- eral, if the machine is to be grounded, it should be connected
sent a fire hazard. The standard muffler included with this with a #8 or larger copper wire to a solid earth ground such as
welder does not qualify as a spark arrester. When required a metal water pipe going into the ground for at least ten feet
by local regulations, a suitable spark arrester must be and having no insulated joints, or to the metal framework of a
installed and properly maintained. building which has been effectively grounded. The U.S.
National Code lists a number of alternate means of grounding

CAUTION
Use of an incorrect arrester may lead to engine damage or LIFT BAIL
performance loss. Contact the engine manufacturer for spe- A lift bail is provided for lifting with a hoist.
cific recommendations.
--------------------------------------------------------------------------------
LOCATION/VENTILATION WARNING
Always operate the welder with the doors closed. Leaving the • Lift only with equipment of ade-
doors open changes the designed air flow and may cause quate lifting capacity.
overheating. • Be sure machine is stable when
lifting.
The welder should be located to provide an unrestricted flow of • Do not lift this machine using
clean, cool air. Also, locate the welder so that engine exhaust lift bale if it is equipped with a
fumes are properly vented to an outside area. heavy accessory such as trailer
or gas cylinder.
ANGLE OF OPERATION FALLING • Do not lift machine if lift bale is

Engines are designed to run in the level condition which is EQUIPMENT can damaged.
where the optimum performance is achieved. The maximum cause injury. • Do not operate machine while
angle of continuous operation is 20 degrees in all directions, 30 suspended from lift bale.
degrees Intermittent (less than 10 minutes continuous) in all ------------------------------------------------------------------------
directions.
TRAILER (See Optional Features) RECOMMENDED COPPER CABLE SIZES


If the user adapts a non-Lincoln trailer, the user must

assume responsibility that the method of attachment (61 to 76m)
and usage does not result in a safety hazard nor dam- 250 100% 1 1/0
age the welding equipment. Some of the factors to be
considered are as follows: 300 60% 1/0 2/0
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
PRE-OPERATION SERVICE
the welding equipment so there will be no undue CAUTION
stress to the framework.
3. Proper placement of the equipment on the trailer to READ the engine operating and maintenance instruc-
ensure stability side to side and front to back when tions supplied with this machine.
being moved and when standing by itself while ------------------------------------------------------------------------
ness of surface on which the trailer will be operat-
WARNING
ed; environmental conditions, likely maintenance.

from tank.
VEHICLE MOUNTING
WARNING
fueling.
DIESEL FUEL
can
fumes to clear before starting
Improperly mounted concentrated loads may cause fire
engine.
components to fail.
• Only transport this Equipment on serviceable ------------------------------------------------------------------------

DIESEL FUEL ONLY
vehicles which are rated and designed for such
OIL
loads.
• Distribute, balance and secure loads so vehicle
This unit is supplied from the factory with the engine
is stable under conditions of use.

crankcase filled with a high quality SAE 10W/30 oil.
• Do not exceed maximum rated loads for compo-
This oil should be acceptable for most typical ambient
nents such as suspension, axles and tires.
temperatures. Consult the engine operation manual
• Mount equipment base to metal bed or frame of
for specific engine manufacturerʼs recommendations.
vehicle.
Upon receipt of the welder, check the engine dipstick to
• Follow vehicle manufactureʼs instructions.
be sure the oil is at the “full” mark. DO NOT overfill.
------------------------------------------------------------------------
FUEL
POLARITY CONTROL AND CABLE SIZES
Fill the fuel tank with the grade of fuel recommended in
With the engine off, route the electrode and work the Engine Operatorʼs manual. Make sure the valve on
cables through the strain relief bracket on the base and the water separator is in the open position.
ing rail. (See size recommendations below.) For pos-
itive polarity, connect the electrode cable to the termi- COOLING SYSTEM
electrode cable to the “-” stud. These connections

The radiator has been filled at the factory with a 50-50
mixture of ethylene glycol antifreeze and water. Check
sary.
the radiator level and add a 50-50 solution as needed
(see engine manual or antifreeze container for alter-
When welding at a considerable distance from the

Battery Charging
WARNING

away.

skin.
careful when boosting, charging or work-
ing near battery.

a) Installing a new battery - disconnect the
negative cable from the old battery first and
connect the negative cable to the new battery
last.
b) Connecting a battery charger - remove the
battery from the welder by disconnecting the

negative cable first, then the positive cable and
the battery first, then connect the negative lead to

b) Using a booster.

ignition switch, turn it off when engine is not
running.

------------------------------------------------------------------------
The CLASSIC® 300D KUBOTA is equipped with a wet

charged.


Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3


B3.2 OPERATION B3.2
ENGINE OPERATION COLD WEATHER STARTING:
WARNING With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to

Do not attempt to use this equipment until you about -5°F (-20°C), it maybe desirable to install cold-
have thoroughly read the engine manufacturerʼs starting aides.
manual supplied with your welder. It includes
important safety precautions, detailed engine start-
ing, operating and maintenance instructions, and Note: Extreme cold weather staring may require longer
parts lists. glow plug operation.
-------------------------------------------------------
• Do not touch electrically live parts or WARNING
Under NO conditions should ether or other starting
ground
• Always wear dry insulating gloves. fluids be used!
------------------------------------------------------- ------------------------------------------------------------------------
• Use in open, well ventilated areas or HIGH ALTITUDE OPERATION:
At higher altitudes, output derating may be necessary.

For maximum rating, derate the welder 4% for every
--------------------------------------------------------
MOVING PARTS can injure. 300 meters (984 ft.) above 1500 meters (4920 ft.).
guards off. Contact a Kubota Service Representative for any
• Stop engine before servicing. engine adjustments that may be required.
------------------------------------------------------------------------ STOPPING THE ENGINE
See additional warning information at the
front of this operatorʼs manual. 1. Turn the “IGNITION” switch to “OFF”
Operate the welder with the doors closed. Leaving the
doors open changes the designed air flow and can At the end of each dayʼs welding, check the crankcase
cause overheating. oil level, drain accumulated dirt and water from the
water separator and refill the fuel tank to minimize
STARTING THE CLASSIC® 300D KUBOTA V2203M moisture condensation in the tank. Also, running out of
DIESEL ENGINE fuel tends to draw dirt into the fuel system.
1. Turn the “IDLER” switch to “HIGH”. When hauling the welder between job sites, close the
2. Turn the “IGNITION” switch to “ON”. valve on the water separator.
3. Press the Glow Plug button for 20 to 30 seconds. (max-
imum 60 seconds). If the fuel supply is cut off or runs out while the fuel
4. Press the Glow Plug button and the Start button at the pump is operating, air may be entrapped in the fuel dis-
same time. When the engine starts running, release tribution system. If this happens, bleeding of the fuel
both buttons. If the engine fails to start in 20 seconds, system may be necessary. Use qualified personnel to
wait 30 seconds and repeat the above procedure. do this per the instructions in the MAINTENANCE sec-
5. Observe the oil pressure. If no pressure shows within tion of this manual.
30 seconds, stop the engine and consult the engine
operating manual. To stop the engine, turn the “IGNI- ENGINE BREAK-IN
TION” switch to “OFF”.
6. If the engine protection warning light comes on during Lincoln Electric selects high quality, heavy-duty indus-
cranking or after start up, the “IGNITION” switch must trial engines for the portable welding machines we
be turned “OFF” to reset the engine protection system. offer. While it is normal to see a small amount of
7. Allow the engine to run at high idle speed for several crankcase oil consumption during initial operation,
minutes to warm the engine. Stop the engine and excessive oil use, wet stacking (oil or tar like substance
recheck the oil level, after allowing sufficient time for at the exhaust port), or excessive smoke is not normal.
the oil to drain into the pan. If the level is down, fill it to
the full mark again. The engine controls were properly
set at the factory and should require no adjusting when
received.

B3.3 OPERATION B3.3
Larger machines with a capacity of 350 amperes and DUTY CYCLE

higher, which are operated at low or no-load conditions
The NEMA output rating of the CLASSIC® 300D KUB-
for extended periods of time are especially susceptible

to the conditions described above. To accomplish suc- OTA is 300 amperes at 32 arc volts on a 60% duty
cessful engine break-in, most diesel-powered equip- cycle (consult Specifications in this manual for alternate
ment needs only to be run at a reasonably heavy load ratings). Duty cycle is based on a ten minute period;
within the rating of the welder for some period of time thus, the welder can be loaded at rated output for six
during the engineʼs early life. However, if the welder is minutes out of every ten minute period.
subjected to extensive light loading, occasional moder-
ate to heavy loading of the engine may sometimes be CONTROL OF WELDING CURRENT
necessary. Caution must be observed in correctly
loading a diesel/generator unit. CAUTION
1. Connect the welder output studs to a suitable DO NOT TURN THE “CURRENT RANGE SELEC-
resistive load bank. Note that any attempt to short TOR” WHILE WELDING because the current may
the output studs by connecting the welding leads arc between the contacts and damage the switch.
together, direct shorting of the output studs, or ------------------------------------------------------------------------
connecting the output leads to a length of steel will
result in catastrophic damage to the generator and The “Current Range Selector” provides five overlap-
voids the warranty. ping current ranges. The “Fine Current Adjustment”
2. Set the welder controls for an output current and adjusts the current from minimum to maximum within
voltage within the welder rating and duty cycle. each range. Open circuit voltage is also controlled by
Note that any attempt to exceed the welder rating the “Fine Current Adjustment” permitting control of the
or duty cycle for any period of time will result in arc characteristics.
catastrophic damage to the generator and voids
the warranty. A high open circuit voltage setting provides the soft
3. Periodically shut off the engine and check the “buttering” arc with best resistance to pop-outs pre-
crankcase oil level. ferred for most welding. To get this characteristic, set
the “Current Range Selector” to the lowest setting that
still provides the current you need and set the “Fine
WELDER OPERATION Current Adjustment” near maximum. For example: to
obtain 175 amps and a soft arc, set the “Current
WARNING Range Selector” to the 190-120 position and then
adjust the “Fine Current Adjustment” for 175 amps.
• Do not touch electrically live parts or When a forceful “digging” arc is required, usually for
electrode with skin or wet clothing. vertical and overhead welding, use a higher “Current
Range Selector” setting and lower open circuit voltage.
ground.
For example: to obtain 175 amps and a forceful arc,
FUMES & GASES can be dangerous. set the “Current Range Selector” to the 240-160 posi-
• Keep your head out of the fumes. tion and the “Fine Current Adjustment” setting to get
• Use ventilation or exhaust to remove 175 amps.
electrodes when trying to operate with long arc tech-
WELDING SPARKS can cause fire or niques at settings at the lower end of the open circuit
explosion.
voltage range.
CAUTION
DO NOT attempt to set the “Current Range Selector”
ARC RAYS can burn.
• Wear eye, ear, and body protection. between the five points designated on the nameplate.
------------------------------------------------------------------------
------------------------------------------------------------------------ These switches have a spring loaded cam which

almost eliminates the possibility of setting this switch
between the designated points.

B3.4 OPERATION B3.4
IDLER OPERATION The AC auxiliary power, supplied as a standard, has a

rating of 3.0 kVA of 115/230 VAC (60 hertz).
Start the engine with the “Idler” switch in the “High”

position. Allow it to run at high idle speed for several With the 3.0 kVA, 115/230 VAC auxiliary power, one
minutes to warm the engine. See Specifications for 115V duplex and one 230V duplex, grounding type
operating speeds. receptacle are provided. The circuit is protected with
circuit breakers.
The idler is controlled by the “Idler” toggle switch on
the welder control panel. The switch has two positions The rating of 3.0 kVA permits a maximum continuous
as follows: current of 13 amps to be drawn from the 230 volt
1. In the “High” position, the engine control unit from the 115 volt duplex receptacle. The 115 volt
increases the engine to high idle speed. duplex receptacle has a configuration which permits 20
amps to be drawn from either half. The total combined
2. In the “Auto” / position, the idler oper- load of all receptacles is not to exceed 3.0 kVA.
ates as follows:
An optional power plug kit is available. When this kit is
a. When welding or drawing power for lights or tools specified, the customer is supplied with a plug for each
(approximately 100 watts minimum) from the recep- receptacle.
tacles, the engine operates at high idle speed.

When the High Speed Adjustment knob is in the MIN
b. When welding ceases or the power load is turned position, the frequency of the AC auxiliary output may
off, a preset time delay of about 15 seconds starts. be reduced to approximately 55 Hertz. It is recom-
This time delay cannot be adjusted. mended that the High Idle Speed Adjustment knob
should be in the MAX position when using the AC aux-
c. If the welding or power load is not re-started before iliary output.
the end of the time delay, the engine control unit
reduces the engine to low idle speed.
AUXILIARY POWER
Start the engine and set the “IDLER” control switch to

the “High Idle” mode. Voltage is now correct at the
receptacles for auxiliary power. This must be done
before a tripped GFCI receptacle can be reset proper-
ly. See the MAINTENANCE section for detailed infor-

mation on testing and resetting the GFCI receptacle.
CLASSIC® 300D WITH KUBOTA V2203M DIESEL ENGINE

Low Idle (1400 RPM)-No Load 0.30 gal/hr ( 1.14 ltrs/hr)
High Idle (1800 RPM)-No Load 0.46 gal/hr ( 1.74 ltrs/hr)
3,000 Watts 0.61 gal/hr ( 2.31 ltrs/hr )


Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3.1


OPTIONAL FEATURES (Field Installed) Remote Control Kit (K924-5) - Contains remote
control rheostat and 100 ft. (30.5 m) cable for adjust-
ing the OCV at the welding site. (For Codes 10911 and
GENERAL OPTIONS
above.)
Remote Control Kit (K2464-1) - Contains remote

WARNING control rheostat (for adjusting the CC “STICK” OCV),
and 100ft.(30.5m) cable. (See Wiring/Connection
Pipe Thawing with an arc welder can cause fire, Diagram Section G)
explosion, damage to electric wiring or to the arc
welder if done improperly. The use of an arc welder TIG OPTIONS
it recommended or supported by Lincoln Electric. TIG Module (K930-2) - Provides high frequency and
------------------------------------------------------------------------ shielding gas control for AC and DC GTAW (TIG) weld-
ing applications. Its compact case is designed for easy
Power Plug Kit (K802D) - A power plug kit for the aux- carrying, complete with a handle. High frequency
iliary power receptacles is available. (Provides a plug bypass is built in. The K936-4 control cable is
for each receptacle.) required.
GFCI Receptacle Kit (K1690-1) - Includes one UL PTA-26V TIG Torch (K1783-9) - Air cooled 200 amp-
approved 115V ground fault circuit interrupter duplex torch equipped with valve for gas flow control. 25Ft.
type receptacle with cover and installation instructions. length.
Replaces the factory installed 115V duplex receptacle.
Each receptacle of the GFCI duplex is rated at 20 Magnum Parts Kit For PTA-26V TIG TorchKP509
amps. Maximum total current from the GFCI duplex is
limited to 20 amps. (For Codes 11112, 11113). See Control Cable (K936-4) (required for TIG Module) -
MAINTENANCE section for detailed information on Control Cable for connecting the K930-2 Tig Module.
testing and resetting the GFCI receptacle.
Arc Start Switch (K814) (required for TIG Module) -
Spark Arrestor Kit (K903-1) - Includes a heavy gage Comes with a 25ft.(7.6m) cable. Attaches to the TIG
steel, approved spark arrestor, clamp and adapter for torch for convenient finger control.
mounting to the muffler exhaust pipe.
Contactor Kit (K938-1) (required for TIG Module) -
TRAILER (K953-1) - Two-wheeled trailer with optional fender Provide “Cold” tungsten Tip when welding with the TIG
and light package. For highway use, consult applicable feder- Module.
al, state, and local laws regarding possible additional require-
ments. There is a choice of 2 hitches, a fender & a light pack- Control Cable Extension (K937-45) - Allows the TIG
age. Module to be operated at distances up to 200 ft. from
K953-1 Trailer the power source.Available in 45 ft. (13.7m).
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch Water Valve Kit (K844-1)- For use with a water-cooled
K959-1 Fender & Light Kit TIG torch. Installs inside TIG Module.
K965-1 Cable Rack
Service Indicator Kit K1858-1 - Provides a GO / NO-

GO visual indication of air cleaner element useful ser-
vice life. Filter service based on restriction readings
allows the longest life possible from the filter and best
engine protection.
STICK OPTIONS
K704 ACCESSORY SET - Includes 35 feet (10 m) of

electrode cable and 30 feet (9 m) of work cable, head-
shield, work clamp and electrode holder. Cable is rated
at 500 amps, 60% duty cycle.

WIRE FEED OPTIONS

Magnum Spool Gun (K487-25)-Hand held semiauto-
Wire Feed Module (K623-1) - Provides constant volt-

age (CV) output with improved arc stability for matic wire feeder requires SG Control Module. 25 ft.
Innershield welding. Excellent for MIG welding. (7.6m)length.
LN-25. (Factory installed on the K1643-6). Gun) -The interface between the power source and
SG Control Module (K488) (For Magnum Spool
the spool gun. Provides control of wire speed and gas

LN-25 Wire Feeder (K449)-Portable CC/CV unit for flow.
flux-cored and MIG welding. Includes Gas Solenoid &
Internal Contactor. Requires Wire Feed Module. Input Cable (K691-10) ( For SG Control Module) -
For Lincoln engine drives with 14-pin MS-type connec-
tion provides separate 115V NEMA receptacle and out-
put stud connections. 10 ft. (3.1m)length.
Remote Voltage Control Kit for LN-25 (K444-2)


Magnum® 350 Innershield Gun (for LN-25)(K126-2)-
.062-3/32” (1.6-2.8mm) wire.
Magnum® 300 MIG Gun for LN-25 K1802-1 - With

15 ft. (4.5m) cable. For .035”-.045” (0.9-1.2mm) gas
shielded (Includes Connector Kit).
LN-23P Wire Feeder (K316L-1)-Portable CV unit for

Innershield pipe welding. Control cable operates con-
tactor inside Wire Feed Module for “cold” electrode.
Requires LN-23P Adapter Kit (K350-1) and Gun and
Cable Assembly.
LN-23P Adapter Kit (K350-1)-Required to adapt LN-

23P to any Lincoln power source. Makes 14 pin con-

nection at power source.
Magnum® 250 Innershield Gun (for LN-23P) (K355-10)-

62° gun tube for PipeWelding (KP1909-1)-

Recommended modification for K355-X or K345-X
guns with 90° gun tubes. Compatible with K126-1,-2
K264-8 and K355-10.

NOTES

C3.4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.2
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.4


MAINTENANCE 4. Follow the engine service schedule in this manual
WARNING
and the detailed maintenance and troubleshooting in
the engine manufacturerʼs manual.

work. Turn the engine off before working inside COOLING SYSTEM
the machine. In some cases, it may be necessary
to remove safety guards to perform required The CLASSIC® 300D KUBOTA is equipped with a
maintenance. Remove guards only when neces- pressure radiator. Keep the radiator cap tight to pre-
sary and replace them when the maintenance vent loss of coolant. Clean and flush the cooling sys-
requiring their removal is complete. Always use tem periodically to prevent clogging the passage and
the greatest care when working near moving overheating the engine. When antifreeze is needed,
parts. always use the permanent type.
BEARINGS
blower fan. If a problem cannot be corrected by

high weighs approximately one half ounce. Over-
ground greasing is far worse than insufficient greasing.
When greasing the bearings, keep all dirt out of the
------------------------------------------------------------------------ area. Wipe the fittings completely clean and use clean
ENGINE EXHAUST can kill. equipment. More bearing failures are caused by dirt
• Use in open, well ventilated areas or introduced during greasing than from insufficient

------------------------------------------------------------------------
WARNING
guards off.
• Stop engine before servicing. Uncovered rotating equipment can be dangerous.
• Keep away from moving parts. Use care so your hands, hair, clothing or tools do
------------------------------------------------------------------------ not catch in the rotating parts. Protect yourself

See additional warning information at from particles that may be thrown out by the rotat-
front of this operatorʼs manual. ing armature when stoning the commutator.
------------------------------------------------------------------------
- Commutator damage

weld.

Replace brushes when they wear within 1/4”(3.5mm) PURGING AIR FROM FUEL SYSTEM
of the pigtail. A complete set of replacement brushes (KUBOTA V2203M ENGINE)
should be kept on hand. Lincoln brushes have a
WARNING
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
Keep fuel clear of open flames or arcs, allow
speed until contact is made across the full face of the
engine to cool before working on the fuel system.
brushes. After stoning, blow out the dust with low pres-
Wipe up any spilled fuel and do not start engine
sure air.
until fumes clear.
To seat slip ring brushes, position the brushes in place. ------------------------------------------------------------------------
Then slide one end of a piece of fine sandpaper If the engine is running rough and you suspect air has
between slip rings and brushes with the coarse side been trapped in the fuel system, (e.g. the engine was
against the brushes. With slight additional finger pres- allowed to run out of fuel) perform the following steps
sure on top of the brushes, pull the sandpaper around using qualified personnel:
the circumference of the rings - in direction of rotation
only - until brushes seat properly. In addition, stone slip 1. Fully open the air bleeding valve by turning it
ring with a fine stone. Brushes must be seated 100%. counter clockwise, it is located on top of the fuel
injection pump next to the oil filler. (see figure D3.3)

IDLER MAINTENANCE Air Bleeding

Valve
CAUTION
Before doing electrical work, disconnect the bat-
tery.
------------------------------------------------------------------------
FIGURE D3.3
2. Turn the engine by pressing the start button until
the engine runs smoothly (this should take approx-
ground. Damage to the engine alternator and the
imately 10 seconds).
Engine Control Unit can result from incorrect connec-
tion.
3. Fully close the air bleeding valve by turning it clock-

wise.
ing of the Engine Control Unit, current sensing
Contact your Kubota Engine repair facility if problems
printed circuit board and battery.
persist.
position.
NAMEPLATES

item number.

ENGINE SERVICE
FIRST SERVICE (50 HOURS)
EVERY 30O HOURS OR 9 MONTHS


I Coolant level
R Coolant (NOTE 3) 9.5 qrts., 9.0L
R R Engine oil (NOTE 1 & 3) 8.0 qrts., 7.6L (including filter)
R R Engine oil filter Kubota #16414-32430
C Drain water separator & fuel strainer
R Fuel filter canister Kubota #16631-43560
C Fuel pre-filter element Kubota #15831-43380
R Alternator drive belt Kubota # 17480-97010
C Air filter (earlier check may be req'd)

R Air filter element Donaldson # P821575

I Valve clearances Intake .0071"-.0086", Exhaust .0071"-.0086"
I Battery
Notes:


TING PROCEDURE


restarted.




2. Engine Assembly
6. Exciter and Stator
8. Roof & Doors

1 2
4
5
7
9
6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4


TECHNICAL SPECIFICATIONS - CLASSIC® 300D PERKINS


System
4 Cylinder 135 cu. in 12VDC battery Fuel: 15 gal.

4 Cycle (2.2 ltrs) (Group 24, 650 57 L.
Perkins Naturally Aspirated High Idle 1800 cold crank amps)
404D-22 Water-Cooled Low Idle 1400 Bore x Stroke 2.0 KW Starter Oil: 10.30 Qts.
EPA Diesel Engine Full Load 1725 9.75 L.
Tier 4 interim Cast Iron Cylinder, 3.3” x 3.9”
Compliant Block/Crankcase (84mm x 100mm) Coolant: 9.5 Qts.
32.7HP @1800 RPM 9.0 L.
65 A. Alternator
w/ built in reg.

DESCRIPTION RATED DC OUTPUT * Duty DC CURRENT RANGE
40-350 Amps
220-Max.
300 Amp DC Welder 30V @ 250A 100% 160-240
Min.-90

Auxiliary Power (1)
26 Amps @ 115V
13 Amps @ 230V

K1643-7 CSA
w/o Wire Feed Module 1354 lbs.
(Code 11472) 45.5 in. 24.00 in. 65.0 in. (616 kg)
(1156 mm) (610 mm) (1651 mm
K1643-8 CSA
w/ Wire Feed Module 1389lbs.
(Codes 11473) (630 kg)


operation.
The Classic® 300D Perkins is a heavy duty, engine dri- Engine Idler - The Classic® 300D Perkins is
ven, DC arc welding power source, capable of provid- equipped with an electronic automatic engine idler. It
ing constant current output for stick welding or DC TIG automatically increases and decreases engine speed
welding. This welder is wound with all copper coils, when starting and stopping welding or using auxil-
rated at 300 amps/32 Volts, and provides other iary power. A built-in time delay permits changing
Classic® features such as improved door latches and electrodes before the engine slows to its low idle
stainless hinges. With the addition of the optional speed. The “Idler” control switch on the panel locks the
K623-1 Wire Feed Module™, the Classic® 300D idler in high idle position when desired.
Perkins will provide constant voltage output for running
the LN-7, LN-23P, or LN-25 wire feeders. (The Wire Auxiliary Power - 3.0 KVA of nominal 115/230V, 60Hz,
Feed Module is factory installed on the K1643-8). The AC. Output voltage is maintained within ± 10% at all
optional K924-5 Remote Control Kit, provides a remote loads up to rated capacity. (See Optional Features
control rheostat for remote fine current and open circuit Section C for Power Plug Kit.)
voltage adjustment. See Section C for description.
GFCI Receptacle - One UL approved 115V ground
fault circuit interrupter duplex type receptacle is stan-
The Classic® 300D Perkins has an Electronic Engine dard. See the MAINTENANCE section for detailed
Protection System. In the event of sudden low oil pres- information on testing and resetting the GFCI recepta-
sure or high coolant temperature, the engine immedi- cle.
ately shuts down. The Classic® 300D Perkins has a
current range of 40-350 DC amps with output ratings Welder Enclosure - The complete welder is rubber
as follows: mounted on a rugged steel “C” channel base.

These units are also capable of providing 3 KVA of output terminals are labeled (+) and (-).
250A @ 30V 100% dard.
300A @ 32V 60%

115/230 volts of 60 cycle AC auxiliary power.
elbow are standard.
The Classic® 300D Perkins uses the Perkins 404D-22 Engine Hour Meter - A meter to record hours of oper-
industrial water-cooled diesel engine. ation.
DESIGN FEATURES Engine Protection - The system shuts the engine

down in the event of sudden low oil pressure or high
Control Panel coolant temperature. A warning light on the control
Both the engine and the welder controls are located on
one recessed panel at the exciter end of the machine.
The welder controls consist of a five step “Current
Oil Drain Valve - A ball valve, hose and clamp are
Range Selector” switch and a “Fine Current
standard.
“Start” button, an “Ignition” switch, an “Idler” control
Remote Control - The Remote / Local Switch and
switch, and a “Glow Plug” button for easier cold weath-
Receptacle are standard.
er starting.


gauge, for auxiliary power one three prong grounding
type receptacles, one GFCI receptacle and circuit
breakers for protection.


WARNING DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under sta-

Do not attempt to use this equipment until you tionary or fixed electrical equipment, the surface shall be
have thoroughly read the engine manufacturerʼs covered with a steel plate at least .06”(1.6mm) thick,
manual supplied with your welder. It includes which shall extend not more than 5.90”(150mm) beyond
important safety precautions, detailed engine the equipment on all sides.
starting, operating and maintenance instructions, --------------------------------------------------------------------------------
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill. MACHINE GROUNDING
• Do not touch electrically live parts or According to the United States National Electrical
electrode with skin or wet clothing. Code, the frame of this portable generator is not
ground required to be grounded and is permitted to serve as
• Always wear dry insulating gloves. the grounding means for cord connected equipment
------------------------------------------------------------------------ plugged into its receptacle.
• Use in open, well ventilated areas or Some state, local, or other codes or unusual operating
vent exhaust outside. circumstances may require the machine frame to be

------------------------------------------------------------------------ extent to which such requirements may apply to your

MOVING PARTS can injure. particular situation and follow them explicitly. A
• Do not operate with doors open or machine grounding stud marked with the symbol is
guards off. provided on the welding generator frame foot. In gen-
• Stop engine before servicing. eral, if the machine is to be grounded, it should be con-
• Keep away from moving parts. nected with a #8 or larger copper wire to a solid earth
ground such as a metal water pipe going into the
------------------------------------------------------------------------
See additional warning information at the ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
front of this operatorʼs manual. has been effectively grounded. The U.S. National
-----------------------------------------------------------
EXHAUST SPARK ARRESTER
Some federal, state or local laws may require that LIFT BAIL
engines be equipped with exhaust spark arresters A lift bail is provided for lifting with a hoist.
WARNING

standard muffler included with this welder does not • Lift only with equipment of adequate
qualify as a spark arrester. When required by local lifting capacity.
regulations, a suitable spark arrester must be installed • Be sure machine is stable when lifting.
and properly maintained. • Do not lift this machine using lift bail if
it is equipped with a heavy accessory
CAUTION such as trailer or gas cylinder.
FALLING • Do not lift machine if lift bail is
Use of an incorrect arrester may lead to engine damage
EQUIPMENT can damaged.
or performance loss. Contact the engine manufacturer for
specific recommendations. cause injury. • Do not operate machine while
------------------------------------------------------------------------ suspended from lift bail.
LOCATION / VENTILATION ----------------------------------------------------------------------------
TRAILER (SEE OPTIONAL FEATURES)
Always operate the welder with the doors closed.
If the user adapts a non-Lincoln trailer, he must assume
responsibility that the method of attachment and usage

does not result in a safety hazard nor damage the weld-
ing equipment. Some of the factors to be considered are
as follows:
outside area.

2. Proper support of, and attachment to, the base of PRE-OPERATION SERVICE
stress to the framework. CAUTION
3. Proper placement of the equipment on the trailer to READ the engine operating and maintenance
ensure stability side to side and front to back when instructions supplied with this machine.
being moved and when standing by itself while ------------------------------------------------------------------------
WARNING
ness of surface on which the trailer will be operat- • Stop engine while fueling.
ed; environmental conditions, likely maintenance. • Do not smoke when fueling.

from tank.
VEHICLE MOUNTING
fueling.
DIESEL FUEL fumes to clear before starting

WARNING
can
Improperly mounted concentrated loads may cause fire

engine.

components to fail. DIESEL FUEL ONLY-Low sulphur

• Only transport this Equipment on serviceable fuel or ultra low sulphur fuel in U.S.A. and Canada.
vehicles which are rated and designed for such ------------------------------------------------------------------------
loads.
• Distribute, balance and secure loads so vehicle OIL
is stable under conditions of use.
• Do not exceed maximum rated loads for compo- This unit is supplied from the factory with the engine
nents such as suspension, axles and tires. crankcase filled with a high quality SAE 10W/30 oil.
• Use appropriate nuts bolts and lockwashers to This oil should be acceptable for most typical ambient
attach the equipment base to the metal bed or temperatures. Consult the engine operation manual
frame of vehicle. for specific engine manufacturerʼs recommendations.
• Follow vehicle manufacturerʼs instructions. Upon receipt of the welder, check the engine dipstick to
------------------------------------------------------------------------ be sure the oil is at the “full” mark. DO NOT overfill.
FUEL
POLARITY CONTROL AND CABLE SIZES
Fill the fuel tank with the grade of fuel recommended in
With the engine off, route the electrode and work
the Engine Operatorʼs manual. Make sure the fuel
cables through the strain relief bracket on the base and
valve on the water separator is in the open position.
ing rail. (See size recommendations below.) For pos-
itive polarity, connect the electrode cable to the termi- COOLING SYSTEM
electrode cable to the “-” stud. These connections The radiator has been filled at the factory with a 50-50
should be checked periodically and tightened if neces- mixture of ethylene glycol antifreeze and water. Check
sary. the radiator level and add a 50-50 solution as needed
(see engine manual or antifreeze container for alter-
When welding at a considerable distance from the nate antifreeze recommendations).
RECOMMENDED COPPER CABLE SIZES


(61 to 76m)
250 100% 1 1/0
300 60% 1/0 2/0

BATTERY CHARGING
WARNING

away.

skin.
• Wear gloves and eye protection and
be careful when boosting, charging
or working near battery.

a) Installing a new battery - disconnect the nega-
tive cable from the old battery first and connect
the negative cable to the new battery last.
b) Connecting a battery charger - remove the bat-
tery from the welder by disconnecting the nega-
tive cable first, then the positive cable and bat-

tery clamp. When reinstalling, connect the neg-
ative cable last.
the battery first, then connect the negative lead
to the ground lead on the base.

b) Using a booster.
To prevent BATTERY DISCHARGE, if you have an

ignition switch, turn it off when engine is not r u n -
ning.

------------------------------------------------------------------------
The Classic® 300D Perkins is equipped with a wet

charged.


Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4.3


B4.2 OPERATION B4.2
WARNING

------------------------------------------------------------------------
------------------------------------------------------------------------ Note: Extreme cold weather starting may require
• Use in open, well ventilated areas or longer glow plug operation.
WARNING
------------------------------------------------------------------------
guards off.
• Keep away from moving parts. HIGH ALTITUDE OPERATION:
------------------------------------------------------------------------
The engine will run correctly up to an altitude of 600m
See additional warning information at the (2000ft.). If the engine is to be operated permanently at
front of this operatorʼs manual. an altitude above this, the fuel consumption and
exhaust emissions may be excessive.
-----------------------------------------------------------
Contact the Perkins Application Department for any
Operate the welder with the doors closed. Leaving the engine adjustments that may be required.
doors open changes the designed air flow and can
cause overheating. STOPPING THE ENGINE
1. Turn the “IGNITION” switch to “OFF”

STARTING THE CLASSIC® 300D PERKINS
404D-22 DIESEL ENGINE At the end of each dayʼs welding, check the crankcase
1. Turn the “IDLER” switch to “HIGH”. water separator located on the fuel rail. Refill the fuel
2. Turn the “IGNITION” switch to “ON”. tank to minimize moisture condensation in the tank.
3. Press the Glow Plug button for 20 to 30 seconds. Also, running out of fuel tends to draw dirt into the fuel
(maximum 60 seconds). system.
4. Press the Start button. When the engine starts
running, release both buttons. If the engine fails to When hauling the welder between job sites, close the
start in 20 seconds, wait 30 seconds and repeat fuel feed valve on the separator located on the fuel rail.
5. Observe the oil pressure. If no pressure shows If the fuel supply is cut off or runs out while the fuel
within 30 seconds, stop the engine and consult the pump is operating, air may be entrapped in the fuel dis-
engine operating manual. To stop the engine, turn tribution system. If this happens, bleeding of the fuel
the “IGNITION” switch to “OFF”. system may be necessary. Use qualified personnel to
6. If the engine protection warning light comes on do this per the instructions in the MAINTENANCE sec-
during cranking or after start up, the “IGNITION” tion of this manual.
protection system.

B4.3 OPERATION B4.3
ENGINE BREAK-IN DUTY CYCLE
The NEMA output rating of the Classic® 300D Perkins is 300

Lincoln Electric selects high quality, heavy-duty industrial

engines for the portable welding machines we offer. amperes at 32 arc volts on a 60% duty cycle (consult
While it is normal to see a small amount of crankcase oil Specifications in this manual for alternate ratings). Duty
consumption during initial operation, excessive oil use, cycle is based on a ten minute period; thus, the welder can
wet stacking (oil or tar like substance at the exhaust port), be loaded at rated output for six minutes out of every ten
or excessive smoke is not normal. minute period.
Larger machines with a capacity of 350 amperes and CONTROL OF WELDING CURRENT
higher, which are operated at low or no-load conditions for
extended periods of time are especially susceptible to the
CAUTION
conditions described above. To accomplish successful DO NOT TURN THE “CURRENT RANGE SELECTOR”
engine break-in, most diesel-powered equipment needs WHILE WELDING because the current may arc between
only to be run at a reasonably heavy load within the rating the contacts and damage the switch.
of the welder for some period of time during the engineʼs -------------------------------------------------------------------------------
early life. However, if the welder is subjected to extensive The “Current Range Selector” provides five overlapping cur-
light loading, occasional moderate to heavy loading of the rent ranges. The “Fine Current Adjustment” adjusts the cur-
engine may sometimes be necessary. Caution must be rent from minimum to maximum within each range. Open cir-
observed in correctly loading a diesel/generator unit. cuit voltage is also controlled by the “Fine Current
Adjustment” permitting control of the arc characteristics.
1. Connect the welder output studs to a suitable resis-
tive load bank. Note that any attempt to short the A high open circuit voltage setting provides the soft “butter-
output studs by connecting the welding leads togeth- ing” arc with best resistance to pop-outs preferred for most
er, direct shorting of the output studs, or connecting welding. To get this characteristic, set the “Current Range
the output leads to a length of steel will result in cat- Selector” to the lowest setting that still provides the current
astrophic damage to the generator and voids the you need and set the “Fine Current Adjustment” near maxi-
warranty. mum.
2. Set the welder controls for an output current and volt-
age within the welder rating and duty cycle. Note that For example: to obtain 175 amps and a soft arc, set the
any attempt to exceed the welder rating or duty cycle “Current Range Selector” to the 190-120 position and then
for any period of time will result in catastrophic dam- adjust the “Fine Current Adjustment” for 175 amps.
age to the generator and voids the warranty.
3. Periodically shut off the engine and check the When a forceful “digging” arc is required, usually for vertical
crankcase oil level. and overhead welding, use a higher “Current Range
Selector” setting and lower open circuit voltage.

WELDER OPERATION For example: to obtain 175 amps and a forceful arc, set the
“Current Range Selector” to the 240-160 position and the
WARNING “Fine Current Adjustment” setting to get 175 amps.
ELECTRIC SHOCK can kill. Some arc instability may be experienced with EXX10 elec-
• Do not touch electrically live parts or trodes when trying to operate with long arc techniques at set-
electrode with skin or wet clothing. tings at the lower end of the open circuit voltage range.
------------------------------------------------------------------------------- CAUTION
FUMES & GASES can be dangerous.
• Keep your head out of the fumes. DO NOT attempt to set the “Current Range Selector” between
• Use ventilation or exhaust to remove the five points designated on the nameplate.
fumes from breathing zone. --------------------------------------------------------------------------------
------------------------------------------------------------------------------- These switches have a spring loaded cam which almost elim-
WELDING SPARKS can cause fire or inates the possibility of setting this switch between the des-
explosion.
ignated points.
-------------------------------------------------------------------------------
ARC RAYS can burn.
-------------------------------------------------------------------------------

B4.4 OPERATION B4.4
IDLER OPERATION AUXILIARY POWER

Start the engine with the “Idler” switch in the “High” If a GFCI receptacle is tripped, See the MAINTE-
position. Allow it to run at high idle speed for several NANCE section for detailed information on testing and
minutes to warm the engine. See Specifications for resetting the GFCI receptacle.
operating speeds.
The idler is controlled by the “Idler” toggle switch on the rating of 3.0 KVA of 115/230 VAC (60 hertz).
follows: With the 3.0 KVA, 115/230 VAC auxiliary power, one
115V GFCI and one 230V duplex, grounding type
1. In the “High” position, the idler solenoid deac- receptacles are provided. The circuit is protected with
tivates, and the engine goes to high idle speed. The circuit breakers.
The rating of 3.0 KVA permits a maximum continuous
2. In the “Auto” / position, the idler oper- current of 13 amps to be drawn from the 230 volt
ates as follows: duplex receptacle. Or a total of 20 amps can be drawn
from the 115 volt GFCI receptacle. The total combined
a. When welding or drawing power for lights or tools
load of all receptacles is not to exceed 3.0 KVA.

(approximately 100 watts minimum) from the
receptacles, the idler solenoid deactivates and the An optional power plug kit is available. When this kit is
engine operates at high idle speed. specified, the customer is supplied with a plug for each
receptacle.
b. When welding ceases or the power load is turned
starts. This time delay cannot be adjusted.
c. If the welding or power load is not re-started

before the end of the time delay, the idler solenoid
activates and reduces the engine to low idle
speed.
CLASSIC® 300D PERKINS WITH PERKINS 104D-22 DIESEL ENGINE

3000 Watts 0.59 gal/hr ( 2.23 ltrs/hr)


Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C4.2
Wire Feeder Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C4.3


OPTIONAL FEATURES (Field Installed) TIG OPTIONS
TIG Module K930-2

GENERAL OPTIONS
Provides high frequency and shielding gas control for
AC and DC GTAW (TIG) welding applications. Its com-
WARNING pact case is designed for easy carrying, complete with
a handle. High frequency bypass is built in.
Pipe Thawing with an arc welder can cause fire, Additionally, the K936-3 control cable is required if
explosion, damage to electric wiring or to the arc remote control is used. If remote control is not used the
welder if done improperly. The use of an arc welder K936-4 control cable is required.
it recommended or supported by Lincoln Electric. PTA-26V TIG Torch K1783-9
------------------------------------------------------------------------ Air cooled 200 amp torch equipped with valve for gas
Power Plug Kit K802D flow control. 25Ft. length.
A power plug kit for the auxiliary power receptacles is
available. (Provides a plug for each receptacle.) Magnum Parts Kit For PTA-26V TIG Torch KP509
Spark Arrestor Kit K903-1 Control Cable K936-4 (required for TIG Module)
Includes a heavy gage steel, approved spark arrestor, Control cable for connecting the K930-2 TIG Module.
clamp and adapter for mounting to the muffler exhaust

pipe. Arc Start Switch K814 (required for TIG Module)
Comes with a 25ft.(7.6m) cable.
TRAILER K953-1 Attaches to the TIG torch for convenient finger control.
Two-wheeled trailer with optional fender and light package.
For highway use, consult applicable federal, state, and local Contactor Kit K938-1 (required for TIG Module)
laws regarding possible additional requirements. There is a Provide “Cold” tungsten Tip when welding with the TIG
choice of 2 hitches, a fender & a light package. Module.
Ball Hitch K958-1 Control Cable Extension K937-45

Lunette Eye Hitch K958-2 Allows the TIG Module to be operated at distances up
Fender & Light Kit K959-1 to 200 ft. from the power source.Available in 45 ft.
Cable Rack K965-1 (13.7m).
Service Indicator Kit K1858-1 Water Valve Kit K844-1

Provides a GO / NO-GO visual indication of air clean- For use with a water-cooled TIG torch. Installs inside
TIG Module.
er element useful service life. Filter service based on

restriction readings allows the longest life possible
from the filter and best engine protection.
STICK OPTIONS
ACCESSORY SET K704

Includes 35 feet (10 m) of electrode cable and 30 feet
(9 m) of work cable, headshield, work clamp and elec-
trode holder. Cable is rated at 500 amps, 60% duty
cycle.
Remote Control Kit K924-5

Contains remote control rheostat and 100 ft. (30.5 m)
cable for adjusting the OCV at the welding site.

WIRE FEEDER OPTIONS Magnum Spool Gun K487-25

Hand held semiautomatic wire feeder requires SG
Wire Feed Module K623-1

Provides constant voltage (CV) output with improved Control Module. 25 ft. length.
arc stability for Innershield welding. Excellent for MIG
welding. Recommended wire feeders are the LN-7,
SG Control Module K488 (For Magnum Spool Gun)
LN-23P and LN-25. (Factory installed on the K1643-2). The interface between the power source and the
spool gun. Provides control of wire speed and gas
flow.
LN-25 Wire Feeder K449
Portable CC/CV unit for flux-cored and MIG welding. Input Cable K691-10 ( For SG Control Module)
Includes Gas Solenoid & Internal Contactor. Requires For Lincoln engine drives with 14-pin MS-type connec-
Wire Feed Module.
tion, separate 115V NEMA receptacle and output
stud connections. 10 ft. length.

Magnum® 350 Innershield Gun for LN-25 K126-2
.062-3/32” (1.6-2.8mm) wire.
Magnum® 300 MIG Gun for LN-25 K1802-1

With 15 ft. (4.5m) cable. For .035”-.045” (0.9-1.2mm)
gas shielded (Includes Connector Kit).
LN-23P Wire Feeder K316L-1

Portable CV unit for Innershield pipe welding. Control
cable operates contactor inside Wire Feed Module for
“cold” electrode. Requires LN-23P Adapter Kit (K350-
1) and Gun and Cable Assembly.
LN-23P Adapter Kit K350-1

Required to adapt LN-23P to any Lincoln power
source. Makes 14 pin connection at power source.
Magnum® 250 Innershield Gun for LN-23P K355-10

reduced speed switch. For pipewelding, an M11476
62° gun tube for PipeWelding KP1909-1


guns with 90° gun tubes. Compatible with K126-1,-2,
K264-8 and K355-10.

NOTES

C4.4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.4
GFCI Receptacle Testing & Resetting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.5
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.6


SAFETY PRECAUTIONS 4. Follow the engine service schedule in this manual

and the detailed maintenance and troubleshooting in
WARNING
the engine manufacturerʼs manual.

Have qualified personnel do the maintenance COOLING SYSTEM

work. Turn the engine off before working inside
the machine. In some cases, it may be necessary The Classic® 300D Perkins is equipped with a pres-
to remove safety guards to perform required sure radiator. Keep the radiator cap tight to prevent
maintenance. Remove guards only when neces- loss of coolant. Clean and flush the cooling system
sary and replace them when the maintenance periodically to prevent clogging the passage and over-
requiring their removal is complete. Always use heating the engine. When antifreeze is needed, always
the greatest care when working near moving use the permanent type.
parts.
BEARINGS
blower fan. If a problem cannot be corrected by This welder is equipped with a double-shielded ball

electrode with skin or wet clothing. high weighs approximately one half ounce. Over-
• Insulate yourself from work and greasing is far worse than insufficient greasing.
ground
• Always wear dry insulating gloves. When greasing the bearings, keep all dirt out of the
------------------------------------------------------------------------ equipment. More bearing failures are caused by dirt
introduced during greasing than from insufficient

------------------------------------------------------------------------
MOVING PARTS can injure. WARNING
guards off. Uncovered rotating equipment can be dangerous.
• Stop engine before servicing. Use care so your hands, hair, clothing or tools do
• Keep away from moving parts. not catch in the rotating parts. Protect yourself
------------------------------------------------------------------------ from particles that may be thrown out by the rotat-

See additional warning information at ing armature when stoning the commutator.
front of this operatorʼs manual. ------------------------------------------------------------------------
- Commutator damage


weld.

Replace brushes when they wear within 1/4” of the pig- PURGING AIR FROM FUEL SYSTEM
tail. A complete set of replacement brushes should be (PERKINS 404D-22 ENGINE)


WARNING
tator as the armature rotates at full speed until contact Keep fuel clear of open flames or arcs, allow
is made across the full face of the brushes. After ston- engine to cool before working on the fuel system.
ing, blow out the dust with low pressure air. Wipe up any spilled fuel and do not start engine

IDLER MAINTENANCE Vent Screw
CAUTION
------------------------------------------------------------------------
FIGURE D4.3
2. Operate the electric fuel pump by turning the
lems persist.
tery.
2. Idler solenoid is activated for low idle.

position.
NAMEPLATES

item number.


MAINTENANCE
D4.4

TING PROCEDURE


restarted.




2. Engine Assembly
6. Exciter & Stator
7. Welding Generator & Coupling
8. Roof & Doors
1
4
5
7
9
6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.3
Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.4


TECHNICAL SPECIFICATIONS – CLASSIC® 300G (K1754-1)

INPUT - GASOLINE ENGINE
Make/Model Description Speed (RPM) Displacement Ignition Capacities

cu. in. (Ltrs.) System
High Idle 1800 Delco Voyager Fuel: 15 gal.

4 Cylinder High Energy 57 Ltrs.
GM 4 Cycle
3.0 Liter Water-Cooled Full Load 1800 Distributor Type Oil: 4.5 Qts.
Gasoline Engine 4.3 Ltrs.
Classic® 300G Cast Iron Cylinder 183.0(3.0) Electronic
(K1754-1) Block/Crankcase Low Idle 1360
Cooling 9.9 Qts.
53.0 HP @
9.4 Ltrs.
1800 RPM
RATED OUTPUT - WELDER
DESCRIPTION RATED DC OUTPUT* DUTY CYCLE DC CURRENT RANGE
VOLTS @ RATED AMPS Fine Adjustment in each Range
300 Amp DC Welder

30V @ 250A 100%
All Copper Windings
40-350 Amps
Pure DC Power NEMA Rating
32V @ 300A 60%
Generator
OUTPUT - GENERATOR
Auxiliary Power 1
3000 Watts, 60 Hz. AC
(26 Amps @ 115V), (13 Amps @ 230V)
ENGINE OPERATING LOAD FUEL CONSUMPTION

Low Idle (1360 RPM)-No Load .89 gal/hr (3.37 ltrs/hr)
High Idle (1800 RPM)-No Load 1.32 gal/hr (5.00 ltrs/hr)
AC Auxiliary-115 Volts-26 Amps 1.42 gal/hr (5.32 ltrs/hr)

50 Amps @ 22 Volts @ 60% Duty Cycle 1.24 gal/hr (4.70 ltrs/hr)
100 Amps @ 24 Volts @ 60 % Duty Cycle 1.27 gal/hr (4.82 ltrs/hr)
150 Amps @ 26 Volts @ 60% Duty Cycle 1.33 gal/hr (5.04 ltrs/hr)
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
40.94** in. 24.00 in. 66.91in.

1039.9 mm 609.6 mm 1700 mm 1330 lbs. (603kg.)
**Top of enclosure, add 8.0” (203.2mm) for exhaust
(1) 115V will operate either 60 Hz. or 50/60 Hz. power tools, lights etc.

SAFETY PRECAUTIONS
CAUTION
WARNING
DO NOT MOUNT OVER COMBUSTIBLE SUR-

Do not attempt to use this equipment until you FACES.

have thoroughly read the engine manufacturerʼs Where there is a combustible surface directly under
manual supplied with your welder. It includes stationary or fixed electrical equipment, the surface
important safety precautions, detailed engine shall be covered with a steel plate at least .06”(1.6mm)
thick, which shall extend not more than 5.90”(150mm)
and parts lists.
------------------------------------------------------------------------ beyond the equipment on all sides.
ELECTRIC SHOCK can kill. ------------------------------------------------------------------------
• Do not touch electrically live parts or MACHINE GROUNDING
electrode with skin or wet clothing. According to the United States National Electrical Code,
• Insulate yourself from work and the frame of this portable generator is not required to be
ground
• Always wear dry insulating gloves. grounded and is permitted to serve as the grounding
------------------------------------------------------------------------ means for cord connected equipment plugged into its
ENGINE EXHAUST can kill. receptacle.
vent exhaust outside. Some state, local, or other codes or unusual operating
circumstances may require the machine frame to be

-----------------------------------------------------------------------
MOVING PARTS can injure. extent to which such requirements may apply to your
• Do not operate with doors open or particular situation and follow them explicitly. A machine
guards off. grounding stud marked with the symbol is provided
• Stop engine before servicing. on the welding generator frame foot. In general, if the
• Keep away from moving parts. machine is to be grounded, it should be connected with
------------------------------------------------------------------------ a #8 or larger copper wire to a solid earth ground such
See additional warning information at the as a metal water pipe going into the ground for at least
front of this operatorʼs manual. ten feet and having no insulated joints, or to the metal
----------------------------------------------------------- framework of a building which has been effectively
grounded. The U.S. National Code lists a number of
PRE-OPERATION INSTALLATION alternate means of grounding electrical equipment.
EXHAUST SPARK ARRESTER LIFT BAIL

A lift bail is provided for lifting with a hoist.
Some federal, state or local laws may require that
engines be equipped with exhaust spark arresters

when they are operated in certain locations where WARNING
unarrested sparks may present a fire hazard. The stan-
dard muffler included with this welder does not qualify
as a spark arrester. When required by local regula- • Lift only with equipment of
tions, a suitable spark arrester must be installed and adequate lifting capacity.
properly maintained. • Be sure machine is stable
when lifting.
CAUTION • Do not lift this machine using
lift bail if it is equipped with a
Use of an incorrect arrester may lead to engine dam- heavy accessory such as trail-
er or gas cylinder.
age or performance loss. Contact the engine manu-
facturer for specific recommendations. FALLING • Do not lift machine if lift bail is
------------------------------------------------------------------------ EQUIPMENT can damaged.
LOCATION / VENTILATION cause injury. • Do not operate machine while
Always operate the welder with the doors closed. suspended from lift bail.
------------------------------------------------------------------------

ed flow of clean, cool air. Also, locate the welder so that
engine exhaust fumes are properly vented to an out-
side area.
TRAILER (See ACCESSORY Section) When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
If the user adapts a non-Lincoln trailer, he must
assume responsibility that the method of attachment RECOMMENDED COPPER CABLE SIZES
and usage does not result in a safety hazard nor dam- Cables Sizes for Combined Length
age the welding equipment. Some of the factors to be Up to 200 ft. 200 to 250 ft.
considered are as follows: Amps Duty Cycle 60.96 m 200 to76.2 m
250 100% 1 1/0
2. Proper support of, and attachment to, the base of 300 60% 1/0 2/0
stress to the framework. PRE-OPERATION SERVICE
3. Proper placement of the equipment on the trailer to
ensure stability side to side and front to back when CAUTION
being operated or serviced. READ the engine operating and maintenance instruc-
4. Typical conditions of use, i.e., travel speed, rough- tions supplied with this machine.
ness of surface on which the trailer will be operated;
environmental conditions, likely maintenance. WARNING
(1) Consult applicable federal, state and local laws regarding specific
WARNING
from tank.
fueling.
VEHICLE MOUNTING GASOLINE fumes to clear before starting

Improperly mounted concentrated loads may can cause fire engine.

cause unstable vehicle handling and tires or other or explosion. • Do not overfill tank, fuel expan-
components to fail. sion may cause overflow.
• Only transport this Equipment on serviceable ------------------------------------------------------------------------

GASOLINE FUEL ONLY
vehicles which are rated and designed for such
loads. OIL
• Distribute, balance and secure loads so vehicle This unit is supplied from the factory with the engine
is stable under conditions of use. crankcase filled with a high quality SAE 10W/30 oil.
• Do not exceed maximum rated loads for compo- This oil should be acceptable for most typical ambient
nents such as suspension, axles and tires. temperatures.
• Mount equipment base to metal bed or frame of Consult the engine operation manual for specific
vehicle. engine manufacturerʼs recommendations. Upon
• Follow vehicle manufacturerʼs instructions. receipt of the welder, check the engine dipstick to be
------------------------------------------------------------------------ sure the oil is at the “full” mark. DO NOT overfill.
POLARITY CONTROL AND CABLE SIZES FUEL

With the engine off, route the electrode and work Fill the fuel tank with the grade of fuel recommended
cables through the strain relief bracket on the base and in the Engine Operatorʼs manual. Make sure the fuel
connect to the studs located below the fuel tank mount- valves on the sediment bowl and the water separator
ing rail. (See size recommendations below.) For are in the open positions.
Positive polarity, connect the electrode cable to the
terminal marked “+”. For Negative polarity, connect COOLING SYSTEM
the electrode cable to the “-” stud. These connections
The radiator has been filled at the factory with a 50-50
mixture of ethylene glycol antifreeze and water.

sary.
Check the radiator level and add a 50-50 solution as
needed (see engine manual or antifreeze container for
alternate antifreeze recommendations)

BATTERY CHARGING
WARNING

away.

skin.
• Wear gloves and eye protection and
be careful when boosting, charging
or working near battery.

• Installing a new battery - disconnect the negative
cable from the old battery first and connect the
negative cable to the new battery last.
• Connecting a battery charger remove the battery
from the welder by disconnecting the negative

cable first, then the positive cable and battery

clamp. When reinstalling, connect the negative
cable last.
• Using a booster - connect the positive lead to the
battery first, then connect the negative lead to

• Installing a new battery.
• Using a booster.

ignition switch, turn it off when engine is not run-
ning.

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


Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A5.6
NOTES

A5.6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5.2
Control of Welding Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5.4


B5.2 OPERATION B5.2
SAFETY PRECAUTIONS CAUTION

WARNING
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

Where there is a combustible surface directly under
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs stationary or fixed electrical equipment, the surface
manual supplied with your welder. It includes shall be covered with a steel plate at least .06”(1.6mm)
important safety precautions, detailed engine thick, which shall extend not more than 5.90”(150mm)
starting, operating and maintenance instructions, beyond the equipment on all sides.
and parts lists. ------------------------------------------------------------------------
------------------------------------------------------------------------ The Classic® 300G uses the GM 3.0L industrial water-
• Do not touch electrically live parts or cooled gasoline engine.
electrode with skin or wet clothing. RATED OUTPUT DUTY CYCLE
ground 250A @ 30V 100%
• Always wear dry insulating gloves. 300A @ 32V 60%
------------------------------------------------------------------------
DESIGN FEATURES
---------------------------------------------------- Control Panel
MOVING PARTS can injure. Both the engine and the welder controls are located on
• Do not operate with doors open or one recessed panel at the exciter end of the machine. The
guards off. welder controls consist of a five step “Current Range
• Stop engine before servicing. Selector” switch and a “Fine Current Adjustment” rheo-
• Keep away from moving parts. stat. The welder is equipped with a “Start” button, an
------------------------------------------------------------------------ “Ignition” switch, an “Idler” control switch, and a “Glow
See additional warning information at the Plug” button for easier cold weather starting.
front of this operatorʼs manual.
Operate the welder with the doors closed. Leaving the gauge, a battery charging ammeter, an oil pressure
doors open changes the designed air flow and can cause gauge, two three prong grounding type receptacles and
overheating. four circuit breakers for auxiliary power.
operation.
The Classic® 300G is a heavy duty, engine driven, DC arc Engine Idler Control - The Classic® 300G is equipped
welding power source, capable of providing constant cur- with an electronic automatic engine idle control. It auto-
rent output for stick welding or DC TIG welding. This matically increases and decreases engine speed when
welder is wound with all copper coils, rated at 300 starting and stopping welding or using auxiliary
amps/32 Volts, and provides other Classic® features such power. A built-in time delay permits changing electrodes
as improved door latches and stainless hinges. With the before the engine slows to its low idle speed. The “Idler”
addition of the optional K623-1 Wire Feed Module™ the control switch on the panel locks the idler in high idle posi-
Classic® 300G will provide constant voltage output for tion when desired.
running the LN-7, LN-23P, or LN-25 wire feeders. The
optional K924-4 Remote Control Kit (field installed) pro- Auxiliary Power - 3.0 kVA of nominal 115/230V, 60Hz,
vides a switch, or K924-5 Remote Control Kits provide a AC. Output voltage is maintained within ± 10% at all
receptacle and a remote control rheostat for remote fine loads up to rated capacity. (See Optional Features in
current and open circuit voltage adjustment. Section C for Power Plug Kit.)
Welder Enclosure - The complete welder is rubber

The Classic® 300G has an electronic Engine Protection mounted on a rugged steel “C” channel base.
system. In the event of sudden low oil pressure or high
coolant temperature, the engine immediately shuts down. The output terminals are placed at the side of the
The Classic® 300G has a current range of 40-350 DC machines so that they are protected by the door. The out-
amps with output ratings as follows: put terminals are labeled (+) and (-).
These units are also capable of providing 3 kVA of
115/230 volts of 60 cycle AC auxiliary power. Cranking System - A 12 volt electric starter is standard.

B5.3 OPERATION B5.3
Air Cleaner - Heavy duty two stage dry type. • When hauling the welder between job sites, close the
fuel feed valve beneath the fuel tank.
Muffler-A Muffler and stainless steel exhaust outlet
elbow are standard. • If the fuel supply is cut off or runs out while the fuel
pump is operating, air may be entrapped in the fuel
Engine Hour Meter - A meter to record hours of opera- distribution system. If this happens, bleeding of the
tion. fuel system may be necessary. Refer to the instruc-
tions in the MAINTENANCE section of this manual.
down in the event of sudden low oil pressure or high REFER TO THE ENGINE
panel will indicate such a fault. To reset the engine for Operation and maintenance manual for additional
restarting, turn the ignition switch off then on. information on the engine supplied with this welder.
High Idle RPM (OCV) Adjustment- A potentiometer is
mounted on the output rail that allows the operator to WELDER OPERATION
adjust the high idle engine speed between 1700 and
1800 RPMʼS in 20 RPM increments. This is to allow fur- DUTY CYCLE
WARNING
ther adjustment of the OCV. Total OCV adjustment
range is about 10 Volts.


STARTING THE CLASSIC® 300G GM 3.0L • Do not touch electrically live parts or
GASOLINE ENGINE electrode with skin or wet clothing.
1. Turn the “IDLER” switch to “HIGH”.(Optional ) FUMES & GASES can be dangerous.
2. Turn the “IGNITION” switch to “ON”. • Keep your head out of the fumes.
3. Press the Start button. When the engine starts run- • Use ventilation or exhaust to remove
ning, release button. If the engine fails to start in 20 fumes from breathing zone.
seconds, wait 30 seconds and repeat the above pro-
cedure. WELDING SPARKS can cause fire or
4. Observe the oil pressure. If no pressure shows with- explosion.
in 30 seconds, stop the engine and consult the • Keep flammable material away.
engine operating manual. To stop the engine, turn
the “IGNITION” switch to “OFF”.
5. Allow the engine to run at high idle speed for sev- ARC RAYS can burn.
eral minutes to warm up. If idle control switch is left • Wear eye, ear, and body protection.
in “Auto” position, engine will run at 1600 RPM until
engine coolant temperature reaches 130 F.
Under NO conditions should ether or other starting
fluids be used!
------------------------------------------------------------------------- The NEMA output rating of the Classic® 300G is 300
amperes at 32 arc volts on a 60% duty cycle (consult
STOPPING THE ENGINE Specifications in this manual for alternate ratings).
Duty cycle is based on a ten minute period; thus, the
• Turn the “IGNITION” switch to “OFF” welder can be loaded at rated output for six minutes
out of every ten minute period.
• At the end of each dayʼs welding, check the crankcase
sediment bowl under the fuel tank and refill the fuel
tank to minimize moisture condensation in the tank.
Also, running out of fuel tends to draw dirt into the fuel
system.

B5.4 OPERATION B5.4
CONTROL OF WELDING CURRENT • When welding or drawing power for lights or tools
(approximately 100-150 watts minimum) from the
CAUTION receptacles, the engine operates at high idle speed.
DO NOT TURN THE “CURRENT RANGE SELEC- • When welding ceases or the power load is turned off,
TOR” WHILE WELDING because the current may a preset time delay of about 10 seconds starts. This
arc between the contacts and damage the switch. time delay cannot be adjusted.
------------------------------------------------------------------------
The “Current Range Selector” provides five overlap- • If the welding or power load is not re-started before
ping current ranges. The “Fine Current Adjustment” the end of the time delay the throttle body controller
adjusts the current from minimum to maximum within reduces the engine to low idle speed.
each range. Open circuit voltage is also controlled by
the “Fine Current Adjustment” permitting control of the AUXILIARY POWER
arc characteristics.
A high open circuit voltage setting provides the soft rating of 3.0 kVA of 115/230 VAC (60 hertz).
“buttering” arc with best resistance to pop-outs pre-
ferred for most welding. To get this characteristic, set With the 3.0 kVA, 115/230 VAC auxiliary power, one
the “Current Range Selector” to the lowest setting that 115V duplex and one 230V duplex, grounding type
still provides the current you need and set the “Fine receptacle are provided. The circuit is protected with
Current Adjustment” near maximum. For example: to circuit breakers.
obtain 175 amps and a soft arc, set the “Current Range
Selector” to the 190-120 position and then adjust the The rating of 3.0 kVA permits a maximum continuous
“Fine Current Adjustment” for 175 amps. current of 13 amps to be drawn from the 230 volt
When a forceful “digging” arc is required, usually for from the 115 volt duplex receptacle. The 115 volt
vertical and overhead welding, use a higher “Current duplex receptacle has a configuration which permits 20
Range Selector” setting and lower open circuit voltage. amps to be drawn from either half. The total combined
For example: to obtain 175 amps and a forceful arc, set load of all receptacles is not to exceed 3.0 kVA.
the “Current Range Selector” to the 240-160 position
and the “Fine Current Adjustment” setting to get 175 An optional power plug kit is available. When this kit is
amps. specified, the customer is supplied with a plug for each
receptacle.
electrodes when trying to operate with long arc tech- THROTTLE BODY DEICING SYSTEM
niques at settings at the lower end of the open circuit

voltage range. The welder has been designed to allow continuous
year-round operation. Engine coolant is channeled
CAUTION through the Throttle Bottle Injector (TBI) housing to
prevent the build up of ice on the TBI throat around the
DO NOT attempt to set the “Current Range Selector” throttle plate. The electronic controller is programmed
between the five points designated on the nameplate. to automatically compensate for the build up of ice on
------------------------------------------------------------------------ the throttle plate. There will be no noticeable change in
These switches have a spring loaded cam which the operation of the welder should icing develop. On
almost eliminates the possibility of setting this switch start-up, there is a possibility for the engine to over-
between the designated points. speed ( to a maximum of 2000 RPM ) for up to 10 sec-
onds after throttle body icing conditions have occurred.
IDLER CONTROL OPERATION The electronic governor will correct itself for the new
operating conditions and normal operation will resume.
The idle is controlled by the “Idler” toggle switch on the
follows:
1. In the “High” position, and the engine goes to high

idle speed. The speed is controlled by the governor.
2. In the “Auto” / position, the engine oper-

ates as follows:

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C5
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C5.2


OPTIONAL EQUIPMENT (Field Installed)

Accessory Set (K704) - Includes 35 ft. (10.7m) elec- Wire Feed Module (K623-1) - Provides constant volt-
trode and 30 ft. (9.1m) work cables, headshield, work age (CV) output with improved arc stability for
clamp and electrode holder. Innershield welding. Excellent for MIG welding.
LN-25.
WARNING GFCI Receptacle Kit (K1690-1) - Includes one UL
approved 115V ground fault circuit interrupter duplex
Pipe Thawing with an arc welder can cause fire, type receptacle and installation instructions. Replaces
explosion, damage to electric wiring or to the arc the factory installed 115V duplex receptacle. Each
welder if done improperly. The use of an arc welder receptacle of the GFCI duplex is rated at 20 amps.
for pipe thawing is not approved by the CSA, nor is Maximum total current from the GFCI duplex is limited
it recommended or supported by Lincoln Electric. to 20 amps.
------------------------------------------------------------------------
Power Plug Kit (K802D) - A 20 amp power plug kit for TIG Module - Portable, high frequency unit with gas
the auxiliary power receptacles is available. (Provides valve for TIG welding. Rated at 300 amps / 60% duty
a plug for each receptacle.) cycle. (Request Publication E3.205).
Order K930-2
Remote Control Kit (K924-4) - Contains switch,
receptacle, remote control rheostat, and 100 ft (30.5m) Control Cable - Connects TIG Module to the Classic®
cable for adjusting the OCV at the welding site. 300G.
Order K936-4
Trailer (K953-1) - Two-wheeled trailer with optional
fender and light package. For highway use, consult Arc Start Switch - Provides on/off control at the TIG
applicable federal, state, and local laws regarding pos- Module.
sible additional requirements. Their is a choice of 2 Order K814
hitches, a fender & a light package. Order:
K953-1 Trailer Contactor Kit - For use with TIG Module.
K958-1 Ball Hitch Order K938-1
K958-2 Lunette Eye Hitch
K959-1 Fender & Light Kit. Control Cable Extension - Allows the TIG Module to
K965-1 Cable Storage Rack be operated at distances up to 200 ft. from the power
source. Available length: 45 ft. (13.7m).
Order K937-45
Remote Control Kit (K924-5) - Contains a remote
control rheostat, and 100 ft. (30.5m) cable for adjust- Water Valve Kit - For use with a water-cooled TIG
ing the OCV at the welding site. Torch. Installs inside of TIG Module.
Order K844-1
Remote Control Kit (K2464-1) - Contains a remote
control rheostat (for adjusting the CC “STICK” OCV), K2261-1 OIL DRAIN KIT - Includes ball valve, hose
remote control potentiometer (for adjusting the CV and clamp.
“WIRE” OCV), and 100ft.(30.5m) cable.

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5
Idler Control Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.3
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.4


SAFETY PRECAUTIONS • When necessary, remove the sediment bowl, if so

equipped, from beneath the fuel tank and clean out
WARNING any accumulated dirt and water.
Have qualified personnel do the maintenance • Follow the engine service schedule in this manual
work. Turn the engine off before working inside and the detailed maintenance and troubleshooting in
the machine. In some cases, it may be necessary the engine manufacturerʼs manual.
to remove safety guards to perform required
maintenance. Remove guards only when neces- COOLING SYSTEM
sary and replace them when the maintenance
requiring their removal is complete. Always use The Classic® 300G is equipped with a pressure radia-
the greatest care when working near moving tor. Keep the radiator cap tight to prevent loss of
parts. coolant. Clean and flush the cooling system periodical-
ly to prevent clogging the passage and overheating the
Do not put your hands near the engine cooling engine. When antifreeze is needed, always use the
blower fan. If a problem cannot be corrected by permanent type. Capacity = 9.9 qts (9.4 Ltrs.).
following the instructions, take the machine to
the nearest Lincoln Field Service Shop. BEARINGS
-----------------------------------------------------------------------

• Do not touch electrically live parts or bearing having sufficient grease to last indefinitely
electrode with skin or wet clothing. under normal service. Where the welder is used con-
• Insulate yourself from work and stantly or in excessively dirty locations, it may be nec-
ground essary to add one half ounce of grease per year. A pad
• Always wear dry insulating gloves. of grease one inch wide, one inch long, and one inch
------------------------------------------------------------------------ high weighs approximately one half ounce. Over-
ENGINE EXHAUST can kill. greasing is far worse than insufficient greasing.
vent exhaust outside. When greasing the bearings, keep all dirt out of the
------------------------------------------------------------------------ equipment. More bearing failures are caused by dirt
MOVING PARTS can injure. introduced during greasing than from insufficient
• Do not operate with doors open or grease.
guards off.
• Stop engine before servicing. COMMUTATOR AND BRUSHES
------------------------------------------------------------------------
See additional warning information at WARNING
front of this operatorʼs manual. Uncovered rotating equipment can be dangerous.

----------------------------------------------------------- Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself
from particles that may be thrown out by the rotat-
ing armature when stoning the commutator.
GENERAL INSTRUCTIONS ------------------------------------------------------------------------
Shifting of the commutator brushes may result in:
• Blow out the welder and controls with an air hose at - Change in machine output
least once every two months. In particularly dirty - Commutator damage
locations, this cleaning may be necessary once a - Excessive brush wear
week. Use low pressure air to avoid driving dirt into
Periodically inspect the commutator, slip rings, and
the insulation.
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
• “Current Range Selector” contacts should not be
Commutators and slip rings require little attention.
greased. To keep the contacts clean, rotate the cur-
However, if they are black or appear uneven, have

practice is to turn the handle from maximum to mini-
using fine sandpaper or a commutator stone. Never
mum setting twice each morning before starting to
use emery cloth or paper for this purpose.
weld.
• Put a drop of oil on the “Current Range Selector”

Replace brushes when they wear within 1/4” of the pig- PURGING AIR FROM FUEL SYSTEM (GM
tail. A complete set of replacement brushes should be 3.0L ENGINE)
kept on hand. Lincoln brushes have a curved face

WARNING
to fit the commutator. Have an experienced mainte-
nance man seat these brushes by lightly stoning the
commutator as the armature rotates at full speed until Keep fuel clear of open flames or arcs, allow
contact is made across the full face of the brushes. engine to cool before working on the fuel system.
After stoning, blow out the dust with low pressure air. Wipe up any spilled fuel and do not start engine
between slip rings and brushes with the coarse side The fuel system operates as follows, The fuel pump
against the brushes. With slight additional finger pres- will operate for a maximum of 3 seconds when the igni-
sure on top of the brushes, pull the sandpaper around tion switch is turned “ON”. The pump will restart once
the circumference of the rings - in direction of rotation the start button is pushed and continue when the
only - until brushes seat properly. In addition, stone slip engine starts. To purge the system of air if fuel lines
ring with a fine stone. Brushes must be seated 100%. have been removed, the ignition switch can be toggled
“ON” and “OFF” (at 3 second intervals) until fuel flows
Arcing or excessive exciter brush wear indicates a pos- through the fuel return line in the neck of the tank.

Service Shop check and realign the shaft. The GM 3.0L engine does not require the system to be
bled. If the engine runs out of fuel and the tank is
refilled, the engine will restart within a few seconds if
IDLER CONTROL MAINTENANCE the engine is properly tuned.
CAUTION ENGINE MAINTENANCE
Before doing electrical work, disconnect the bat- Refer to the engine operation and maintenance manu-
tery. al for additional information on the engine.
------------------------------------------------------------------------
ground. Damage to the engine alternator and the TBI
controller can result from incorrect connection.
• Proper operation of the idle control requires good

grounding of the TBI controller, and battery.
• If desired, the welder can be used without automatic

idling by setting the “Idler” switch to the “High” posi-
tion.
NAMEPLATES

item number.

ENGINE SERVICE

FIRST SERVICE - (50 HOURS)
ENG INE SERVICE (NOTE 2)

I Coolant level

I Radiator for contamination or blockage
R Coolant (NOTE 3) 9.9 qrts, 9.4L
I Engine oil level ( NOTE 1 )
R R Engine oil ( NOTE 1 & 3 ) 4.5 qrts, 4.3L ( including filter )
R R Engine oil filter AC PF25
C C Drain fuel bowl
R Fuel filter canister PSI# 32500292
I Tension of Alternator/ Fan belt
I Alternator/ Fan belt wear
R Alternator Belt Good Year 11AV0955
R Fan Belt Good Year 11AV1220
R Spark Plugs (Gap = 0.040) 4 - AC R46TS
( I All nuts and bolts for tightness
4 C C Air filter (earlier check may be req'd)
R Air filter element Donaldson#P181050 Nelson #70206N
I Battery BCI GROUP 45
Notes (1) Consult Engine Operators Manual for oil Recommendations.

(2) Consult engine operators manual for additional maintenance schedule information.
2/01
(4) Clean the air filter if the engine is operating in very dusty conditions.
These preventative maintenance periods apply to average conditions of operation.

If necessary, use shorter periods. S20919-3


2. Engine Assembly
6. Exciter and Stator
8. Roof & Doors
9. Alternator Brush Holder

2
4
5
7
10
6

NOTES

D5.6
Return to Master TOC E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2/E-3
Battery, Starter, Engine & Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4/E-5
Engine, Generator Armature, Frame, Alternator Stator & Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7E-8
Engine Idler Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-9/E-10
DC Generator Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-11


E-2 THEORY OF OPERATION E-2
FIGURE E.1 - GENERAL DESCRIPTION (Classic® 300G, Zenith Fuel System/GM Engine)
SELECTOR
SWITCH
NEGATIVE
OUTPUT
CURRENT TERMINAL
SENSOR
P.C. BOARD
IDLE
SWITCH 115 & 230VAC
RECEPTACLES
ENGINE
RPM CONTROL ENGINE
CONTROL GENERATOR
FUEL PUMP COMPONENTS FRAME
AND
SERIES
ZENITH
SENSORS
HOUR METER COILS
E.C.U.
GASOLINE
ENGINE FAILURE LAMP ALTERNATOR STATOR
GENERATOR
ENGINE
COMMUTATOR
ARMATURE
BRUSHES
MECHANICAL ARMATURE ROTATOR
IGNITION COUPLING SHAFT
&
SWITCH
-
SLIP
RINGS
+
ENGINE
ALTERNATOR
INTERPOLE
RESIDUAL
COILS
MAGNETISM FLASHING
FIELD
SHUNT
WINDINGS
AMMETER START FIELD
RECTIFIER
STARTER
MOTOR
GENERATOR
FIELD CONTROL
RHEOSTAT POSITIVE
OUTPUT
TERMINAL
BATTERY
GENERAL DESCRIPTION
The Classic® 300 welding machines are heavy duty,
engine driven DC arc welding power sources capable
of providing constant current output for stick welding or
DC TIG welding. Also, a total of 3000 watts of auxiliary
power is available at the 115 or 230VAC receptacles.
The Classic® 300 is manufactured with all copper
windings.
NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

FIGURE E.2 - GENERAL DESCRIPTION (Classic® 300D, Perkins Engine)

TEMP.
SWITCH
ENGINE
FAILURE IDLE SWITCH SELECTOR
LAMP AUTO POSITION SWITCH REED
RELAY NEGATIVE
CR2
OUTPUT
=
HOUR TERMINAL
IDLER / ENGINE METER
PROTECTION
P.C. BOARD
OIL
PRESSURE
115 & 230VAC
RECEPTACLES
IGNITION GENERATOR
SWITCH
FRAME
TOROIDAL
FUEL SERIES CURRENT
GLOW
GLOW
PLUGS
IDLER
SOLENOID
FUEL
PUMP PUMP COILS TRANSFORMER
PLUG SOLENOID
(PERKINS)
BUTTON
ALTERNATOR STATOR
DIESEL GENERATOR
COMMUTATOR
BRUSHES
ENGINE
ARMATURE
ALTERNATOR
ENGINE
COUPLING SHAFT
&
SLIP EXCITER WINDING
-
RINGS
+
AMMETER
START
BUTTON INTERPOLE
RESIDUAL
COILS
STARTER MAGNETISM FLASHING
MOTOR FIELD
SHUNT
WINDINGS
FIELD
RECTIFIER
GENERATOR
FIELD CONTROL
BATTERY RHEOSTAT POSITIVE
OUTPUT
TERMINAL
FIGURE E.3 - GENERAL DESCRIPTION (Classic® 300D, Kubota Engine)
SELECTOR
SWITCH
NEGATIVE
OUTPUT
TERMINAL
CURRENT
SENSOR
P.C. BOARD
ENGINE
IDLE SWITCH
ENGINE
CONTROL
ENGINE FAILURE LAMP
HOUR WATER ENGINE
TEMP. SPEED
METER ACTUATOR 115 & 230VAC
UNIT
SENSOR SENSOR
RECEPTACLES
(ECU)
OIL PRESSURE SWITCH
GENERATOR
FRAME
(KUBOTA)
SERIES
COILS
TEMPERATURE SWITCH
IGNITION
DIESEL
SWITCH
ALTERNATOR STATOR
ENGINE GENERATOR
COMMUTATOR
GLOW MECHANICAL
BRUSHES
ARMATURE ROTATOR
ARMATURE
ENGINE PLUG COUPLING SHAFT
&
ALTERNATOR BUTTON SLIP
-
RINGS
+
GLOW
PLUGS INTERPOLE RESIDUAL
COILS
MAGNETISM FLASHING
AMMETER FIELD
ENGINE START SHUNT
STARTER WINDINGS
RPM CONTROL BUTTON
FIELD
RELAY
(CUSTOM ARC)
STARTER RECTIFIER
MOTOR
GENERATOR
FIELD CONTROL
RHEOSTAT POSITIVE
BATTERY OUTPUT
TERMINAL


FIGURE E.4 - BATTERY, STARTER, ENGINE, ALTERNATOR & PROTECTION CIRCUITS

(Classic® 300G, Zenith Fuel System/GM Engine)
SELECTOR
SWITCH
NEGATIVE
OUTPUT
CURRENT TERMINAL
SENSOR
P.C. BOARD
IDLE
SWITCH 115 & 230VAC
RECEPTACLES
ENGINE
RPM CONTROL ENGINE
CONTROL GENERATOR
AND
SERIES
ZENITH
SENSORS
HOUR METER COILS
E.C.U.
GASOLINE
GENERATOR
ENGINE
COMMUTATOR
ARMATURE
BRUSHES
&
SWITCH
-
SLIP
RINGS
+
ENGINE
ALTERNATOR
INTERPOLE
RESIDUAL
COILS
MAGNETISM FLASHING
FIELD
SHUNT
WINDINGS
AMMETER START FIELD
RECTIFIER
STARTER
MOTOR
GENERATOR
FIELD CONTROL
RHEOSTAT POSITIVE
OUTPUT
TERMINAL
BATTERY
BATTERY, STARTER, ENGINE,

ALTERNATOR & PROTECTION
CIRCUITS
The 12VDC battery powers the starter motor and,
through the ignition switch, the engine protection cir-
cuitry. In the event of a low oil pressure or a high
coolant temperature condition, the engine protection

system shuts the engine off.
The idle / engine protection PC board or, the engine

control unit (ECU) monitors the oil pressure sensor,
and the coolant temperature sensor. If either sensor “
faults,” the engine is shut down.
The engine alternator supplies “charging” current for

the battery circuit. If the alternator would cease to func-
tion correctly, due to a broken fan belt or other mal-
function, the engine protection system would shut the
engine down.



(Classic® 300D, Perkins Engine)
TEMP.
SWITCH
ENGINE
RELAY NEGATIVE
CR2
OUTPUT
=
HOUR TERMINAL
PROTECTION
P.C. BOARD
OIL
PRESSURE
115 & 230VAC
RECEPTACLES
IGNITION GENERATOR
SWITCH
FRAME
TOROIDAL
FUEL SERIES CURRENT
GLOW
GLOW
PLUGS
IDLER
SOLENOID
FUEL
PLUG SOLENOID
(PERKINS)
BUTTON
ALTERNATOR STATOR
DIESEL GENERATOR
COMMUTATOR
BRUSHES
ENGINE
ARMATURE
ALTERNATOR
ENGINE
COUPLING SHAFT
&
-
RINGS
+
AMMETER
START
BUTTON INTERPOLE
RESIDUAL
COILS
MOTOR FIELD
SHUNT
WINDINGS
FIELD
RECTIFIER
GENERATOR
FIELD CONTROL
OUTPUT
TERMINAL

(Classic® 300D, Kubota Engine)
SELECTOR
SWITCH
NEGATIVE
OUTPUT
TERMINAL
CURRENT
SENSOR
P.C. BOARD
ENGINE
IDLE SWITCH
ENGINE
CONTROL
ENGINE FAILURE LAMP
HOUR WATER ENGINE
TEMP. SPEED
UNIT
SENSOR SENSOR
RECEPTACLES
(ECU)
OIL PRESSURE SWITCH
GENERATOR
FRAME
(KUBOTA)
SERIES
COILS
TEMPERATURE SWITCH
IGNITION
DIESEL
SWITCH
ALTERNATOR STATOR
ENGINE GENERATOR
COMMUTATOR
GLOW MECHANICAL
BRUSHES
ARMATURE ROTATOR
ARMATURE
&
-
RINGS
+
GLOW
COILS
MAGNETISM FLASHING
AMMETER FIELD
ENGINE START SHUNT
STARTER WINDINGS
RPM CONTROL BUTTON
FIELD
RELAY
(CUSTOM ARC)
STARTER RECTIFIER
MOTOR
GENERATOR
FIELD CONTROL
RHEOSTAT POSITIVE
BATTERY OUTPUT
TERMINAL


ENGINE, GENERATOR ARMATURE CURRENT RANGE SELECTOR

AND FRAME, ALTERNATOR STA- The selector switch acts as a coarse current
TOR AND ROTOR adjustment by allowing for varying amounts of

series windings to be included in the welding cur-
rent path. The series coils and selector switch are
EXCITATION (FLASHING) connected in series with the negative output ter-
When the engine is started and running, voltage minal.
produced by residual magnetism in the DC weld-
ing generator passes through a “flashing” diode, FINE CURRENT ADJUSTMENT
and is applied to the alternator rotor via a brush The field rheostat control functions as a fine out-
and slip ring configuration. This excitation (“flash- put current adjustment by controlling the current
ing”) voltage magnetizes the rotor lamination. The through the shunt windings. This controls the
alternator rotor is connected to the armature shaft, amount of magnetism created in the shunt field
which is mechanically coupled to the engine. The windings. Open circuit weld voltage can also be
rotating magnet (rotor) induces a voltage in the controlled by the field rheostat control.
stationary windings of the alternator stator.
ENGINE HIGH IDLE RPM (OCV)
AUXILIARY AND FIELD FEEDBACK ADJUSTMENT

COILS Classic® 300G (Codes 10659, 10912, and 11135)
There are two isolated windings incorporated in The Classic® 300G utilizes an electronic engine
the stator lamination assembly. One of these control system manufactured by Zenith fuel sys-
windings is tapped and provides 115VAC and tems LLC. This system maintains a steady RPM
230VAC of auxiliary power to the appropriate by constantly sensing engine speed and making
receptacles. The other 115VAC isolated winding is adjustments as needed.
rectified to a DC voltage and is used to supply
field feedback voltage to the rotor. It also supplies A potentiometer mounted on the output rail allows
voltage, through the generator field rheostat con- the operator to adjust the high idle engine speed
trol, to the field shunt windings in the main gener- between 1700 and 1800 RPMʼs in 20 RPM incre-
ator frame. ments. This is to allow further adjustment of the
welding generator open circuit voltage (OCV).
INTERPOLE AND SERIES COILS Total OCV adjustment range is about 10 Volts.
The generator armature rotates within the mag-

netic field created by the shunt field windings. A
DC voltage is induced in the armature and is
transferred, through the armature commutator
and brushes, to the series and interpole coils. The
interpole coils, which are connected in series with
the positive output terminal, are located so as to
counteract any magnetic influences that could
cause mechanical distortion in the rotating arma-
ture. The series coils are designed to oppose or
“buck” the DC voltage that is generated in the
armature.


FIGURE E.8 - CLASSIC® 300D, PERKINS ENGINE

TEMP.
SWITCH
ENGINE
RELAY NEGATIVE
CR2
OUTPUT
=
HOUR TERMINAL
PROTECTION
P.C. BOARD
OIL
PRESSURE
115 & 230VAC
RECEPTACLES
IGNITION GENERATOR
SWITCH
FRAME
TOROIDAL
FUEL SERIES CURRENT
GLOW
GLOW
PLUGS
IDLER
SOLENOID
FUEL
PLUG SOLENOID
(PERKINS)
BUTTON
ALTERNATOR STATOR
DIESEL GENERATOR
COMMUTATOR
BRUSHES
ENGINE
ARMATURE
ALTERNATOR
ENGINE
COUPLING SHAFT
&
-
RINGS
+
AMMETER
START
BUTTON INTERPOLE
RESIDUAL
COILS
MOTOR FIELD
SHUNT
WINDINGS
FIELD
RECTIFIER
GENERATOR
FIELD CONTROL
OUTPUT
TERMINAL
FIGURE E.9 - CLASSIC® 300D, KUBOTA ENGINE
SELECTOR
SWITCH
NEGATIVE
OUTPUT
TERMINAL
CURRENT
SENSOR
P.C. BOARD
ENGINE
IDLE SWITCH
ENGINE
CONTROL
ENGINE FAILURE LAMP
HOUR WATER ENGINE
TEMP. SPEED
UNIT
SENSOR SENSOR
RECEPTACLES
(ECU)
OIL PRESSURE SWITCH
GENERATOR
FRAME
(KUBOTA)
SERIES
COILS
TEMPERATURE SWITCH
IGNITION
DIESEL
SWITCH
ALTERNATOR STATOR
ENGINE GENERATOR
COMMUTATOR
GLOW MECHANICAL
BRUSHES
ARMATURE ROTATOR
ARMATURE
&
-
RINGS
+
GLOW
COILS
MAGNETISM FLASHING
AMMETER FIELD
ENGINE START SHUNT
STARTER WINDINGS
RPM CONTROL BUTTON
FIELD
RELAY
(CUSTOM ARC)
STARTER RECTIFIER
MOTOR
GENERATOR
FIELD CONTROL
RHEOSTAT POSITIVE
BATTERY OUTPUT
TERMINAL


Classic® 300D Perkins (Codes 10545, 10546, Classic® 300D Kubota (Codes: 11112, 11113,
10657, 10658, 10911, 10927, 11110, 11111, 11243, 11244, 11413, 11414, 11474, and 11475)
11248, 11249, 11280, 11281, 11411, 11412,

11472, and 11473) The Kubota powered Classic® 300D machines
utilize an electronic engine control system which
The Perkins powered Classic® 300D machines is a part of the Kubota engine. This system main-
have a mechanical governor that maintains the tains a steady RPM by constantly sensing engine
engine RPM when the engine is running at high speed and making adjustments as needed.
speed. There is no operator control for RPM as
there is with 300G or 300D Kubota. The Custom Arc Control, a potentiometer mount-
ed on the lower right control panel, allows the
operator to adjust the high idle engine speed
between 1650 and 1800 RPM. This is to allow fur-
ther adjustment of the OCV. Total OCV adjust-
ment range is about 15 volts.
FIGURE E.7 - CLASSIC® 300G, ZENITH FUEL SYSTEM / GM ENGINE
SELECTOR
SWITCH
NEGATIVE
OUTPUT
CURRENT TERMINAL
SENSOR
P.C. BOARD
IDLE
SWITCH
115 & 230VAC

RECEPTACLES
ENGINE
RPM CONTROL ENGINE
CONTROL GENERATOR
AND
SERIES
ZENITH
SENSORS
HOUR METER COILS
E.C.U.
GASOLINE
GENERATOR
ENGINE
COMMUTATOR
ARMATURE
BRUSHES

&
SWITCH
-
SLIP
RINGS
+
ENGINE
ALTERNATOR
INTERPOLE
RESIDUAL
COILS
MAGNETISM FLASHING
FIELD
SHUNT
WINDINGS
AMMETER START FIELD
RECTIFIER
STARTER
MOTOR
GENERATOR
FIELD CONTROL
RHEOSTAT POSITIVE
OUTPUT
TERMINAL
BATTERY


ENGINE IDLER CIRCUIT

Classic® 300G (Codes 10659, 10912, and Classic® 300D Perkins (Codes 10545, 10546,
11135) 10657, 10658, 10911, and 10927)
The Zenith ECU used in the Classic® 300G con- The above models use a high speed solenoid,
trols whether the engine operates at high idle or connected to the governor linkage, and operated
low idle. Closing the circuit between pins #11 and by the idler/engine protection PC board. In these
#13 of the ECU signal that high RPM is required machines, the solenoid increases the RPM when
and the engine immediately accelerates to high activated.
idle RPM. Opening this will cause the engine
RPM to drop to low idle speed, (about 1360 RPM) When the idle switch is in the auto position, and
after a delay of about 15 seconds. If the pin #11 welding current is being drawn, the reed switch
to pin #13 circuit is re-closed during this delay, CR2 is closed. This signals the idler PC board to
engine RPM will remain high. activate the high speed solenoid, which then
increases the engine speed to high idle RPM.
The current sensor PC board detects current flow When auxiliary power is being used, the current is
in both the auxiliary and the weld circuits. When passed through the toroidal current transformer.
sufficient current is flowing in either of these cir- This also signals the idler PC board to activate the
cuits, the current sensor PC board closes the #11 high speed solenoid. When welding ceases or
- #13 circuit, when current flow ceases, the circuit the auxiliary load is removed, a preset time delay
is opened. of about 15 seconds starts. When this 15 second
delay has passed, the idler PC board deactivates
The idle switch and the current sensing PC board the high speed solenoid, and allows the machine
are wired in parallel across the #11 - #13 circuit will return to a low speed condition. If welding is
described above. When the idle switch is set to resumed, or an auxiliary load is applied during this
the high position, the contacts are closed and the delay, the solenoid will remain active and the
ECU operates the engine continuously at high engine RPM remains high.
RPM. When the idle switch is in the Auto position,
the contacts are open, and the current sensor PC When the idle switch is in the high position, the
board has control of the #11 - #13 circuit. reed switch CR2 is bypassed, signaling the PC
board to activate the solenoid.
Classic® 300D Perkins (Codes 11110, 11111,

11248, 11249, 11280, 11281, 11411, 11412,
11472, and 11473)
The above models use a two winding idle sole-
noid, connected to the governor linkage, and
operated by the idler/engine protection PC board.
The engine normally runs at high RPM, and is
controlled by the governor. When the idle switch
is in the auto position and no weld or auxiliary
loads are applied, the idler/engine protection PC
board starts a 15 second delay. When this delay
has passed, both the pull and hold coils of the
solenoid are activated. After about 0.75 seconds,
the pull coil is deactivated leaving the still active
hold coil to maintain the low idle position of the
solenoid.


When the idle switch is in the auto position, and The current sensor PC board detects current flow
welding current is being drawn, the reed switch in both the auxiliary and the weld circuits. When
CR2 is closed. This signals the idler PC board to sufficient current is flowing in either of these cir-
deactivate the idle solenoid, allowing the governor cuits, the lead connected to pin #31 is grounded,
to increase the engine speed to high RPM. When signaling that high RPM is required. When cur-
auxiliary power is being used, the current is rent flow ceases, the lead connected to pin #31 is
passed through the toroidal current transformer. disconnected from chassis ground, and the
This also signals the idler PC board to deactivate engine idles down after the delay described
the idle solenoid. When welding ceases or the above.
auxiliary load is removed, a preset time delay of
about 15 seconds begins. When this 15 second The idle switch and the current sensing PC board
delay has passed, the PC board activates the idle are wired in parallel between chassis ground and
solenoid, as described above, and pulls the the pin#31 circuit described above. When the idle
engine governor linkage to the low idle RPM posi- switch is set to the high position, the contacts are
tion. If welding is resumed, or an auxiliary load is closed and the ECU operates the engine continu-
applied during this delay, the engine RPM will ously at high RPM. When the idle switch is in the
remain high. Auto position, the contacts are open, and the cur-
rent sensor PC board controls whether the pin

When the idle switch is in the high position, the #31 circuit is grounded or open.
reed switch CR2 is bypassed, signaling the PC
board to leave the solenoid inactive
Classic® 300D Kubota (Codes: 11112, 11113,

11243, 11244, 11413, 11414, 11474, and 11475)
The Kubota engine control unit (ECU) used in the
Classic® 300D controls whether the engine oper-
ates at high idle or low idle. Grounding pin #31 of
the ECU signals that high RPM is required and
the engine immediately accelerates to high idle
RPM. Opening the circuit between pin #31and
chassis ground will cause the engine RPM to drop
to low idle speed, after a delay of about 15 sec-
onds. If the chassis ground to pin #31 circuit re-

closed during this delay, engine RPM will remain
high.


FIGURE E.10 - DC GENERATOR MACHINES

C
F U
I R
E R
L E
D N
T
SHUNT FIELD WINDINGS
DC CURRENT
MAGNETIC FIELD
GENERATOR BRUSH
MECHANICAL ARMATURE
COUPLING SHAFT
ARMATURE BRUSH
MAGNETIC FIELD
DC CURRENT
SHUNT FIELD WINDINGS
C
F U
I R
E R
L E
D N
T
DC GENERATOR 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. The armature coil sides are placed at opposite
points on the rotating shaft with the conductors parallel

to the shaft. The armature assembly is normally turned
at a constant speed by a source of mechanical power
connected to the shaft. Rotation of the armature
through the magnetic field produced by the stationary
field winding induces a coil voltage in the armature
winding. The voltage induced in an individual armature
coil is an alternating (AC) voltage, which must be recti-
fied. In a conventional machine, rectification is provid-
ed mechanically by means of a commutator. A commu-
tator is a cylinder formed of copper segments insulated
from each other and mounted on, but insulated from,
the rotating shaft. Each copper segment is connected
to a corresponding armature winding. Stationary car-
bon brushes held against the commutator surface con-
nect the armature windings to external terminals. The
commutator provides full-wave rectification, transform-
ing the voltage waveform between brushes and mak-

ing available a DC voltage to the external circuit.


Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-12
NOTES

E-12
F-1 TROUBLESHOOTING AND REPAIR F-1
TABLE OF CONTENTS
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Brush & Slip Ring Service Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25
Engine Alternator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25

Engine Fuel System Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-27
Engine Protection System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29
Engine RPM Adjustment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31
Flash Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-35
Rocker Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37
Exciter Rotor Resistance and Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-41
Shunt Field Coil Resistance and Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-45
Shunt Field Coil Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47
Exciter Stator Short Circuit and Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-49

Weld Circuit Ground and Short Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-51
Welding Generator Brush & Commutation Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . .F-53
Series Coil Short Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-57
Voltage Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-59/F-61
Alternator Rotor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-63
Alternator Stator Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-69
Generator Frame Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-75
Generator Armature Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-81

Retest and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-83

HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger to
the technician and machine operator and will invalidate your factory warranty. For your
safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed throughout this manual.
---------------------------------------------------------------------------------------------------------------------------
This Troubleshooting Guide is provided to Step 3. RECOMMENDED
help you locate and repair possible machine COURSE OF ACTION
malfunctions. Simply follow the three-step The last column labeled “Recommended
procedure listed below. Course of Action” lists the most likely com-
ponents that may have failed in your
Step 1. LOCATE PROBLEM (SYMPTOM). machine. It also specifies the appropriate
Look under the column labeled “PROBLEM test procedure to verify that the subject com-
(SYMPTOMS)”. This column describes pos- ponent is either good or bad. If there are a
sible symptoms that the machine may exhib- number of possible components, check the
it. Find the listing that best describes the components in the order listed to eliminate
symptom that the machine is exhibiting. one possibility at a time until you locate the
Symptoms are grouped into the following cause of your problem.
categories: output problems, function prob-
lems and welding problems. All of the referenced test procedures
referred to in the Troubleshooting Guide are
Step 2. PERFORM EXTERNAL TESTS. described in detail at the end of this chapter.
The second column labeled “POSSIBLE Refer to the Troubleshooting and Repair
AREAS OF MISADJUSTMENT(S)” lists the Table of Contents to locate each specific
obvious external possibilities that may con- Test Procedure. All of the specified test
tribute to the machine symptom. Perform points, components, terminal strips, etc. can
these tests/checks in the order listed. In be found on the referenced electrical wiring
general, these tests can be conducted with- diagrams and schematics. Refer to the
out removing the case wrap-around cover. Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call 1-888-935-3877.
-----------------------------------------------------------------------------------------------------------------------------------

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Donʼt set the

ELECTRIC SHOCK PC board on or near paper, plastic or cloth which
can kill. could have a static charge. If the PC board canʼt be
installed immediately, put it back in the static-shield-
• Have an electrician install and ing bag.
service this equipment. Turn the
input power OFF at the fuse box - If the PC board uses protective shorting jumpers,
before working on equipment. Do donʼt remove them until installation is complete.
not touch electrically hot parts.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop-
CAUTION er failure analysis.
Sometimes machine failures appear to be due to PC 4. Test the machine to determine if the failure
board failures. These problems can sometimes be symptom has been corrected by the
traced to poor electrical connections. To avoid prob- replacement PC board.
lems when troubleshooting and replacing PC boards,

please use the following procedure: NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability
that the PC board is the most likely component NOTE: Allow the machine to heat up so that all
causing the failure symptom. electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board
to assure that the PC board is properly 5. Remove the replacement PC board and
connected. substitute it with the original PC board to
recreate the original problem.
3. If the problem persists, replace the suspect PC
a. If the original problem does not reappear by
board using standard practices to avoid static
substituting the original board, then the PC
electrical damage and electrical shock. Read
board was not the problem. Continue to look
the warning inside the static resistant bag and
for bad connections in the control wiring
perform the following procedures:
harness, junction blocks, and terminal strips.
PC board can be damaged by static electricity. b. If the original problem is recreated by the
- Remove your bodyʼs static substitution of the original board, then the PC
charge before opening the static- board was the problem. Reinstall the
shielding bag. Wear an anti-static replacement PC board and test the machine.
wrist strap. For safety, use a 1 6. Always indicate that this procedure was
Meg ohm resistive cord connected followed when warranty reports are to be
ATTENTION to a grounded part of the submitted.
Static-Sensitive equipment frame.
NOTE: Following this procedure and writing on the
Devices - If you donʼt have a wrist strap, warranty report, “INSTALLED AND SWITCHED PC
Handle only at touch an un-painted, grounded,
BOARDS TO VERIFY PROBLEM,” will help avoid
Static-Safe part of the equipment frame. Keep denial of legitimate PC board warranty claims.
Workstations touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must

be either conductive, anti-static or static-dissipative.

Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Both the weld and auxiliary Make sure the engine is Perform the Engine RPM
output voltages are low. operating at high idle speed. Adjustment Test.
Make sure that no load is Perform the Brush and Slip

connected to either the weld or Ring Service Procedure.
auxiliary outputs.
Perform the Flash Voltage
test.
Perform Exciter Rotor

Resistance and Ground Test.
There is no, or very low weld Check that the remote/local Perform the Brush and Slip
switch (if so equipped) is in Ring Service Procedure.

output, and no auxiliary output.

the local control position.
Perform the Flash Voltage
Check that the auxiliary power test.
circuit breakers and Ground
Fault Circuit Interrupters Perform the Exciter Rotor
(GFCIs) (if so equipped) are Resistance and Ground Test.
not tripped.
NOTE: GFCIs will not reliably

reset, unless engine is
operating at high idle
RPM.
Check all leads and cables for

damaged or poor connections.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.


OUTPUT PROBLEMS
There is no, or very low weld Check that the remote/local Perform the Welding
output voltage. The auxiliary switch (If so equipped) is Generator Brush and
output is normal. positioned correctly. Commutator Inspection and
Service Procedure.
If a remote current control is
being used, try switching to Perform the Shunt Field Coil
local control. The remote Resistance and Ground
current control may be faulty. Test.
Check all leads and cables for Perform the Shunt Field
damaged or poor connections. Circuit Voltage Test.
Check for damaged or poor

connections at the brush

holders, series and interpole
coils, weld output terminals,
and all the conductors
connecting these components.
The Armature may be faulty.
There is no auxiliary voltage, Check that the auxiliary power Check for auxiliary voltage at
weld output is normal. circuit breakers are not tripped. the receptacle input terminals,
if normal voltage is present,
If the machine is equipped with replace receptacle.
a ground fault circuit
interrupter (GFCI), it may be Check for auxiliary voltage at
tripped. the connections closest to the

exciter stator windings. See

NOTE: GFCIs will not reliably wiring diagram.
reset, unless engine is
operating at high idle • If normal voltage is present,
RPM. check the wiring and circuit
breakers between the test
Check all leads and cables for points and the receptacle.
damaged or poor connections. Repair or replace any defective
parts or wiring.
• If normal voltage is not

present, check for damaged
conductors between the test
points and the winding. If the
conductors are good, the stator
is defective.
CAUTION
Call 1-888-935-3877.


OUTPUT PROBLEMS
The output takes a long time to N/A Check the “flashing” diode
build up and the AC auxiliary located on the DC welding
voltage varies when the fine generator brush holder. The
current control is adjusted. diode may be “shorted” or
installed incorrectly.
CAUTION
Call 1-888-935-3877.


OUTPUT PROBLEMS
The weld output is considerably Check welding cables for Perform the Engine RPM
less than indicated on the dials damaged or poor connections. Adjustment Test.
or varies abnormally. Auxiliary
output appears normal. Welding cable may be Check the exciter brushes
excessively long, too small, or and, if necessary, perform the
coiled. Try using a set of Exciter Brush and Slip Ring
short test cables of adequate Service Procedure.
size.
Check the welding generator
If a remote current control is brushes and, if necessary,
being used, try switching to perform the Welding
local control. The remote Generator Brush and
current control may be faulty. Commutator Inspection and
Service procedure.
The engine may not be

maintaining steady RPM. Check all the large weld
Make sure there is an current carrying leads inside
adequate supply of clean, the machine for damaged
fresh fuel. Replace fuel filters conductors, insulation, and
if necessary. Have engine poor connections.
serviced by a qualified engine
technician. Check the wiring that
connects the exciter, field
bridge rectifier, rheostat,
remote/local switch, and the
shunt coils. Check for
damaged conductors,
insulation, and poor
connections.
Replace the Exciter Diode

Bridge with a new or known

good bridge.
(Diode bridges will sometimes

appear good under test, but
fail while under a normal
operating load.)
Check the 64 Ohm fine

current control rheostat,
replace if necessary.
Check remote/local switch.

Replace if necessary.
Perform the Exciter Rotor

Resistance and Ground
Test.
CAUTION
Call 1-888-935-3877.


OUTPUT PROBLEMS
The weld output is considerably N/A Perform the Shunt Field Coil
less than indicated on the dials Resistance and Ground
or varies abnormally. Auxiliary Test.
output appears normal.
Check the Generator brush
rocker position; perform the
(Continued)
Rocker Adjustment
Procedure if necessary.
The weld output is considerably If a remote current control is The engine RPM may be too
higher than indicated on the being used, try switching to high; perform the Engine RPM
dials. Auxiliary voltage appears local control. The remote Adjustment Test.
normal. current control may be faulty.
There may be a short circuit in
the series field coils. Perform
the Weld Circuit Ground and
Short Circuit Test and Series
Coil Short Circuit Test.

Perform the Shunt Field Coil

Verify that the rocker is

positioned correctly, according
to the factory drill mark.
Perform the Rocker
Adjustment Procedure if
necessary.
CAUTION
Call 1-888-935-3877.


WELDING PROBLEMS
The welding arc is loud and The weld current or voltage The engine RPM may be
spatters excessively. settings may be incorrect. incorrect; perform the Engine
RPM Adjustment Test.
The polarity may be incorrect
for the process in use. Check the exciter brushes
and slip rings, and if
If a remote current control is necessary, perform the Brush
being used, try switching to and Slip Ring Service
local control. The remote Procedure.
current control may be faulty.
Check the DC welding
generator brushes and
commutator. Perform the
Welding Generator Brush

and Commutator Inspection
and Service Procedure.
Replace the Exciter Diode

Bridge with a new or known
good bridge.
(Diode bridges will sometimes

appear good under test, but
fail while under a normal
operating load.)

Test.
Perform the Shunt Field Coil


Test.
Verify that the rocker is

positioned correctly, according
to the factory drill mark.
Adjust the rocker position per

the procedure in this manual.
CAUTION
Call 1-888-935-3877.


WELDING PROBLEMS
The welding arc frequently “pops The fine current control The engine RPM may be
out”. Welding heat seems rheostat may be set too low. incorrect; perform the Engine
normal and auxiliary output Try increasing the fine current RPM Adjustment Test.
voltage appears normal. control setting. Drop the range
selector to a lower setting if Check the exciter brushes
arc is too hot. and slip rings. If necessary,
perform the Brush and Slip
If a remote control is being Ring Service Procedure.
used, try switching to local
control. The remote control Check the DC welding
unit may be faulty. generator brushes and
commutator. If necessary,
Check welding cables for perform the Welding
Generator Brush and
damaged or poor connections.

Commutator Inspection and

Welding cable may be Service procedure.
excessively long, too small, or
coiled. Try using a set of short Perform the Flash Voltage
test cables of adequate size. test.
Perform the Shunt Field

Circuit Voltage Test.
Check that the rocker is

aligned to the factory drill
mark, and perform the
Rocker Adjustment
Procedure if necessary.
CAUTION
Call 1-888-935-3877.


WELDING PROBLEMS
The engine will not crank when The battery may be Make sure battery is fully
the start button is pressed. discharged. Check, and if charged and properly
necessary, charge or replace connected per the wiring
(Classic® 300G and 300D the battery. diagram. Check for positive
Perkins) battery voltage where the
The battery cables or battery lead from the start button
connections may be loose or connects to the starter
corroded. Service the battery solenoid, while holding in the
terminals. start button. (Lead #84 on
Classic® 300G, lead #52 on
Classic® 300D Perkins)
• If no voltage is present, check

the connections and wiring

connecting the starter
solenoid, the ammeter, and
the start push button switch.
(See the wiring diagram) If
the wiring and connections
are good, replace the push
button switch.
• If voltage is present, check

that the engine block is
properly connected to the
negative battery terminal. If
the engine block is properly
connected, the
starter/solenoid is defective
and should be serviced or
replaced.
CAUTION
Call 1-888-935-3877.


FUNCTION PROBLEMS
The engine will not crank when The battery may be Make sure battery is fully
the start button is pressed. discharged. Check, and if charged and properly
necessary, charge or replace connected per the wiring
(Classic® 300D Kubota) the battery. diagram. Turn on the
run/stop switch, and within 30
The battery cables or battery seconds, press the start
connections may be loose or button while checking for
corroded. Service the battery positive battery voltage where
terminals. the lead #62 connects to the
starter solenoid.
• If voltage is present when the

start button is pressed, check
that the engine block is

properly connected to the
negative battery terminal. If
the engine block is properly
connected, the
starter/solenoid is defective
and should be serviced or
replaced.
• If no voltage is present:
• Check the wiring connecting

the starter solenoid, ammeter,
start relay, and start button.
See wiring diagram.
• Check the start button.
• Check for battery voltage at

the start relay coil, between
leads #212C(+) and lead
#55(-) within 30 seconds of
turning on the run/stop switch
and while pressing the start
button.
• If voltage is present, replace

the start relay.
• If voltage is not present,

check the #55 lead, all the
conductors and devices
between the #212C lead and
the positive battery terminal.
CAUTION
Call 1-888-935-3877.


FUNCTION PROBLEMS
The engine will not crank when • Check that the Engine Control
the start button is pressed. Module (ECU) is getting
battery power and has a good
(Classic® 300D Kubota) ground connection (See
wiring diagram)
(Continued)
• Check lead #52B between the
start button and the ECU.
• Replace the ECU.
The engine cranks when the Make sure the run/stop switch Perform the Engine Fuel
start button is pressed, but will is in the run position. System Voltage Tests.
not start.
The run/stop switch may have

(Classic® 300G and Classic® been left in the run position for
300D Perkins) more that 30 seconds (60
seconds for some models).
Reset the engine protection
system by moving the run/stop
switch off, then on again.
Check that the battery circuit

breaker is not tripped.
Check that there is an

adequate supply of fresh clean
fuel, and that the fuel shut-off
valve is open.
Check and if necessary,

replace the fuel filter.
(Classic® 300D Perkins only)
If the machine is being used in

a cold climate, the Glow Plugs
may need to be used. See the
welder operatorsʼ manual and
the engine operatorʼs manual
for detailed instructions.
(Classic® 300D Perkins only)
There may be air in the fuel

system. See the engine
manufacturerʼs manual and
bleed all air from the fuel
system.
CAUTION
Call 1-888-935-3877.


FUNCTION PROBLEMS
The engine cranks when the Make sure the run/stop switch Verify that the engine control
start button is pressed, but will is in the run position. unit is getting battery power
not start. at pin #15, Lead 212D and a
The run/stop switch may have good chassis ground
(Classic® 300D Kubota) been left in the run position for connection at pins #1 and
more that 30 seconds (60 #19.
seconds for some models).
Reset the engine protection Check the wiring and
system by moving the run/stop connections between the
switch off, then on again. engine control unit and the
speed sensor, the water
Check that there is an sensor and the actuator.
adequate supply of fresh clean
fuel, and that the fuel shut-off If the control unit has power,
valve is open. a good chassis ground

connection and the wiring
Check and if necessary, described above is in good
replace the fuel filter. condition, the engine and
If the machine is being used in engine control components
a cold climate, the Glow Plugs should be checked by a
may need to be used. See the qualified Kubota repair
welder operatorsʼ manual and technician.
the engine operatorʼs manual
for detailed instructions.
There may be air in the fuel

system. See the engine
manufacturerʼs manual and
bleed all air from the fuel
system.
CAUTION
Call 1-888-935-3877.


FUNCTION PROBLEMS
The engine starts normally, but The oil pressure may be low. The idle/engine protection PC
shuts down after running for Check the oil level and add oil board, engine control unit,
several seconds. as needed. If necessary, alternator, oil pressure switch,
contact the engine or engine coolant temperature
manufacturer, or a qualified switch may be faulty.
engine specialist to determine Perform the Engine
the cause of the low oil Protection System Test.
pressure condition, and make
any required adjustments or
repairs.
The engine alternator belt may

be loose or broken. Replace
the belt and/or adjust the belt

tension.
The engine may be

overheated. Contact the
engine manufacturer, or a
qualified engine specialist to
determine the cause of the
overheat condition, and make
any required adjustments or
repairs.
The engine will not develop full Check that there is an Perform the Engine RPM
power. adequate supply of fresh clean Adjustment Test.
fuel, and that the fuel shut-off
valve is fully open. There may be internal
problems with the engine.
Check the fuel and air filters, Contact the engine

replace if necessary. manufacturer or a qualified
engine repair technician.
CAUTION
Call 1-888-935-3877.


FUNCTION PROBLEMS
The engine will not shut down N/A Check the run/stop switch,
when the run/stop switch is replace if necessary.
moved to the stop position.
There may be a failure in the
engine or engine control unit.
Contact the engine
manufacturer or a qualified
engine technician.
The battery does not stay The battery may be faulty. Perform the Engine Alternator
charged. Recharge and test the battery. Test.
Replace it if necessary.
The engine alternator drive belt

may be loose. Replace and/or
adjust the belt tension.
CAUTION
Call 1-888-935-3877.


FUNCTION PROBLEMS
The machine will not idle down Make sure the idle switch is in Check the Idle Switch for
to low RPM when weld and the “AUTO IDLE” position. proper operation. See wiring
auxiliary loads are removed. diagram.
The machine has normal weld Make sure there is no external
and auxiliary output. The engine load on the weld terminals or Perkins powered units:
starts and shuts down normally. the auxiliary power The idle solenoid linkage, if
receptacles. Disconnect the so equipped, may be bent or
weld cables and unplug out of adjustment. Check that
anything that may be the linkage moves freely and
connected to the auxiliary that the plunger does not bind
receptacles. in any way.
For machines equipped with Check that the solenoid can

an idle solenoid, check for freely pull in and solidly seat

mechanical restrictions in the against its internal stop.

idler solenoid linkage.
The idle solenoid may have
failed. Disconnect the
solenoid leads and check the
resistance of the solenoid
coil. See machine schematic
for correct solenoid coil
resistance. Check the
resistance from the solenoid
leads to the solenoid body,
resistance should be very
high, 500,000 (500k) ohms
minimum.
Perform the Engine RPM

Adjustment Test.
The 2-CR Reed relay may be

faulty. The reed relay should
be electrically open if no
current is flowing in the weld
circuit. If there is continuity
through the reed relay when
the machine is off, it is
defective and should be
replaced.
There may be voltage in the

toroidal current sensor circuit.
Unplug the current sensor
from the PC board. See
wiring diagram.
CAUTION
Call 1-888-935-3877.


FUNCTION PROBLEMS
The machine will not idle down If the machine idles down
to low RPM when weld and after the sensor is unplugged,
auxiliary loads are removed. check the wiring between the
The machine has normal weld PC board and toroidal current
and auxiliary output. The engine sensor for damaged insulation
starts and shuts down normally. and electrical contact with
other electrically live
(Continued) components. (See the wiring
diagram) If the wiring is
good, there is likely a load on
the auxiliary circuit. Check all
wiring and components in the
AC auxiliary circuit. (See
wiring diagram)
If the machine still will not

idle down, check all wiring
connected to the solenoid.
See the wiring diagram. Look
for damaged wiring, poor
connections, dirty or corroded
terminals, etc. If all of the
wiring is good, replace the PC
board.
For Classic® 300G and
Kubota powered units:
Unplug the current sensor PC
board.
If the machine will not idle
down, check all the wiring
connecting to the current

sensor.
If all the wiring is good,
replace the engine control
unit.
If the engine idles down when
the sensor is disconnected,
reconnect the sensor, then
disconnect the leads that loop
through the current sensor
sensing unit. (See wiring
diagram)
If the engine does not idle
down, replace the current
sensor PC board.
CAUTION
Call 1-888-935-3877.


FUNCTION PROBLEMS
The engine goes to low idle, but Make sure there are no The low idle RPM may be too
will not stay at low idle. The external loads on the weld low. Perform the engine idle
machine has normal weld and terminals or the auxiliary adjustment procedure.
auxiliary output. The engine power receptacles. Disconnect
starts and shuts down normally. the weld cables and unplug The idle solenoid linkage may
anything that may be be out of adjustment. Check
connected to the auxiliary that the linkage moves freely
receptacles. and that the plunger is not
binding in any way. Check
that the solenoid can freely
pull in and solidly seat
against its internal stop.
The idle solenoid may have

failed. Disconnect the

solenoid leads and check the
resistance of the solenoid
coil. See machine schematic
for correct solenoid
resistance. Check the
solenoid for a grounded coil;
the resistance between
chassis ground and either
solenoid lead wire should be
500k Ohms (500,000 Ohms)
minimum.
There may be a poor or

intermittent connection in the
solenoid wiring, or a
component may be opening

while under load. Check the
idle switch and the wiring
between the switch, the
solenoid, and the PC Board.
Repair or replace any poor
connections, damaged wiring,
or faulty components. (See
wiring diagram)
The idle/engine protection PC

board may be faulty.
CAUTION
Call 1-888-935-3877.


FUNCTION PROBLEMS
The engine goes to low idle, but N/A For Classic® 300G and
will not stay at low idle. The Kubota powered Classic®
machine has normal weld and 300D:
auxiliary output. The engine
starts and shuts down normally. Check all wiring connecting
the current sensor and the
(Continued) engine control unit.
Unplug the current sensor.
If the machine still will not

stay at low idle, replace the
engine control unit.
If the machine goes to and

maintains low idle RPM,
reconnect the sensor and
disconnect the wires passing
through the sensing coil.
If the problem persists,

replace the current sensor PC
board. If the problem is
unchanged, check for current
flowing in the LEDS that pass
through the sensor.
The engine will not go to high N/A The Idle switch may be
idle when the idle switch is defective.
moved to the “High” position.
The idle system functions Wiring connecting the idle

normally while welding or using switch may be faulty.
auxiliary power. The engine See Wiring Diagram.
starts and shuts down normally.
The engine will not go to high Check that the welding cables The idle/engine protection PC
idle when striking an arc or and the auxiliary power lead board may have failed.
when using auxiliary power. connections are tight and in
The engine goes to high idle, good condition. The current sensor PC board
and the weld and auxiliary may have failed.
power are normal when the idle
switch is in the “High Idle”
position. The engine starts,
runs, and shuts down normally.
CAUTION
Call 1-888-935-3877.


FUNCTION PROBLEMS
The engine will not go to high Check that the welding cables, Perkins powered models:
idle when striking an arc. The electrode holder, and work
automatic idle system functions clamp are tight and in good The 2 CR Reed Relay, or the
normally when using auxiliary condition. wiring that connect it to the
power. Weld and auxiliary PC board and chassis ground
power are normal when the idle This may be normal operation may be faulty. The Reed
switch is in the “High Idle” if the machine has a Wire relay should close when
position. The engine starts, Feed Module, and is operating sufficient current is drawn
runs, and shuts down normally. in CV mode. See the from the weld output
operatorʼs manual for the Wire terminals.
Feed Module.
The idle/engine protection PC
board may be faulty.
Classic® 300G and

Classic® 300D Kubota
powered machines:
The weld current sense wire

that passes through the
current sensor may have a
poor electrical connection.
These leads are not
numbered on Classic® 300G.
on Kubota powered
machines; these are leads
67A and 67B.
Take these connections apart,

clean them thoroughly and
securely reconnect them.
Check the condition of the

crimp connections and
replace any that are loose,
corroded or suspect in any
way.
CAUTION
Call 1-888-935-3877.


FUNCTION PROBLEMS
The engine will not go to high The load applied to the The Toroidal Current
idle when using auxiliary power. auxiliary receptacles may be Transformer or the wiring
The automatic idle system too low. A load of 150 Watts connecting it to the
functions normally when welding. minimum is required for the idler/engine protection PC
Weld and auxiliary power is idle system to operate reliably. board may be faulty.
normal when the idle switch is in
the “High Idle” position. The Check that any power cords The idler/engine protection
engine starts, runs, and shuts are in good condition and PC board may be faulty.
down normally. properly connected.
Verify that any devices

operating from the auxiliary AC
power are operating correctly
and are in good condition. Try

plugging the device into

another source of AC power to
be sure it is functioning
properly.
Some devices may test the

input power for correct voltage
and frequency before they will
operate. If such a device is
being used, the idle switch will
need to be placed in the “High”
position. The current drawn by
many of these devices, when
testing the power, is too low to
reliably activate the automatic
idle system.
CAUTION
Call 1-888-935-3877.

BRUSH & SLIP RING SERVICE PROCEDURE

(Exciter/Auxiliary Power Alternator)
WARNING
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. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
PROCEDURE DESCRIPTION
This procedure provides guidance in testing and maintaining the brush and slip ring sys-
tem of the Exciter/Auxiliary power alternator.
MATERIALS NEEDED
Miscellaneous Hand Tools
500 or 600 grit Emery Cloth
180 Sand Paper
220 or 320 grit commutator stone (Optional)

BRUSH & SLIP RING SERVICE PROCEDURE (continued)

(Exciter/Auxiliary Power Alternator)
PROCEDURE
1. Remove the round end cover from the exciter. Seating Brushes
2. Examine brushes, slip rings and brush holder. If brushes have been replaced, repositioned or are
not making full contact with the slip rings, it will be
• Brushes should be clean and free of oil and
necessary to re-seat them. This can be done by
grease.
placing a strip of 180 grit sandpaper between the
• The brushes should be of sufficient length slip rings and the brushes. Make sure the abrasive
and have adequate spring tension. side is against the brushes. Pull the strip around
(Generally, the brushes should be replaced if the circumference of the slip rings in the direction
either brush has less than 1/4” remaining of the rotor rotation only. Repeat this procedure
before it reaches the end of itʼs travel.) until the surface of each brush is in full contact with
its matching slip ring.
• Brushes should be making good, continuous
contact with the slip rings, and should be rid- Use low pressure compressed air to thoroughly
ing near the center of the slip rings. (The blow the carbon, commutator stone and sandpaper
brush holder bracket may need to be slightly dust from the machine before operating.
bent to achieve acceptable alignment.)
Securely connect the leads to the brush terminals
Note: If slip rings are very dark in color, display (see wiring diagram) and replace the alternator
evidence of excessive arcing, or a have cover if testing and service is complete.
worn prematurely, these may be signs of a
grounded or shorted rotor. Perform the
Exciter Rotor Resistance and Ground
Test.
3. Check for evidence of sticking brushes.
Sticking brushes will normally result in the slip
rings being pitted and discolored from exces-
sive arcing. Another sign of sticking brushes is
instability or loss of both weld and auxiliary out-
put, but the machine may begin to work proper-
ly for a short time after being jarred or moved.
If there is any evidence that the brushes may

have been sticking in the brush holders, a new
brush holder and brush assembly should be
installed.
Cleaning the Slip Rings
In the event that the slip rings become dirty, discol-
ored or mildly pitted, it is necessary to clean them
using a very fine 500 or 600 grit emery cloth.
CAUTION
A 220 or 320 grit commutator stone may be used.
Commutator stones should only be used by expe-
rienced technicians who have the knowledge and
proper equipment to use them safely.

ENGINE ALTERNATOR TEST PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This test will determine if the engine alternator is operating normally.
MATERIALS NEEDED
Multimeter
Miscellaneous hand tools
Wiring diagram

ENGINE ALTERNATOR 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.
For Perkins powered machines:
Check voltage as follows:
Run/stop switch off:
Chassis ground to the B+ terminal of the alternator,
the meter should read battery voltage.
Chassis ground to the alternator flash/sense lead,

lead #59. The meter should read 0 volts.
Run/stop switch on:
Chassis ground to the flash/sense lead, lead #59.
The meter should read about 12 Volts DC. If the
engine is not started, this voltage will drop to zero
after about 30 seconds. (This time may be 60 sec-
onds on some models.)
Engine running:
Chassis ground to the B+ terminal of the alternator.
The meter should read about 13.5 to 14.2 VDC.
Chassis ground to the alternator flash/sense lead.
The meter should read about 10 Volts DC.
NOTE: A closed temperature switch or oil pressure
switch can also cause the flash/sense volt-

age to measure low; perform the Engine
Protection System test before replacing the
alternator.
If the voltages are significantly different from those
shown above, check the wiring connected to the
alternator for faulty connections or bad insulation.
If the wiring is good, the alternator is probably
faulty and should be serviced or replaced.
For Kubota powered machines:
Check the wiring connecting the alternator to the
ammeter, ignition switch, and engine control mod-
ule.
If the wiring and connections are in good condition,
the alternator and engine control unit should be

checked by a qualified Kubota engine technician.

ENGINE FUEL SYSTEM VOLTAGE TEST PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This test will determine if the fuel system is getting the electrical power needed to function
correctly.
MATERIALS NEEDED
Multimeter

ENGINE FUEL SYSTEM VOLTAGE TEST PROCEDURE (continued)

PROCEDURE
1. Open and secure the side door.
NOTE: Secure the doors in the open position using
remove the doors or securely restrain them
to prevent them from falling closed.
Perkins powered models:
Locate the fuel solenoid and attach a voltmeter to
the leads. Turn on the run/stop switch. Within 30
seconds, read the voltage on the meter. The volt-
age should read about 12 VDC. Voltage should
also be checked at the fuel pump for models that
have one. See wiring diagram.

Note: The engine protection system will shut off the
power to both the solenoid and the fuel pump
if the engine is not started within about 30
seconds. Move the run/stop switch off then
on again to reset.
If battery voltage is present at the solenoids and
the fuel pump (If equipped), and the starter motor
is cranking the engine normally, the problem is like-
ly in the engine. Engine problems should be diag-
nosed and repaired by a qualified Perkins engine
technician.
If battery voltage is not present, check for a tripped
fuel system circuit breaker (Earlier units only)
Check the wiring and connections on the
Idle/Engine protection PC board, the engine fuel

system injection pump solenoid, the fuel pump (for
engines having an electric fuel pump.), and chas-
sis ground. Look for dirty, corroded, or damaged
terminals, including the Molex terminals connect-
ing the wiring to the PC board. Look for poor crimp
connections and damaged wiring.
Check that the PC board is getting battery voltage
from the run/stop switch and that it is securely
grounded.
If the board is getting power, is properly grounded,
and the wiring and connections described above is
in good condition, replace the PC board.

ENGINE PROTECTION SYSTEM TEST PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This test will help pinpoint a failure of the engine protection system and should be done if
the engine fault light turns on and the engine shuts down shortly after startup, and the
engine is not actually in a fault condition.
MATERIALS NEEDED
Multimeter
Wiring diagram
IMPORTANT
Before proceeding with this test, verify that the engine has normal
oil pressure, is not overheated, and the alternator drive belt is in
place and properly tensioned.

ENGINE PROTECTION SYSTEM TEST PROCEDURE (continued)

PROCEDURE 10. Shut off the engine and reconnect any one of
the three leads that had been disconnected in
1. Open the side doors on the Classic® 300 steps 1 through 3, then start the engine and
machine. allow it to run. If the engine shuts down, the
NOTE: Secure the doors in the open position using component that had just been connected is
the door restraint system. If the machine faulty and should be repaired or replaced.
does not have a door restraint system, 11. If the engine continues to run after reconnect-
remove the doors or securely restrain them ing one of the wires, repeat step #9, connecting
to prevent them from falling closed. one of the two remaining wires, then repeat
Classic® 300D Perkins powered machines: step #9 again connecting the last wire. Repair
or replace any faulty component.
CAUTION Be certain to reconnect all lead wires and close the
doors when testing and service is complete.
The following procedure will temporarily disable Classic® 300D Kubota powered machines:
the engine protection system. Be absolutely certain
that engine temperature and oil pressure are with- The Kubota engine control module will flash the
in the normal range. IF THE ENGINE IS PERMIT- engine protection fault light, indicating where the
TED TO RUN WHITE OVERHEATED OR WITH fault was detected. See the machine schematic for
TOW OIL PRESSURE, SEVERE ENGINE DAM- a list of codes. Use this code to determine what
AGE WILL LIKELY RESULT, AND THE ENGINE sensor or associated wiring is causing the problem
WARRANTY WILL NOT COVER THE DAMAGE. and check the wiring.
Be absolutely certain that all wires are connected The sensors and engine control unit are part of the
when the test is completed. Kubota engine. If the wiring and connections are in
2. Disconnect the lead wire connecting the PC good condition, the engine should be serviced by a
board to the engine coolant temperature gage qualified Kubota service technician.
or switch. See wiring diagram.
3. Disconnect the lead wire connecting the PC
board to the engine oil pressure switch.
4. Disconnect the flash/sense lead connecting
the PC board to the engine alternator.
5. Insulate and/or position these leads so they

cannot touch chassis ground, any other electri-
cal conductor, or be damaged by any moving
parts.
6. Start the engine and allow it to run.
7. If the engine still shuts down, thoroughly check
the three wires that had been disconnected in
steps 1 through 3. Be particularly aware of
damaged insulation, or anything that may
cause one of these conductors to come in con-
tact with chassis ground.
8. If no problems are discovered with the wiring
or insulation, the Idler/Engine shutdown PC
board is faulty and should be replaced.
9. If the engine continues to run with these wires

disconnected, one of the engine protections
switches is faulty or the engine alternator is
faulty.

ENGINE RPM ADJUSTMENT TEST PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This test will determine if the engine is operating at the correct RPM, for both high and low
idle positions.
MATERIALS NEEDED
Strobe tachometer
Frequency counter or Multimeter with frequency counter function
Bright colored marking pencil or marker
Note: The engine RPM on the Classic® 300G and 300D with the Kubota engine is not
adjustable. The electronic modules on these machines maintain RPM based on
internal programming and the position of the RPM adjustment potentiometer or
"Custom Arc" control. RPM should still be checked to determine if these sys-
tems are functioning correctly.

ENGINE RPM ADJUSTMENT TEST PROCEDURE (continued)

PROCEDURE Frequency counter method:
1. Turn the engine off. NOTE: A dedicated frequency counter can be used
for this test, but many high quality digital
2. Place the RPM adjustment potentiometer or multimeters also have this function, and
"Custom Arc" control to maximum (Classic® can be easily utilized. See the manufactur-
300G and Classic® 300D Kubota models only.) er's instructions for your frequency counter
3. Open the side door. or multimeter.
NOTE: Secure the door in the open position using Set your frequency counter per the meter manu-
the door restraint system. If the machine facturer's instructions, and plug the probes into one
does not have a door restraint system, of the 120VAC auxiliary receptacles.
remove the door or securely restrain it to Start the engine and place the idle switch in the
prevent it from falling closed. "HIGH IDLE" position. Make sure that there is no
Classic® 300D Perkins only: load on the machine and allow the engine RPM to
stabilize.
Check that the linkage attaching the solenoid to the
engine speed control lever is properly aligned and The frequency should read between 59.7 and 60.3
in good condition. Hz.
Strobe-Tach Method: Move the idle switch to the "AUTO IDLE" position
and wait for the engine RPM to drop and stabilize
Place a highly visible mark on the engine crank- at the low idle RPM.
shaft pulley, or another rotating component con-
nected to the engine crankshaft. The frequency counter should read as follows:
Connect the strobe-tach according to the manufac- • 44.2 to 49.2 Hz. for Classic® 300G and Classic®
turer's instructions. 300Ds powered by the Perkins 104.22 engines.
Start the engine and place the idle switch in the • 45 to 48.3 Hz. for Classic® 300Ds powered by
"HIGH IDLE" position. Make sure that there is no other Perkins engines
load on the machine and allow the engine RPM to • 46.3 to 47 Hz. for Classic® 300D Kubota models.
stabilize.
If either of the readings is incorrect, proceed to the
Direct the strobe-tach light on the highly visible "ENGINE RPM ADJUSTMENT PROCEDURE"
mark that had been applied earlier and synchro- later in this section.
nize the light with the rotating mark. See the

strobe-tach manufacturer's instructions. NOTE: For Lincoln Electric 1800 RPM (4 Pole)
machines, that have 60 Hz AC auxiliary
The tach should read between 1790 and 1810 power; the engine RPM can be determined
RPM by multiplying the frequency of the auxiliary
Move the idle switch to the "AUTO IDLE" position power output, in Hz. By 30. (Example: 60
and wait for the engine RPM to drop and stabilize Hz. * 30 = 1800 RPM)
at the low idle RPM.
Synchronize the strobe-tach to read the low idle
RPM.
The tach should read as follows:
• 1325 to 1475 for Classic® 300G and Classic®
300Ds powered by the Perkins 104.22 engines.
• 1350 to 1450 for Classic® 300Ds powered by
other Perkins engines

• 1390 to 1410 for Classic® 300D Kubota models.

If either of the readings is incorrect, proceed to the
"ENGINE RPM ADJUSTMENT PROCEDURE"
later in this section.

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.
High Idle Adjustment:
IMPORTANT: For codes: 11110, 11111, 11248,
11249, 11280, 11281, 11411, 11412, 11472, and
11473 The high idle RPM is set by the engine man-
ufacturer, and should not be changed. If the high
idle RPM is not within the specified range, the
engine should be serviced by a qualified engine
technician.
For codes: 10545, 10546, 10657, 10658, 10911,
and 10927 the high speed solenoid linkage rod

must be lengthened or shortened to obtain the
specified RPM.
IMPORTANT: The solenoid must pull firmly against
its internal stop. The maximum RPM stop screw on
the engine should not be adjusted. If the high idle
RPM cannot be set by adjusting only the solenoid
linkage rod, the engine should be serviced by a
qualified engine technician.
Low idle adjustment:
For codes: 11110, 11111, 11248, 11249, 11280,
11281, 11411, 11412, 11472, and 11473, the idle
solenoid linkage rod must be lengthened or short-
ened to obtain the specified RPM.
IMPORTANT: The solenoid must pull firmly against

its internal stop.

For codes: 10545, 10546, 10657, 10658, 10911,
and 10927, the low idle RPM is set using the low
RPM adjustment screw on the engine.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-34
NOTES

F-34
FLASHING VOLTAGE TEST PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This test checks the exciter rotor flashing voltage.
MATERIALS NEEDED
Multimeter
Wiring diagram

FLASHING VOLTAGE 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.
4. Set the idle switch to "HIGH" and the
RUN/STOP switch to "RUN", and start the
engine.
NOTE: The meter should read about 4 to 6 VDC. If
this voltage reading is correct, the test is
complete. If the voltage measures zero or
significantly lower than specified check for

the following:
• An open flashing diode.
• A poor connection in the flashing circuit.
• Polarity of the main generator may be
reversed.
• The rotor winding maybe shorted,
• The field bridge rectifier may be shorted.
5. Reconnect the AC lead to the Field Bridge.
6. With the engine running at High speed, the nor-
mal rotor voltage is 123 to 133VDC.

ROCKER ADJUSTMENT PROCEDURE

WARNING
manual.
TEST DESCRIPTION
The rocker is the part of the welding generator that supports and positions the 4 sets of
brushes. Its position can be adjusted to fine tune the weld output and influence the weld
characteristics.
Important: The rocker is set at the factory for the best overall performance and long gen-
erator and brush life. Altering this adjustment is normally not recommended unless one or
more of the welding generator components affecting this setting have been replaced. In
very unusual situations, very small adjustments of the rocker may be beneficial if the
machine is operating within the specified limits, but the Arc characteristics are unsatisfac-
tory for the desired application.
CAUTION: Improper rocker adjustment can result in poor performance, reduced
brush life and damage to the welding generator. This adjustment should
only be attempted by an experienced professional.
MATERIALS NEEDED
Resistive load bank, capable of accepting at least a 300 Amp load at 33 VDC.
Volt meter/Ammeter, able to read at least 300 Amps
Drill with 1/8" bit Tachometer or frequency meter.

ROCKER ADJUSTMENT PROCEDURE (continued)

FIGURE F.1 – FACTORY SET POINT DRILL MARK LOCATIONS
EXCITER BRACKET
DRILL MARKS
ROCKER
PROCEDURE
When the rocker is set for the first time at the fac- A tachometer will be required for this phase of the
tory, a 1/8" drill is used to mark the position of both test. See The Engine RPM Adjustment Test for
details about measuring engine RPM.
the rocker and the exciter bracket. See Figure F.1

If a machine is not operating within the specified Initial rocker placement:
limits, and nothing else appears to be faulty, the The rocker should be initially positioned so the cen-
rocker position should be checked. If the drill marks ter of brushes visually lines up with the center of
are not aligned, the rocker and/or the exciter brack- the main poles. Lining up the four brush holder
et should be reset to the original factory position. studs with the four exciter bracket mounting bolts is
If it has been determined that a rocker adjustment acceptable for initial placement. The rocker should
is necessary on an unaltered machine; the rocker be tight against the shoulder of the hub and the
should only be moved in very small increments, clamping screw should be tightened only enough
and the total movement should be no more than to assure the rocker cannot move. DO NOT OVER
1/2 the diameter of the drill mark. TIGHTEN.
IMPORTANT! The following procedures should IMPORTANT: Over tightening the rocker clamp
only be attempted if all the other systems have screw can destroy the rocker.
been thoroughly checked and are functioning
normally.
Setting the rocker if the factory drill mark is

missing or invalid due to component replace-
ment:

ROCKER ADJUSTMENT PROCEDURE (continued)

Check that the brush holders are properly installed If the weld output voltage is lower than specified
and positioned correctly. See the Welding above, the rocker position will need to be adjusted.
Generator Brush and Commutator Inspection Generally, moving the rocker opposite the arma-
and Service procedure. ture rotation direction will increase output voltage.
When making this adjustment, the rocker should
Start the engine, place the idle switch in the high
only be moved in very small increments. The
idle position, and seat the brushes using a com-
adjustment may need to be repeated several times
mutator stone. See the Welding Generator Brush
to achieve the desired result.
and Commutator Inspection and Service
Procedure. Check the OCV, (Open Circuit Voltage)
Place the range selector switch in the maximum Remove the load and check the voltage at the out-
position. Use a load bank to apply a 100% duty put studs. The voltage should measure from 93 to
cycle load (250 amps @ 30 volts). Look at the 99 Volts DC.
brushes while the load is applied. If excessive
After the rocker has been adjusted and the
sparking is observed, adjust the rocker position to
machine is operating normally, the rocker locking
minimize sparking. Generally, moving the rocker
screw should be tightened to 70-75 Inch-Lbs.
slightly in the direction of the armature rotation will

reduce sparking. If new parts had been installed, the new rocker
and/or exciter bracket location should be marked
Continue running the machine under load for at
with a 1/8" drill mark. See Figure F.1.
least 30 minutes to bring the machine up to normal
operating temperature and to fully seat the brush-
es.
Check for Max output.
Remove the load, set the fine current control and
rheostat to maximum, and then adjust the load
bank to apply a 300 Amp load to the machine.
Measure the output voltage, it should read:
• From 33 to 42 VDC for Classic® 3000 and
Classic® 300D Perkins models.
• From 34 to 48 VDC for Classic® 300D Kubota
models.
Measure the engine RPM, it should measure:
• From 1780 to 1810 RPM, for Classic® 3000 mod-
els
• From 1650 to 1750 RPM, for Classic® 300D
Perkins models
• From 1790 to 1810 RPM, for Classic® 300D
Kubota models
If the engine RPM is not within specification,
Perform the Engine RPM Adjustment Test, if the
engine high idle RPM is normal, but the load RPM
is significantly less than specified above, the
engine or governor may be malfunctioning. See the
engine troubleshooting procedures in this manual
and/or have the engine serviced or repaired by a

qualified engine technician.

NOTES

F-40
EXCITER ROTOR RESISTANCE AND GROUND TESTS PROCEDURE

(Exciter / Auxiliary Power Alternator)
WARNING
manual.
TEST DESCRIPTION
This test will determine if the exciter / auxiliary power alternator rotor winding is open,
shorted, or grounded.
MATERIALS NEEDED
Ohmmeter (Analog type meter required for dynamic resistance test.)
Wiring diagram


(Exciter / Auxiliary Power Alternator) (continued)
FIGURE F.2 – LEAD LOCATION

PROCEDURE If these resistance values are normal, continue

testing, using the dynamic rotor resistance and
ground test.
"Static" Tests:
"Dynamic" Tests:
1. Turn the engine off.

(Also referred to as flying resistance test)
2. Remove the round cover from the exciter / aux-
iliary power alternator. This test checks for faults in the rotor winding,
while these windings are being stressed by the
3. Locate and label the leads connected to the
mechanical forces encountered during normal
rotor brush holder assembly. Remove the
operation.
leads. This will electrically isolate the rotor
windings. NOTE: This test is best performed with a good
quality analog type ohmmeter. Many digital
4. Using the ohmmeter, check the rotor winding
meters will not provide stable or accurate
resistance across the slip rings. Normal resis-
resistance readings while the rotor is spin-
tance is approximately 41.5* ohms, at 77°F.
ning.
(25° C.) See Figure F.2
This test requires that the brushes and slip rings
5. Measure the resistance to ground. Place one
are clean, in good condition, and are properly seat-
meter probe on either of the slip rings. Place the
ed.
other probe on any good unpainted chassis
ground. The resistance should be very high, at Perform the Brush and Slip RIng Service
least 500,000 (500k) ohms. Procedure if necessary.

6. If the resistance measurements are not as
specified the rotor may be faulty and should be
replaced.


(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. It is recommended that the ohmmeter
leads be securely attached to the brush termi-
nals, using clips or terminals BEFORE starting
the engine.
8. Start the engine and run it at high idle speed
(1800 RPM). The resistance should read
approximately 42* ohms at 770F (250C).
9. Shut off engine, and move one of the ohmmeter
leads to a good clean chassis ground connec-
tion.
10. Restart the engine and run it at high idle speed

(1800 RPM). The resistance should be very
high, at least 500,000 (500k) ohms.
11. If the resistance readings differ significantly
from the values indicated, recheck the brushes
and the brush spring tension. If the brushes
and slip rings are good, replace the rotor.
12. Securely connect the leads to the brush termi-
nals (see wiring Diagram) and replace the
alternator cover if testing and service is com-
plete.
*NOTE: The resistance of the copper windings will
change with temperature. Higher temperatures will
produce higher resistance, and lower temperatures
will produce lower resistance.

NOTES

F-44
SHUNT FIELD COIL RESISTANCE AND GROUND TEST PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This procedure will determine if the welding generator shunt field coils are open, shorted
or grounded.
Important: The machine should be clean and windings must be completely dry before
this test is done.
MATERIALS NEEDED
Multimeter
Wiring diagram

SHUNT FIELD COIL RESISTANCE AND GROUND TEST

PROCEDURE (continued)
PROCEDURE
1. Turn the engine off. Shunt coil ground test:
2. Open either or both of the doors on the 7. With the jumper plug or wire feed module
machine. unplugged from J5, measure the resistance
between either the brown or blue wires and a
NOTE: Secure the doors in the open position using good clean chassis ground. The resistance
the door restraint system. If the machine does not should be very high, 500,000 (500k) Ohms min-
have a door restraint system, remove the doors or imum.
securely restrain them to prevent them from falling
closed. 8. If the resistance is still lower than 500,000
(500k) Ohms, check the shunt coil lead wires
Test the shunt coil resistance: between the test points and the coils. Also
3. Remove the jumper plug or wire feed module check the lead wire connecting the two shunt
harness plug from J5. Locate the brown and coils together inside of the generator. Look for
blue wires in J5, (pin numbers 3 and 5). Check pinched wires and damaged insulation. If the
the resistance between these two leads. low resistance is determined to be between
Resistance should measure about 59 ohms at chassis wound and one of the shunt coils,
77°F. (25° C.) replace the coil set.
NOTE: It is always best to place probes in the lead 9. Reconnect the wires and replace any covers
end of Molex connectors. Molex pins can that have been removed.
be easily damaged if probes are inserted in
the connection pin end.
*NOTE: The resistance in the copper windings will
4. If the resistance reading is correct, proceed to change with temperature. Higher temperatures will
the Shunt Field Coil Resistance and Ground produce slightly higher resistance, and lower tem-
Test peratures will produce slightly lower resistance.
5. If the resistance is significantly higher than 59*
ohms, check the wiring between the test points
and the shunt coils. Check the lead wire con-
necting the two shunt coils together inside the
generator frame. See the wiring diagram and
the internal generator diagram. If these lead

wires and connections are undamaged, one of
the coils is likely open. Replace the shunt field
coil set.
6. If the resistance is significantly lower than 59*
Ohms, check the wiring between the test points
and the coils for damaged insulation, pinched
wires, etc. If the lead wires and insulation are in
good condition, replace the shunt coil set.

SHUNT FIELD CIRCUIT VOLTAGE TEST PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This procedure will determine if the shunt field coils are receiving the necessary power to
operate correctly.
This test should be done if there is little or no output from the welding generator, but aux-
iliary output is normal.
MATERIALS NEEDED
Multimeter
Wiring diagram

SHUNT FIELD CIRCUIT VOLTAGE TEST PROCEDURE (continued)

PROCEDURE
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.
3. Place the field rheostat in the maximum posi-
tion.
4. Place the remote/local switch in the local posi-
tion.
5. Place the idle switch in the high idle position,

start the engine and allow it to stabilize at high
idle RPM.
6. Locate the J5 Molex connector located in the
harness close to the generator lead block.
7. Test for DC voltage between the brown and
blue wires, pins #3 and #5. The voltage should
be between 123 and 133 VDC.
8. If the measured voltage is normal, but there is
still no usable output from the welding genera-
tor, perform the Shunt Field Coil Resistance
and Ground Test.
9. If the correct voltage is not present at the J5
harness plug, check for voltage at the positive
and negative terminals of the field bridge rectifi-

er. See Wiring Diagram.
10. If 123 to 133 VDC is present at the field bridge
rectifier, check the wiring and connections
between the rectifier, the rheostat, the
remote/local switch, and the J5 Molex connec-
tor. Check the rheostat and the remote/local
switch for proper operation. See Wiring
Diagram.

EXCITER STATOR SHORT CIRCUIT & GROUND TEST PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This test will determine if there are undesirable electrical connections between the exciter
stator windings and chassis ground, or between individual windings within the exciter sta-
tor.
This test should be performed if flashing voltage is present at the rotor slip rings, rotor
resistance, the D1 field bridge rectifier, and all associated wiring are proven to be good,
but the exciter stator output voltage fails to build-up to normal levels, or is too high in one
or more of the windings.
MATERIALS NEEDED
Multimeter

EXCITER STATOR 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
remove the doors or securely restrain them
to prevent them from falling closed.
2. Make sure that nothing is plugged into the aux-
iliary receptacles.
3. Disconnect and isolate the ground lead con-
nected to the neutral side of the 115 VAC auxil-
iary receptacle. See the wiring diagram.
4. Disconnect and isolate the exciter winding
leads. (Leads 214 and 215) In earlier codes,

these wires were color coded yellow and did not
have numbers. See the wiring diagram.
5. Using an ohmmeter; check the resistance
between the following points. Resistance
should read very high, 500,000 (500k) ohms
minimum.
• From chassis ground and one of the exciter
winding leads.
• From chassis ground and one of the neutral
terminals of the 115 VAC receptacle. (The neu-
tral terminal is the longer of the two slots.)
• From one of the neutral terminals of the 115
VAC receptacle to one of the exciter leads.
6. If any of these readings are less than 500,000

(500k) ohms, be certain that the windings are
completely dry and check for grounded compo-
nents or wiring that remain connected to the
stator, such as circuit breakers, receptacles,
etc. See wiring diagram. If necessary, discon-
nect and isolate the stator leads as close to the
stator winding as possible.
7. If the low resistance to ground, or between indi-
vidual stator windings is determined to be with-
in the stator, the stator is defective and should
be replaced.

WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This procedure checks for grounded components in the weld circuit. It also checks for a
short circuit condition between the positive and negative components of the weld circuit.
This test cannot detect a short circuit within the armature or a turn to turn short circuit with-
in a coil or coil set.
Important: The machine must be clean and completely dry before this test is done.
MATERIALS NEEDED
Multimeter
Wiring diagram

WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST PROCEDURE

(continued)
PROCEDURE
1. Turn the engine off. 9. If the resistance measurement is too low, check
the heavy weld current carrying leads and con-
Weld circuit ground test: nections for damaged insulation or dirt buildup
2. Measure the resistance between either of the between the negative (Series Coils) and posi-
two weld output terminals and a clean chassis tive (Interpole Coils) circuits. If the low resis-
ground connection. tance point is between the stator coils, the coils
will require replacement or repair. Check for
The resistance measurement should be very insulation damage between the yellow and
high 500,000 (500k) Ohms minimum. white leads connecting to J5.
If the resistance is lower than 500k Ohms:
3. Remove the welding generator brushes, or pull
them away from the commutator and isolate
them so they cannot come in contact with any-
thing except the brush holder they are attached

to. Remove the jumper plug or wire feed mod-

ule harness from Plug J5. See wiring diagram.
4. Check the resistance between chassis ground
and each output terminal, and between chassis
ground and the commutator.
If the commutator has low resistance to chassis
ground, the armature will need to be replaced.
5. If the resistance measured at the "POSITIVE"
weld terminal is low, carefully examine the inter-
pole coils, and the heavy leads, and the brush
holders connected to the interpole coils. Check
for damaged, dirty or missing brush holder insu-
lators. Check for a damaged or dirty weld out-
put terminal. Check the yellow lead connecting
the brush holder to Plug J5.

6. If the resistance measured at the "NEGATIVE"

terminal is low, examine the range selector
switch, the series coils, and the heavy leads
and brush holders connected to them. Check
for damaged, dirty or missing brush holder insu-
lators. Check for a damaged or dirty weld out-
put terminal. Check the white lead connecting
the flashing diode to Plug J5.
7. Test for a short circuit condition between
the electrode and work circuits.
8. With the brushes still isolated as described
above, check the resistance between the two
weld terminals. The resistance should be very
high, 500,000 (500k) Ohms minimum.

WELDING GENERATOR BRUSH AND COMMUTATOR

INSPECTION AND SERVICE PROCEDURE
WARNING
manual.
TEST DESCRIPTION
This procedure provides guidelines for checking and servicing the welding generator com-
mutator and brushes.
MATERIALS NEEDED
120-150 grit commutator stone
220-320 grit commutator stone
IMPORTANT: Do not use emery cloth or paper to clean the commutator. Use only sand
paper or a commutator stone.
Caution: Stoning the commutator involves pressing an abrasive stone against a spin-
ning commutator. This procedure can be hazardous if done without proper
training, tools and protective equipment. Consult the commutator stone manu-
facturer's instructions before attempting this procedure.


INSPECTION AND SERVICE PROCEDURE (continued)
FIGURE F.3 - DRILL MARK LOCATIONS
EXCITER BRACKET
DRILL MARKS
ROCKER
PROCEDURE Blackened Commutator:
1. Shut off the engine. A commutator that appears an even black color all
around may indicate a grounded armature, shorted
2. Open either, or both of the side doors of the weld circuit, a serious overload condition, or out-of-
Classic® 300 machine. adjustment rocker. It could also indicate the use of
NOTE: Secure the doors in the open position using poor quality brushes, or brushes that have been
contaminated with oil or some other foreign sub-


does not have a door restraint system, stance.
remove the doors or securely restrain them • Check the rocker position. Be certain that it is
to prevent them from falling closed. aligned with or very close to the factory drill
3. Disconnect the negative battery cable. mark. See Figure F.3. IMPORTANT: If the rocker
position requires adjustment, do not over tighten
4. Remove the cover protecting the welder gener- the rocker clamping screw. This screw should be
ator brushes. tightened to a torque of 70 to 75 Inch-Lbs. Over
Examine the Commutator: tightening can destroy the rocker.
Normal appearance: • Perform the Weld Circuit Ground and Short

Circuit Test.
The commutator should appear smooth, and have
an even brown color where the brushes ride. • If the weld circuit is not grounded or shorted, and
poor brush quality or contamination is suspect-
ed, replace the brushes and seat them with a
commutator stone or sand paper.
• If brush quality or contamination is not suspect-

ed, clean the commutator by lightly stoning the
surface. See caution note on commutator stone
use.


INSPECTION AND SERVICE PROCEDURE (continued)
Pitted and Are Damaged Commutator: Examine the brushes:

If pitting and arc damage to the commutator is evi- The brushes and springs should all be in place and
dent, the machine may have been used with badly not be excessively worn. Brushes should be
worn brushes. The brush spring tension may have replaced if they are worn to within 1/4" of the pigtail
been too low, or the brushes may have been stick- lead.
ing in the holders. An out-of-adjustment rocker or a
The pigtail lead of each brush should be positioned
serious overload may also cause this condition.
so it allows free movement of the brush while it
• Examine the inside of the brush clovers and wears.
other parts that are close to the commutator. If
The brushes should be seated so that the face of
there is a significant amount of solder and
each brush makes 95% minimum contact with the
debris that has been thrown from the commu-
commutator. Lightly stone the commutator to seat
tator, the armature will need to be replaced and
the brushes. See caution note on commutator
the stator coils must be carefully examined and

stone usage.
tested for damage.
Examine the brush holders:
• Perform the Weld Circuit Ground and Short
Circuit Test. The brush holder insulators must be clean and in
good condition and all of the hardware must be in
• If the brushes are worn out, replace them and
place. Replace any insulators that are cracked or
re-surface or clean the commutator as needed.
damaged in any way.
If the brush springs appear weak, or damaged
in any way, replace them as well. The brush When installing the brush holders, they should be
holder plates and retainers should be clean, rotated toward the brush retainer (clockwise rota-
smooth, and undamaged so the brushes can tion when facing the brush holder mounting screw.)
move freely as they wear. until they stop. The edge of the brush holder plate
should be parallel with the surface of the commu-
• Check the rocker position. Be certain that it is
tator and positioned .030 to .090 from the surface
aligned with or very close to the factory drill
of the commutator. The brush holder mounting
mark. See Figure F.3.
screw should be tightened to a torque of 24 to 28
IMPORTANT: If the rocker position requires adjust- Ft Lbs.
ment, do not over tighten the rocker clamping

The brush holder plate and retainer assembly must
screw. This screw should be tightened to a torque
be clean and smooth. Nothing should prevent free
of 70 to 75 Inch-Lbs. Over tightening can destroy
movement of the brushes. All electrical connec-
the rocker.
tions to the brush holders must be clean, and tight.
The recommended torque for 5/16-18 brush holder
connection screws is 8 Ft-Lbs.
Uneven Commutator appearance:
If the commutator appears to have some normal
colored bars and some blackened bars, the arma-
ture may be shorted.
• If excessive sparking is observed and/or the
weld output is abnormal, the armature should
be replaced.
• If the commutator has uneven color, but there is
no sign of serious generator performance prob-
lems, the commutator may only need to be

cleaned by lightly stoning the surface. See cau-
tion note on commutator stone usage.

NOTES

F-56
SERIES COIL SHORT CIRCUIT TEST PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This test checks the short circuit output of the welding generator at each current range
tap. This test should be done if the output is considerably higher than indicated on the
current controls, or if there appears to be too little difference between the output of adja-
cent range switch positions.
CAUTION: Very high loads will be applied to the generator during these tests.
Loads higher than 250 amps must only be applied long enough to get
stable meter readings. Severe damage may result if a high load is
applied for more than a minute or two.
MATERIALS NEEDED
Load bank, preferably with a shorting contactor.
Length of heavy weld cable about 10 feet long (if load bank has no shorting contactor)
Ammeter, able to accurately read about 450 Amps.

Misc. hand tools
Voltmeter or Multimeter Tachometer or Multimeter that can read frequency

SERIES COIL SHORT CIRCUIT TEST PROCEDURE (continued)

PROCEDURE
1. Place the current range switch in the Max posi- 7. Start the engine and read the current in the
tion, connect the Classic® 300 to a load bank shorting cable. It should read from 95 to 120
and start the engine. Amps.
2. Apply a load of 250 amps and allow the 8. Stop the engine and move the selector switch to
machine to reach normal operating tempera- the 80 to 130 Amp tap. Restart the engine and
ture, (about 30 minutes) read the current in the shorting cable. It should
read from 150 to 200 amps.
3. Move the fine current control to the max posi-
tion, and then adjust the load bank to obtain a 9. Stop the engine and move the selector switch to
300 amp load. the 120 to 190 Amp tap. Restart the engine and
read the current in the shorting cable. It should
4. Read the engine RPM and the voltage at the read from 240 to 300 amps.
output terminals. See the Engine RPM
Adjustment Tests for instructions on how to 10. Stop the engine and move the selector switch
to the 160 to 240 Amp tap. Restart the engine
check RPM.
and read the current in the shorting cable. It

Kubota powered models should read 1790 to 1810 should read from 330 to 410 amps.
RPM, and 34 to 48 VDC at the output terminals.
11. If the current is considerably higher than indi-
Classic® 300G should read 1780 to 1810 RPM cated above for all of the tests, check engine
and 33 to 42 VDC at the output terminals. RPM.
Perkins powered models should read 1650 to 1750 12. If some, but not all of the values are signifi-
RPM, and 33 to 42 VDC at the output terminals. cantly higher than specified, the series coils are
5. Remove the load and place the range switch in likely shorted and should be replaced.
the minimum position.
6. Shut down the engine and place the length of
cable and ammeter between the output termi-
nals, or close the shorting contactor on the load
bank.

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)

HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM
16.6 ms
CH1
0 volts
50 volts 5 ms
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.
Note: Scope probes connected at

machine 115VAC receptacle.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal

NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM

HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AND SELECTOR

SWITCH AT MAXIMUM
CH1
0 volts
50 volts 5 ms
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.
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Coupling.............................DC

TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM

MACHINE LOADED – SELECTOR SWITCH AT MAXIMUM POSITION

CH1
0 volts
20 volts 5 ms
MACHINE LOADED TO 250 AMPS AT 40 VDC
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.

machine output terminals.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Coupling.............................DC

NOTES

F-62
ALTERNATOR ROTOR REMOVAL

AND REPLACEMENT PROCEDURE
WARNING
manual.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the alternator
rotor.
MATERIALS NEEDED
3/8" wrench
1/2" wrench
1-5/8" wrench
Large slot head screwdriver
Small gear puller
5/16” nut driver


AND REPLACEMENT PROCEDURE (continued)
PROCEDURE
2. Using the 7/16” wrench, remove the two bolts
and washers and partially slide out the battery
mounting panel. See Figure F.4
3. With the 1/2" wrench, disconnect the negative
battery cable.
FIGURE F.4 – BATTERY PANEL REMOVAL
NEGATIVE
BATTERY
CABLE
BATTERY
MOUNTING
PANEL


See Figure F.5 for steps 3 - 5.

3. With the 3/8" wrench, loosen the screws on
the left and right sides and bottom of the alter-
nator wrap-around.
4. With the 5/16" wrench, remove the 4 screws
from the alternator cover.
5. Remove the alternator cover and wrap-
around. Be careful to clear the leads.
FIGURE F.5 – ALTERNATOR COVER AND WRAPAROUND REMOVAL
WRAPAROUND
SLIP RINGS
ALTERNATOR
COVER
BRUSHES


See Figure F.6 for steps 6 - 8. 8. With the 1-5/8" socket wrench, remove the
rotor locking nut, washer and sleeve collar.
6. With the 7/16" wrench, remove the two bolts,
nuts and washers mounting the brush holder NOTE: The sleeve collar will have to be
assembly to the stator frame. removed with a gear puller. Be careful
not to damage the rotor slip ring assem-
7. Bend the flat washer away from the rotor lock-
bly. Remove the rotor by pulling it free of
ing nut.
the generator shaft.
FIGURE F.6 – ROTOR REMOVAL
"BENT"
WASHER
STATOR
FRAME
SLEEVE BRUSH
NUT COLLAR HOLDER
ASSEMBLY


Replacement d. The exciter brush spring must lie flat on

the corner of the brush and not touch
9. Carefully mount the rotor onto the generator
either side of the retainer.
shaft. Install a new sleeve collar (part num-
ber T14337), washer, and rotor locking nut. e. With the brushes in place, insert one end
of a minimum 24" long piece of 180 grit
NOTE: Be careful not to damage or deform
sandpaper between the slip rings and
the new sleeve collar. Carefully tap
brushes (abrasive against brushes). With
the new sleeve collar into position.
slight additional finger pressure on top of
The rotor locking nut should be
brushes, pull the paper around the cir-
torqued to 175 ft.-lbs.
cumference of the rings in the direction of
After the rotor locking nut is properly rotation only. Repeat this procedure until
torqued, bend the washer down over the the entire face of the brush is contoured
locking nut. to the radius of the slip ring.
Check rotor air gap. .017" minimum is f. Check the brushes to be certain that there
allowed. is spring tension holding them firmly

against the slip rings.
10. Mount the brush holder assembly to the sta-
tor frame using two bolts, washers, and nuts. 11. Install the alternator cover and wrap-around.
Installing and Seating Exciter Slip Ring Brushes 12. Connect the negative battery cable.
a. Make sure the slip rings are clean and
free from oil and grease.
b. Spacing between the brush holder and
slip rings must be .050" to .090". Adjust
as required.
c. Before placing the exciter brushes in their
holders, twist the brush pigtail at its
entrance to the brush until the strands are
tightly packed and no part of the pigtail
protrudes beyond the brush surface in the
pigtail slot. When the brush is placed in

the holder, clear the pigtail from the side
of the holder to allow free radial move-
ment of the brush.

NOTES

F-68
ALTERNATOR STATOR REMOVAL AND REPLACEMENT PROCEDURE

WARNING
manual.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the alternator
stator.
MATERIALS NEEDED
3/8" nut driver
3/8" wrench
1/2" wrench
Slot head screwdriver
Pry bar
5/8" wrench
7/16" wrench

ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.7 – COMMUTATOR WRAP-AROUND REMOVAL
COMMUTATOR
WRAPAROUND
ALTERNATOR
BRUSH HOLDER
ASSEMBLY
(REMOVED)
PROCEDURE
1. Turn the engine OFF. 8. Remove the tape and using the 3/8"
wrench and slot head screw driver, discon-
2. Perform the Alternator Rotor Removal
nect the black auxiliary power lead from
procedure.
the current transformer. Cut any neces-
3. With the 1/2" wrench, remove the four nuts sary cable ties. See the Wiring Diagram
and bolts holding the case top and doors and Figure F.8.
assembly to the welder frame. Carefully lift
9. Remove the red auxiliary power lead from
up and remove the top and doors assembly.
the CB4 circuit breaker. See the Wiring
4. With the 3/8" nut driver, remove the two Diagram and Figure F.9.
leads from the alternator brush holder

10. Remove the white auxiliary power lead
assembly. Note lead placement. Set brush
from the 115VAC receptacle. Cut any nec-
holder aside.
essary cable ties. See Figure F.9.
5. With the slot head screwdriver, remove the
NOTE: The CB1 circuit breaker may have to
commutator wraparound. See Figure F.7.
be removed to access the terminal for
6. Disconnect the yellow and white wires at the the white lead.
in-line connectors. See the Wiring Diagram
11. Remove the red lead from the negative ter-
and Figure F.8.
minal of the field rectifier bridge. See
7. Disconnect the two yellow leads. One is Figure F.9.
located at the field bridge and the other at
12. Remove the black lead from the positive
the field fuse holder. Cut any necessary
terminal of the field rectifier bridge. See
cable ties. See Figure F.8 and F.9.
Figure F.9.


FIGURE F.8 - LEAD DISCONNECTION POINTS
YELLOW AND WHITE WIRE

IN-LINE CONNECTORS;
YELLOW LEADS; BLACK
CURRENT TRANSFORMER
LEAD
ALL LOCATED BEHIND
CASE FRONT
FIGURE F.9- LEAD DISCONNECTION – CIRCUIT BREAKER, RECEPTACLES, FIELD BRIDGE RECTIFIER
230 VAC RECEPTACLE

CB1 CIRCUIT BREAKER

115 VAC RECEPTACLE
CB4 CIRCUIT BREAKER

FIELD FUSE HOLDER
FIELD RECTIFIER BRIDGE



ALTERNATOR STATOR REMOVAL

AND REPLACEMENT (continued)
13. Clear the leads in preparation for remov- 14. Lift the eight brushes from the commuta-
ing the stator/end bracket. tor. Note the position of the brushes for
reassembly.
FIGURE F.10 - GENERATOR BRUSH HOLDER CABLE REMOVAL

GENERNATOR
BRUSH HOLDER/COIL
CABLES (4)
15. With the 1/2" wrench, disconnect and

clear the four heavy cables from the gen-
erator brush holders to the coils in the
generator frame. It is not necessary to
remove the brush holder jumper cables.
See Figure F.10. Label leads and posi-
tions for re-assembly.


FIGURE F.11 - DRILL SPOT LOCATIONS
BRUSH HOLDER
DRILL SPOT
LOCATION
STATOR END BRACKET

DRILL SPOT
STATOR/END BRACKET
MOUNTING BOLT
16. With the 5/8" wrench, remove the four 22. Connect the four heavy cables from the
bolts mounting the stator/end bracket generator frame coils to the generator
assembly to the generator frame. Note brush holders.
the "drill spot" for reassembly. See Figure
23. Install the eight commutator brushes
F.11.
according to how you marked their posi-
17. With the 7/16" wrench, loosen (do not tions at disassembly.
remove) the generator brush holder
24. Attach the black lead to the positive termi-
clamping bolt. Note the drill spot for
nal of the field rectifier bridge. Attach the
reassembly. See Figure F.11.
red lead to the negative terminal.
18. Carefully pry the stator/end bracket
25. Attach the white auxiliary power lead to

assembly away from the generator frame.
the 115 VAC receptacle. Attach the red
NOTE: The generator brush holder assembly auxiliary power lead to the CB4 circuit
will also be removed. breaker. Attach the black auxiliary power
lead to the current transformer. Tape the
Replacement
bolted connection.
19. Mount the stator/end bracket assembly to
26. Connect the two yellow leads to the field
the generator frame. Line up the mating
bridge and to the field fuse holder.
parts at the stator end bracket drill spot.
Connect the white and yellow wires at the
Tighten the four mounting bolts with the
in-line connectors.
5/8" wrench.
27. Install the commutator wraparound, the
20. Check armature air gap. Minimum gap is
bottom alternator cover, the battery, and
.035." Loosen the four mounting bolts;
the alternator brush holder assembly.
adjust and re-tighten if necessary.
28. Install the alternator rotor according to the
21. Tighten the generator brush holder
reassembly directions in the Alternator
assembly with the 7/16" wrench. Note
Rotor Removal and Replacement pro-

brush holder drill spot.
cedure. Before installing the case top and
sides, replace any cable ties cut for disas-
sembly.

NOTES

F-74
GENERATOR FRAME
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
manual.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the DC genera-
tor frame.
MATERIALS NEEDED
Rope sling
3/4" wrench
1/2" wrench
9/16" wrench
Wood or steel blocks
Pry bars

GENERATOR FRAME
REMOVAL AND REPLACEMENT (continued)
FIGURE F.12 – FUEL TANK / OUTPUT CABLE REMOVAL
(DIESEL ONLY)
FUEL TANK
RETURN LINE
POSITIVE CABLE
COPPER FUEL TANK

STRAP MOUNTING
HARDWARE
FUEL LINE
FUEL
BOWL
PROCEDURE
1. Turn the engine OFF. NOTE: At reassembly, the fuel line may have to
be purged. See the Maintenance sec-
2. Perform the Alternator Rotor Removal tion (Diesel only).

procedure.
8. With the 3/4" wrench, remove the copper
3. Perform the Alternator Stator Removal strap/reed switch assembly from the negative
procedure. output terminal. Clear the strap.
See Figure F.12 for steps 4 - 9. 9. With the 3/4" wrench, remove the cable from
4. Turn off the fuel at the fuel bowl and remove the positive output terminal.
the fuel line. Plug the line to prevent spillage.
5. Remove the fuel return line from the top of the
fuel tank (diesel engine only).
6. With the 9/16" wrench, remove the four nuts,
bolts, and washers that mount the fuel tank to
the rails.
7. Carefully remove the fuel tank.

GENERATOR FRAME
FIGURE F.13 – WIRE AND SELECTOR SWITCH CONNECTIONS
IDLER PC BOARD
SELECTOR
FINE CURRENT SWITCH
ADJUSTMENT
RHEOSTAT
FIELD BRIDGE
IN-LINE CONNECTORS
BLUE/BROWN LEADS

10. Cut all necessary cable ties. 12. Label the cables that are connected to the selector
switch. Otherwise, you will need to see the Wiring
11. Disconnect the blue and the brown wires at the in-
Diagram during reassembly.
line connectors. See Figure F.13 and the Wiring
Diagram. 13. With the 1/2" wrench, remove the cables connect-
ed to the selector switch.

GENERATOR FRAME
FIGURE F.14 – CASE FRONT REMOVAL
STEP #16
STEP #15
STEP #14

14. With the 9/16" wrench, remove the four bolts and
lock washers holding the case front to the welder
frame. There are two bolts on each side.
15. With the 1/2" wrench, remove the two bolts and
nuts and washers from the fuel tank rails - one on
each side.
16. Carefully clear and disconnect any necessary
remaining leads and lift up and set the front panel
assembly to the left side of the machine. Make
sure all leads are clear.

GENERATOR FRAME
FIGURE F.15 – FRAME MOUNTING DETAILS
ROPE SLING
ENGINE/GENERATOR
MOUNTING HOLES
See Figure F.15 for steps 17 - 20. Replacement

17. With the 3/4" wrench, remove the frame 21. Support the generator frame with the rope
mounting bolts, nuts and spacers from the sling. Mount the generator frame to the
feet of the generator frame. engine and armature assembly. Before
removing the rope sling, be careful to sup-
18. With the rope sling around the generator
port the generator frame with the wood or
frame, carefully lift the frame and engine
steel block under the engine adapter plate.
assembly a small distance. Slide the wood

With the 9/16" wrench, install the bolts that
or steel block under the engine adapter
attach the generator frame to the engine.
plate.
22. With the 3/4" wrench, install the frame
19. With the 9/16" wrench, remove the bolts
mounting bolts, nuts, and spacers to the feet
mounting the engine to the generator frame.
of the generator frame. See Figure F.15.
20. Using the rope sling and pry bars, carefully
23. Install the case front to the welder frame.
lift and “wiggle” the generator frame away
See steps 14 - 16.
from the engine and armature assembly. Be
careful to support the generator frame as 24. Connect the cables to the selector switch
you remove it. according to how you labeled them during
disassembly. See the Wiring Diagram if nec-
essary.
25. Reconnect the blue and brown leads at the
in-line connectors.
26. Install the copper strap/reed switch assem-
bly to the negative output terminal.

GENERATOR FRAME
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.
29. Attach the fuel return line at the top of the fuel tank
(Diesel engine only). Remove the plug from the
fuel line and attach it to the fuel bowl.
30. Perform the replacement procedures according to
each of the following:
Alternator Stator Removal and Replacement
Alternator Rotor Removal and Replacement
Before installing the machine case top and sides,
be sure to replace any cable ties cut during disas-
sembly.

GENERATOR ARMATURE
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
manual.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the main
armature.
MATERIALS NEEDED
Rope sling
5/8" wrench
Wood or steel blocks

GENERATOR ARMATURE
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.16 – BLOWER PADDLE REMOVAL
ROPE SLING
BLOWER PADDLE
BLOWER
PADDLE/ARMATURE
MOUNTING BOLTS (8)
PROCEDURE
CAUTION
1. Turn the engine OFF. The armature is now free to be removed from the
2. Perform the Alternator Rotor Removal pro- engine.
cedure.
3. Perform the Alternator Stator Removal pro- Replacement:
cedure.
9. Support the armature with the rope sling.
4. Perform the Generator Frame Removal pro-

Mount the armature to the engine, rotating it

cedure. 1/8 of a turn in either direction to achieve
5. Using the rope sling, support the armature. proper attachment. Before removing the
rope sling, be careful to support the arma-
6. Make sure the engine is supported with the ture with the wood or steel blocks under the
wood or steel blocks. engine. With the 5/8" wrench, install the
7. With the 5/8" wrench, remove the eight bolts eight bolts and lock washers that attach the
and lock washers holding the blower paddles blower paddles and the armature to the
and the armature to the engine flywheel. See engine flywheel.
Figure F.16. 10. Perform the replacement procedures accord-
8. With the armature supported and “balanced” ing to each of the following:
in the rope sling, carefully rotate the armature Generator Frame Removal and Replacement
1/8 turn in either direction to release.
Alternator Stator Removal and Replacement
Alternator Rotor Removal and Replacement

RETEST AFTER REPAIR

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.
OR
• If you repair or replace any electrical components.
ENGINE OUTPUT
Mode No Load RPM Load RPM
Low Idle 1325 - 1475 NA
High Idle 1780 - 1810 1650 - 1750
WELDER DC OUTPUT
Current Control Current Selector Open Circuit Load Volts Load Amps
Rheostat Switch Voltage

Maximum Maximum 91 - 98.5 36 - 45 Gas 350
Maximum Maximum 91 - 98.5 38 - 47 Diesel 350
AC AUXILIARY POWER RECEPTACLE OUTPUT

230 Volt Receptacle 115 Volt Receptacle
Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps
Voltage Voltage
240 - 254 210 - 225 13.8 118 -128 103 - 112 26.0
FIELD AMPS AND VOLTS

(Current Rheostat at Maximum)
Exciter DC Volts Shunt Field Amps Alt. Rotor Amps RPM
123 - 133 2.0 - 2.4 2.2 - 2.6 1780 - 1810


NOTES

F-84
G-1 TABLE OF CONTENTS - DIAGRAM SECTION G-1
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1

Wiring Diagram (Codes 10545, 10546, 10657, 10658) (L10877) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Wiring Diagram (Code 10659) (L11194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Wiring Diagram (Codes 10911, 10927) (L11865) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
Wiring Diagram (Codes 10912, 11135) (L11866) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
Wiring Diagram (Codes 11110, 11111) (M20499) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6
Wiring Diagram (Codes 11112, 11113) (M20432) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7
Wiring Diagram (Codes 11243, 11244) (M20432-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8
Wiring Diagram (Codes 11248, 11249, 11280, 11281) (M20616) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-9

Wiring Diagram (Codes 11411, 11412) (M21292) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-10
Wiring Diagram (Codes 111413, 11414) (M21293) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-11
Schematic – Complete Machine (Codes 11110, 11111) (L12412) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-14
Schematic – Complete Machine (Codes 11112, 11113) (L12265) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-15
Schematic – Complete Machine (Codes 11243, 11244) (L12265-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-16
Schematic – Complete Machine (Codes 11248, 11249, 11280, 11281) (L12561) . . . . . . . . . . . . . . . . . .G-17
Schematic – Complete Machine (Codes 11411, 11412) (L13096) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-18
Wiring Diagram - Wire Feed Module Option (L9259) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-22
Schematic - Wire Feed Module Option (G2562) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-23
Schematic – Idler (Codes 10545, 10546, 10657, 10658, 10911, 10927) (L10826) . . . . . . . . . . . . . . . . .G-24
Schematic – Idler (Codes 11110 thru 11475 Perkins Engine Only) (G4828) . . . . . . . . . . . . . . . . . . . . . .G-25
Schematic – Current Sensor PC Bd (Kubota Engine Only) (S25973) . . . . . . . . . . . . . . . . . . . . . . . . . . .G-26
* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-lay-
ered and are therefore considered to be unserviceable. Assembly drawings of these boards are
no longer provided.

G-2 ELECTRICAL DIAGRAMS G-2
WIRING DIAGRAM - CODES 10545, 10546, 10657, 10658) (L10877)
CLASSIC 300D WIRING DIAGRAM

CONTROL PANEL COMPONENTS
ELECTRICAL SYMBOLS
GLOW PLUGS PER E1537 SHOWN AS VIEWED FROM REAR.
60A P10
NEUTRAL BONDED TO FRAME
61 LEAD COLOR CODE NEUTRE RACCORDE' AU BATI 12 11 10 9 8 7 6 5 4 3 2 1
B-BLACK OR R-RED OR J5
ENGINE PINK W
GRAY B
FAILURE 1 G-GREEN U-BLUE +Y
LAMP 1 2 3 4 5 6 7 8 9 10 N -W
J1 IDLER/ENGINE 2 N-BROWN W-WHITE ALTERNATOR ROTOR U
60C 58 3 Y-YELLOW
PROTECTION
P.C. BOARD
J2 4 SLIP RINGS
-
CB1 R + B 610
53 CIRCUIT BREAKER
SLIP RING
NEAREST
+ 610
58A CB1 APPEARS ON 53B R 602B
EARLIER UNITS ONLY 57 IDLER TO IRON AC AC 600B
GLOW 56A IDLER SWITCH
PLUG START ENGINE 41 1
SOLENOID
HOUR
56
G 115 VOLT 230 VOLT - 600A 2
METER RECEPTACLE RECEPTACLE 42 3
PUMP SOLENOID
B 15A.
+ - IGNITION G 4
SWITCH FUSE Y 602A
52 5
50B 54 RHEOSTAT
51A FUEL PUMP
6
Y J8 P9
60 B
ELECTRIC FUEL SELECTOR
50A B SWITCH
PUMP DOES NOT R
APPEAR ON
EARLIER UNITS G
54B ALTERNATOR
CB2 CB1 CB4 CB3 W AUXILIARY
OIL PRESSURE
TEMPERATURE SWITCH (N.C.) POWER
GAUGE G WINDINGS
STARTING GENERATOR
MOTOR B
59
S G
B (GROUND SCREW A
+A - NEAR FUSE) B
ALTERNATOR
50 B 5 4 3 2 1
+
CURRENT
EXC CR2 REED WELDER
+ W TRANSFORMER RELAY LEAD BLOCK
51
W N
R U
-W
+Y
G
GROUND N
(GROUND SCREW NEAR POSITIVE
GROUND TO ENGINE
ENGINE GAUGES)
NEGATIVE
TO BASE (CC-) (CC+) & (CV+ WITH W.F.M.)
K924-4 REMOTE CONTROL (OPTIONAL) W IRE FEED MODULE (OPTIONAL)

REMOTE CONTROL RECEPTACLE & SWITCH
PLUG FOR ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
G
REMOTE CONTROL CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
X 12 11 10 9 8 7 6 5 4 3 2 1
POTENTIOMETER
* SEE B Y
BELOW R
W
P11 ** SEE BELOW INLINE PLUG
600
X CONNECTORS (P5)
41 R Y
1 W W.F.M.
CAUTION: DAMAGE CAN OCCUR CONTROL
2 R TO THE REMOTE CONTROL
* SEE 3 42 R G PANEL
BELOW SWITCH IF IT IS USED WITHOUT
4 602 THE "P11" PLUG INSTALLED OR A
5 CONNECT #8 LEAD
602 WIRE FEED MODULE INSTALLED. W POS. W IRE FEED
{
6 TO CASE B CONNECT TO POS. & NEG.
W OUTPUT TERMINALS
P8 NEG.
REMOTE SWITCH WIRED
A
RESISTORS
SWITCH FOR LOCAL OR
REMOTE CONTROL SHOWN
IN LOCAL POSITION.
THIS WAY ON EARLIER
UNITS NEGATIVE CV
#2 HEAVY LEAD
MODULE
OUTPUT TERMINAL
PANEL
608
* WITH MACHINE NOT RUNNING, REMOVE PLUG "P9" ON MACHINE FROM CONNECTOR "J8".
THEN CONNECT PLUG "P8" ON REMOTE CONTROL TO CONNECTOR "J8" ON MACHINE. 609
CONNECT TO NEG.
* * IFUNCONNECTED
A WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISPOSE OF THE
PLUG "P10" (IF ONE IS ON THE MACHINE). FASTEN THE NEW PLUG "P11"
REMOTE CONTROL
BRUSH HOLDER
NEARBY, LEAVING IT UNCONNECTED. #2 HEAVY LEAD
IF NO WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISCONNECT PLUG
"P10" ON THE MACHINE FROM CONNECTOR "J5". CONNECT PLUG "P11" FROM THE REMOTE
CONTROL KIT TO CONNECTOR "J5" ON THE MACHINE.
THE RED AND BLACK LEADS ARE USED ON CLASSIC I MACHINES ONLY AND ARE NOT
250 AMP
THERMOSTAT
ASSEMBLY
* WHEN
MACHINE MUST NOT BE RUNNING
MAKING THESE CONNECTIONS.
CONNECTED ON THIS MACHINE. DAMAGE TO THE REMOTE CONTROL AND/OR MACHINE
WILL RESULT IF THE RED AND BLACK LEADS ARE CONNECTED IN THE CLASSIC 300D. 7-13-2001G
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
L10877

WIRING DIAGRAM - (CODE 10659) (L11194)
CLASSIC 300G WIRING DIAGRAM

ZENITH THROTTLE
92 3 RPM CONTROL ELECTRICAL SYMBOLS SHOWN AS VIEWED FROM REAR.
BODY
4 CONTROLLER 10 K PER E1537 P10
5 NEUTRAL BONDED TO FRAME
1 3
72 INJECTOR 90 14 WHITE 2 LEAD COLOR CODE NEUTRE RACCORDE' AU BATI 12 11 10 9 8 7 6 5 4 3 2 1
91 15 CONNECTOR J5
# 19 B - BLACK W
97 21 BLACK G - GREEN B +Y
1 2 3 4 N
+ - 97B 22 CONNECTOR N - BROWN -W
97A ALTERNATOR ROTOR U
FUEL PUMP 1 2 3 4 5 8 9 11 12 13 17 R - RED
81 U - BLUE SLIP RINGS -
71 50 W - WHITE +
A B 99A B 610
77 87B Y - YELLOW SLIP RING
THROTTLE PLATE
COIL ALTERNATOR 96
O - ORANGE + 610
MOTOR 87 NEAREST R 602B
- + 83 82 AC AC
94 TO IRON 600B
97C A B 99D
41 1
+ EXC
- WATER 99C
115 VOLT -
TEMP. 230 VOLT 600A 2
99B 93 RECEPTACLE
SENSOR 95 RECEPTACLE 42 3
PARTS SUPPLIED A B B B
WITH ENGINE DISTRIBUTOR 87A G 15A 4
Y
A B C 76 AIR 602A
ENGINE TEMP. FUSE 5
HOUR METER MAP SENSOR 99E SENSOR RHEOSTAT
ENGINE 6
FAILURE J8 P9
+ - LAMP 78
Y
B
61 89 SELECTOR
CB5 OIL PRESSURE SWITCH & SENSOR B SWITCH
60
AMMETER R
START SENSOR
G WK G
62 74 IGNITION 51 ALTERNATOR
SWITCH SWITCH CB2 CB1 CB4 CB3 W AUXILIARY
WATER TEMP. SENDER
73 POWER
84 SENSOR G WINDINGS
GENERATOR
WATER TEMP. IDLER B
STARTER
MOTOR GAUGE SWITCH G
69 A
S 99
(GROUND SCREW
S 80 4 NEAR FUSE) B
B
3 5 4 3 21
B
2
70 1
R WELDER
+
45
67 CURRENT LEAD BLOCK
OIL PRESS. G SENSOR N
CONTROL PANEL GAUGE U
GROUND SCREW -W
S +Y
GROUND GROUND POSITIVE

NEGATIVE
TO BASE
TO ENGINE (CC-) (CC+) & (CV+ WITH W.F.M.)
K924-4 REMOTE CONTROL (OPTIONAL) WIRE FEED MODULE (OPTIONAL)

REMOTE CONTROL RECEPTACLE & SWITCH ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
{
PLUG FOR
* SEE
BELOW
B
R
X G 12 11 10 9 8 7 6 5 4 3 2 1 REMOTE CONTROL
POTENTIOMETER INLINE PLUG
P11
* * SEE BELOW W.F.M.
CONNECTORS (P5)
1 41 X
CAUTION: DAMAGE CAN OCCUR Y CONTROL
2 600 Y TO THE REMOTE CONTROL PANEL
* BELOW
SEE 3 42 SWITCH IF IT IS USED WITHOUT
THE "P11" PLUG INSTALLED OR A
G
#8 LEAD
4
5
602 WIRE FEED MODULE INSTALLED.
CONNECT W
CONNECT TO POS. & NEG.
{ POS. WIRE FEED
W TO CASE B OUTPUT TERMINALS NEG.
6
P8 RESISTORS
NEGATIVE CV MODULE
OUTPUT TERMINAL #2 HEAVY LEAD
SWITCH FOR LOCAL OR REMOTE CONTROL PANEL
608
SHOWN IN LOCAL POSITION. 609
CONNECT TO NEG.
* WITH MACHINE NOT RUNNING, REMOVE PLUG "P9" ON MACHINE FROM CONNECTOR "J8".
THEN CONNECT PLUG "P8" ON REMOTE CONTROL TO CONNECTOR "J8" ON MACHINE. REMOTE CONTROL BRUSH HOLDER #2 HEAVY LEAD
** IF A WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISPOSE OF THE POTENTIOMETER BOX
UNCONNECTED PLUG "P10" (IF ONE IS ON THE MACHINE) FASTEN THE NEW PLUG "P11"
NEARBY, LEAVING IT UNCONNECTED. 250 AMP
THERMOSTAT
IF NO WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISCONNECT PLUG "P10"
ON THE MACHINE FROM CONNECTOR "J5". CONNECT PLUG "P11" FROM THE REMOTE CONTROL
ASSEMBLY MACHINE MUST NOT BE RUNNING
KIT TO CONNECTOR "J5" ON THE MACHINE.
THE RED AND BLACK LEADS ARE USED ON CLASSIC I MACHINES ONLY AND ARE NOT
WHEN MAKING THESE CONNECTIONS.
CONNECTED ON THIS MACHINE. DAMAGE TO THE REMOTE CONTROL AND/OR MACHINE
WILL RESULT IF THE RED AND BLACK LEADS ARE CONNECTED IN THE CLASSIC 300G. A
L11194

WIRING DIAGRAM - (CODES 10911, 10927) (L11865)
CLASSIC 300D WIRING DIAGRAM

ELECTRICAL SYMBOLS SHOWN AS VIEWED FROM REAR.
GLOW PLUGS PER E1537
NEUTRAL BONDED TO FRAME P10
60A LEAD COLOR CODE NEUTRE RACCORDE' AU BATI
61 12 11 10 9 8 7 6 5 4 3 2 1
B-BLACK OR R-RED OR
ENGINE GRAY PINK J5
W
FAILURE G-GREEN U-BLUE B +Y
1 2 3 4 5 6 7 8 9 10 1 N-BROWN W-WHITE N -W
LAMP 2
J1 IDLER/ENGINE Y-YELLOW ALTERNATOR ROTOR U
60C 58 3
PROTECTION G
P.C. BOARD
J2 4 SLIP RINGS
-
R + 610A 610
X
Y
53
- SLIP RING
NEAREST
+ 610
58A 53B 600C 602B W
57 IDLER TO IRON AC AC 600B 600
GLOW 41 R
56A IDLER SWITCH W
PLUG START ENGINE 41 1
SOLENOID
HOUR
56
G 115 VOLT 230 VOLT
21
- 600A 2
METER RECEPTACLE RECEPTACLE
42 3 42
PUMP SOLENOID B 15A.

+ - IGNITION G 4 602
SWITCH FUSE 215 602A
52 54B 58H 5
51C 54 RHEOSTAT
51A FUEL PUMP
6
214 J8 P8
60 54D B
212A WATER SELECTOR
50A S TEMPERATURE B 15A SWITCH
I GAUGE 20A 810
20A 15A SWITCH FOR LOCAL
GND-E
G TEMPERATURE ALTERNATOR OR REMOTE CONTROL
SWITCH/SENDER CB2 11 11A CB3 820 AUXILIARY
212B CB1 CB4 SHOWN IN LOCAL
G W POWER POSITION.
GND-N G WINDINGS
STARTING S I GENERATOR
MOTOR B
59 OIL PRESSURE
S OIL PRESSURE SWITCH/SENDER G
B G GAUGE (GROUND SCREW A
+ - WK G NEAR FUSE) 11B
50 AMMETER 5 4 3 2 1
B
+
ALTERNATOR CURRENT
EXC CR2 REED WELDER
+ W TRANSFORMER RELAY LEAD BLOCK
51
W N
51G R U
-W
GND-M +Y
G
N
GROUND
(GROUND SCREW NEAR POSITIVE

GROUND TO ENGINE
ENGINE GAUGES)
NEGATIVE
TO BASE (CC-) (CC+) & (CV+ WITH W.F.M.)

PLUG FOR
REMOTE CONTROL ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
POTENTIOMETER
CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
Y X INLINE PLUG
CONNECTORS (P5)
W.F.M.
G
CONTROL
PANEL
CONNECT W
TO CASE B
#8 LEAD
POS. WIRE FEED
{
RESISTORS
OUTPUT TERMINALS NEG.
NEGATIVE CV
#2 HEAVY LEAD
MODULE
OUTPUT TERMINAL
PANEL
608
REMOTE CONTROL 609
POTENTIOMETER BOX
CONNECT TO NEG.
BRUSH HOLDER
#2 HEAVY LEAD
250 AMP
THERMOSTAT
ASSEMBLY
* MACHINE MUST NOT BE RUNNING
C
L11865

WIRING DIAGRAM - (CODES 10912, 11135) (L11866)
CLASSIC 300G WIRING DIAGRAM

ZENITH THROTTLE
92 3 RPM CONTROL
SHOWN AS VIEWED FROM REAR.
4 BODY
CONTROLLER 10 K PER E1537 P10
5 NEUTRAL BONDED TO FRAME
1 3
72 INJECTOR 90 14 WHITE 2 LEAD COLOR CODE NEUTRE RACCORDE' AU BATI 12 11 10 9 8 7 6 5 4 3 2 1
91 15 CONNECTOR J5
# 19 B - BLACK OR GRAY W
97 21 BLACK G - GREEN B +Y
1 2 3 4 N
+ - 97B 22 CONNECTOR R - RED OR PINK -W
97A ALTERNATOR ROTOR U
FUEL PUMP 1 2 3 4 5 8 9 11 12 13 17 U - BLUE
81 W - WHITE SLIP RINGS -
71 50 Y - YELLOW +
A B 99A B 610
77 87B SLIP RING
THROTTLE PLATE
COIL ALTERNATOR 96 + 610 X G
NEAREST
B
MOTOR 87 R 602B
83 82 AC
+
94 TO IRON AC 600B
97C A B 99D
41 1 41
+ EXC
- WATER 99C
115 VOLT -
TEMP. 230 VOLT 600A 2 Y
99B 93 RECEPTACLE 600
SENSOR RECEPTACLE 42 3
95 42
PARTS SUPPLIED A B B B
DISTRIBUTOR 87A G 15A 4
WITH ENGINE
76 AIR Y 602
ENGINE
A B C
FUSE 602A 5
TEMP. W
HOUR METER MAP SENSOR 99E SENSOR RHEOSTAT
ENGINE 6
FAILURE J8 P8
+ - LAMP 78
Y
B
61 89 SELECTOR
CB5 OIL PRESSURE SWITCH & SENSOR B SWITCH
60 R SWITCH FOR LOCAL OR
START AMMETER SENSOR 20A 20A 15A 15A REMOTE CONTROL SHOWN
G WK G IN LOCAL POSITION.
62 74 IGNITION 51 ALTERNATOR
SWITCH SWITCH CB2 CB1 CB4 CB3 W AUXILIARY
WATER TEMP. SENDER
73 POWER
84 SENSOR G WINDINGS
GENERATOR
WATER TEMP. IDLER B
STARTER
MOTOR GAUGE SWITCH G
69 A
S 99
(GROUND SCREW
S 80 4 B
B NEAR FUSE)
3 5 4 3 21
B
2
70 1 WELDER
+
R
45
67 CURRENT LEAD BLOCK
OIL PRESS. G SENSOR N
CONTROL PANEL GAUGE U
GROUND SCREW -W
S +Y
GROUND GROUND POSITIVE

NEGATIVE
TO ENGINE TO BASE (CC-) (CC+) & (CV+ WITH W.F.M.)

PLUG FOR ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
REMOTE CONTROL CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
{
POTENTIOMETER
INLINE PLUG
Y X CONNECTORS (P5)
W.F.M.
G CONTROL
PANEL
CONNECT W #8 LEAD
TO CASE B
{ POS. WIRE FEED
OUTPUT TERMINALS NEG.
RESISTORS
NEGATIVE CV MODULE
OUTPUT TERMINAL #2 HEAVY LEAD
PANEL
608
609
REMOTE CONTROL CONNECT TO NEG.
POTENTIOMETER BOX
BRUSH HOLDER #2 HEAVY LEAD
250 AMP
THERMOSTAT
ASSEMBLY
* MACHINE MUST NOT BE RUNNING
L11866

WIRING DIAGRAM - (CODES 11110, 11111) (M20499)
CLASSIC 300D PERKINS WIRING DIAGRAM
212C
212D
ON NEWER BOARDS, CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR. LEAD COLOR CODE
44
58
59
61
54
93
57
*
J1 BECOMES J31, B-BLACK OR R-RED OR
LEADS CONNECTED TO ENGINE IDLER/ENGINE P.C. BOARD, SEE DETAIL
J2 BECOMES J32, GRAY PINK
1 2 3 4 5 6 7 8 9 10 G-GREEN U-BLUE
J1 B5 AND B6 TERMINALS NEUTRAL BONDED TO FRAME.
P10 N-BROWN W-WHITE
ARE DELETED. NEUTRE RACCORDE AU BATI. 121110 9 8 7 6 5 4 3 2 1
IDLER/ENGINE PROTECTION P.C. BD. 1 J5 Y-YELLOW
400D Y
J2 32 TO CURRENT 400E W
600B
4 TRANSFORMER 48 U
610
B1 B2 B3 B4 B5 B6 N
SLIP RINGS
- ALTERNATOR
610
60A 55 IDLER + +
602B
SOLENOID 610A
GLOW SLIP RING
844 212E B NEAREST
602
PLUGS 844A *55 W 600C AC AC
*57 R TO IRON
PUMP 115 VOLT GFCI J8 P8 W R
212E SOLENOID RECEPTACLE 230 VOLT - 1
41
600
41 G
*212C GND-C 400F RECEPTACLE 21 2

600A
ENGINE 7A 3
42 X
53 *212D *58 HOT LINE HOT LOAD Y
GLOW HOUR *61 15A 4
PLUG START METER
IGNITION 58H FUEL 602A 5 42
SWITCH ENGINE PUMP FUSE 6 W
+ - CB4 FAILURE WHITE LINE WHITE LOAD
RHEOSTAT
10A LAMP
56 *844 IDLER 214 215 REMOTE CONTROL
51C 52 *93 212A 60C SWITCH 6A
51A TEMPERATURE SWITCH AND U Y
43
GND-E
WATER SWITCH/SENDER 810 RECEPTACLE N W
S I ALT. AUX
TEMPERATURE
50A *44 POWER
GAUGE SHUNT
G W 11A WINDINGS
G CB2 CB3 FIELD
CB1
+ - 20A 41 15A 15A
60 820 SELECTOR SERIES FIELD
AMMETER 212B GND-T - +
GND-M
GND-N SWITCH
STARTING 200 *54
G WK 11B 90-MIN
S
MOTOR S I OIL PRESSURE GND-S GROUND 130-80
190-120
+ -
B 50 OIL SWITCH/SENDER SCREW 240-160
PRESSURE G NEAR FUSE 220-MAX
TO IDLER / ENGINE
+
GAUGE *59 11C

PROTECTION P.C.Bd. INTERPOLE COILS
+
EXC
DIODE
51 ALTERNATOR
51G WELDING GENERATOR AND
CURRENT TRANSFORMER
*844A MOV
GND-B REED
*60A BRUSH POSITION SHOWN AS
GND-A SWITCH
VIEWED FROM CONTROL PANEL
GROUND GROUND GROUND SCREW NEAR NEGATIVE POSITIVE
TO BASE TO ENGINE ENGINE GAUGES (CC-) (CC+) & (CV+ WITH W.F.M.)
PLUG FOR REMOTE CONTROL ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
POTENTIOMETER CONNECT "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
INLINE CONNECTORS
Y X PLUG P5
W.F.M.
CONTROL
G B W PANEL
#8 LEAD WIRE FEED
CONNECT TO POS. & NEG. POS.
OUTPUT TERMINALS NEG. MODULE
RESISTORS #2 HEAVY LEAD
NEGATIVE CV
608
OUTPUT TERMINAL
609
PANEL #2 HEAVY LEAD
REMOTE CONTOL CONNECT TO CASE CONNECT TO NEG.
POTENTIOMETER BOX 250 AMP THERMOSTAT ASSEMBLY
BRUSH HOLDER
B
M20499

CLASSIC 300D KUBOTA WIRING DIAGRAM

ENGINE CONTROL UNIT CONNECTOR DETAIL LEAD COLOR CODE
CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR.
B-BLACK OR R-RED OR
25
34
17
LEADS CONNECTED TO ENGINE CONTROL UNIT, SEE DETAIL
9
61 GRAY PINK
93 57 G-GREEN U-BLUE
NEUTRAL BONDED TO FRAME. P10 N-BROWN
GLOW PLUGS 51B
70B NEUTRE RACCORDE' AU BATI. W-WHITE
212D 55 121110 9 8 7 6 5 4 3 2 1
J5 Y-YELLOW
58 844A NOTE: LEADS 70A & 70B ARE RPM CONTROL
70A LEFT OPEN AND WIRE 400D Y
69 400E W
600B
94 TIED INTO HARNESS. 48 U
52B 88
44
610
N
87
86 54
60E SLIP RINGS
- ALTERNATOR
610
56
60F 64
* 57 + +
602B
ACTUATOR SLIP RING 610A
1
10
18
26
1 2 3
ENGINE *56 NEAREST
602
WIRE-TIED TO WIRING 600C AC AC
START HARNESS BEHIND
FAILURE
LAMP ENGINE HOUR METER * 87 *86 * 88 TO IRON
J8 P8 W R
CONTROL PANEL + - 230 VOLT - 600
115 VOLT
1
41 41 G
*52B START RELAY * 61 841A
841
58 *
RECEPTACLE RECEPTACLE
7A 21 2
600A
* 212D TEMP. WATER
3
42
4
X Y
52A 212C IGNITION 4A 15A
55 * SWITCH/ 841B TEMP 602A 5 42
SWITCH FUSE 6 W
53 SENDER GAUGE RHEOSTAT
51B * W G S I
*44 43 400F 214 215 REMOTE CONTROL
GLOW G 6A SWITCH AND U Y
62 212A
GND-E
PLUG 810 RECEPTACLE N W
51A ALT. AUX
GND-N
OIL PRES.
POWER SHUNT
SWITCH/
212B
51C CB2 11 11A WINDINGS FIELD
SENDER 20A CB1 CB4 CB3
50A 20A 41 15A 15A
S I
*54 200 820 SERIES FIELD
GND-M
G SELECTOR
STARTING
S MOTOR
AMMETER WK OIL
PRESSURE
G GND-T SWITCH - +
+- GAUGE 90-MIN
B
+ 50 ALTERNATOR
WATER ENGINE GND-S
130-80
190-120
+ -
L TEMP. SPEED 11B 240-160
* 64 SENSOR SENSOR 841 220-MAX
B
BATTERY 51
212E IG
* 69 *93
94
* 844A 2 TURNS INTERPOLE COILS
60A
60 * 1
3 11C
DIODE
AND
WELDING GENERATOR
GROUND GROUND * 60E GND-B 844 4 67B MOV
TO TO * 60F 842 2
IDLER SWITCH 67A BRUSH POSITION SHOWN AS
BASE ENGINE GROUND SCREW NEAR NEGATIVE POSITIVE
ENGINE GAUGES 3 TURNS VIEWED FROM CONTROL PANEL
(CC-) (CC+) & (CV+ WITH W.F.M.)
INLINE CONNECTORS
Y X PLUG P5
W.F.M.
CONTROL
G B W PANEL
#8 LEAD WIRE FEED
NEGATIVE CV
608
OUTPUT TERMINAL
609
PANEL #2 HEAVY LEAD
BRUSH HOLDER
A
M20432

WIRING DIAGRAM - (CODES 11243, 11244) (M20432-1)

B-BLACK OR R-RED OR
25
34
17
9
61 GRAY PINK
GLOW PLUGS 51B
212D 55 121110 9 8 7 6 5 4 3 2 1
J5 Y-YELLOW
69 400E W
600B
52B 88
44
610
N
87
86 54
60E SLIP RINGS
- ALTERNATOR
610
56
60F 64
* 57 + +
602B
1
10
18
26
1 2 3
ENGINE *56 NEAREST
602
FAILURE
J8 P8 W R
1
41 41 G
841
58 * 115 VOLT GFCI RECEPTACLE
7A 21 2
600A
* 212D TEMP. WATER
RECEPTACLE 3
42
4
X Y
52A 212C IGNITION 400D 400F 15A
55 * SWITCH/ 841B TEMP 602A 5 42
SWITCH HOT LINE HOT LOAD FUSE 6 W
51B * W G S I
400E
*44 43
WHITE LINE WHITE LOAD
214 215 REMOTE CONTROL
GLOW G 6A SWITCH AND U Y
62 212A
GND-E
PLUG 48 810 RECEPTACLE N W
51A 400F ALT. AUX
GND-N
OIL PRES.
820 POWER SHUNT
SWITCH/
212B
51C CB1 11A WINDINGS FIELD
SENDER 20A CB4 CB3
50A 11C 41 15A 15A
S I GND-S
*54 200 820 SERIES FIELD
GND-M
G SELECTOR
STARTING
S MOTOR
AMMETER WK OIL
PRESSURE
G GND-T SWITCH - +
+- GAUGE 90-MIN
B
+ 50 ALTERNATOR
WATER ENGINE
130-80
190-120
+ -
* 64 SENSOR SENSOR 841 220-MAX
51 B
BATTERY
212E IG
* 69 * 94
* 844A 2 TURNS INTERPOLE COILS
60A
60 *93 1
3 11C
DIODE
AND
WELDING GENERATOR
TO TO * 60F 842 2 3 TURNS
ENGINE GAUGES VIEWED FROM CONTROL PANEL
INLINE CONNECTORS
Y X PLUG P5
W.F.M.
CONTROL
G B W PANEL
#8 LEAD WIRE FEED
NEGATIVE CV
608
OUTPUT TERMINAL
609
PANEL #2 HEAVY LEAD
BRUSH HOLDER
B
M20432-1

WIRING DIAGRAM - (CODES 11248, 11249, 11280, 11281) (M20616)
212C
212D
CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR. LEAD COLOR CODE
44
58
59
61
54
93
57
*
B-BLACK OR R-RED OR
ON OLDER BOARDS, LEADS CONNECTED TO ENGINE IDLER/ENGINE P.C. BOARD, SEE DETAIL
GRAY PINK
1 2 3 4 5 6 7 8 9 10 J31 WAS J1, G-GREEN U-BLUE
J31 NEUTRAL BONDED TO FRAME.
J32 WAS J2. P10 N-BROWN W-WHITE
NEUTRE RACCORDE AU BATI. 121110 9 8 7 6 5 4 3 2 1
400D Y
600B
4 TRANSFORMER 48 U
610
B1 B2 B3 B4 N
SLIP RINGS
- ALTERNATOR
610
60A 55 IDLER + +
602B
SOLENOID 610A
GLOW SLIP RING
844 212E B NEAREST
602
*57 R TO IRON
41
600
41 G

600A
ENGINE 7A 3
42 X
GLOW HOUR *61 15A 4
PLUG START METER
RHEOSTAT
10A LAMP
51C 52 *93 212A 60C SWITCH 6A
51A TEMPERATURE SWITCH AND U Y
43
GND-E
S I ALT. AUX
TEMPERATURE
50A *44 POWER
GAUGE SHUNT
G W 11A WINDINGS
G CB2 CB3 FIELD
CB1
+ - 20A 41 15A 15A
GND-M
GND-N SWITCH
STARTING 200 *54
G WK 11B 90-MIN
S
190-120
+ -
TO IDLER / ENGINE
+
GAUGE D+ 11C
*59 INTERPOLE COILS
PROTECTION P.C.Bd.
DIODE
51
B+ ALTERNATOR WELDING GENERATOR AND
CURRENT TRANSFORMER
*844A MOV
GND-B REED
GND-A SWITCH
INLINE CONNECTORS
Y X PLUG P5
W.F.M.
CONTROL
G B W PANEL
#8 LEAD WIRE FEED
NEGATIVE CV
608
OUTPUT TERMINAL
609
PANEL #2 HEAVY LEAD
BRUSH HOLDER
B
M20616

212C
212D
44
58
59
61
54
93
57
*
B-BLACK OR R-RED OR
GRAY PINK
400D Y
600B
4 TRANSFORMER 48 U
610
B1 B2 B3 B4 N
SLIP RINGS
- ALTERNATOR
610
60A 55 IDLER + +
602B
SOLENOID 610A
GLOW SLIP RING
844 212E B NEAREST
602
*57 R TO IRON
41
600
41 G

600A
ENGINE 7A 3
42 X
GLOW HOUR *61 15A 4
PLUG START METER
RHEOSTAT
10A LAMP
51C 52 *93 212A 60C SWITCH
51A TEMPERATURE 6A SWITCH AND U Y
43
GND-E
S I CB2 ALT. AUX
TEMPERATURE
50A *44 15A POWER
GAUGE SHUNT
G W 11A 7A WINDINGS
G FIELD
CB1
+ - 20A 41
GND-M
GND-N SWITCH
STARTING 200 *54
G WK 11B 90-MIN
S
190-120
+ -
TO IDLER / ENGINE
+
GAUGE D+ 11C
*59 INTERPOLE COILS
PROTECTION P.C.Bd.
DIODE
51
B+ ALTERNATOR WELDING GENERATOR AND
CURRENT TRANSFORMER
*844A MOV
GND-B REED
GND-A SWITCH
INLINE CONNECTORS
Y X PLUG P5
W.F.M.
CONTROL
G B W PANEL
#8 LEAD WIRE FEED
NEGATIVE CV
608
OUTPUT TERMINAL
609
PANEL #2 HEAVY LEAD
BRUSH HOLDER
A
M21292


B-BLACK OR R-RED OR
25
34
17
9
61 GRAY PINK
GLOW PLUGS 51B
212D 55 121110 9 8 7 6 5 4 3 2 1
J5 Y-YELLOW
69 400E W
600B
52B 88
44
610
N
87
86 54
60E SLIP RINGS ALTERNATOR -
610
56
60F 64
* 57 + +
602B
1
10
18
26
1 2 3
ENGINE *56 NEAREST
602
FAILURE
J8 P8 W R
1
41 41 G
841
58 * 115 VOLT GFCI RECEPTACLE
7A 21 2
600A
50A * 212D TEMP. WATER
RECEPTACLE 3
42
4
X Y
52A 212C IGNITION 400D 400F 15A N W
55 * SWITCH/ 841B TEMP 602A 5 42 U Y
SWITCH HOT LINE HOT LOAD FUSE 6 W
212E
51B * W G S I
400E
*44 43
GND-M WHITE LINE WHITE LOAD
214 215 REMOTE CONTROL
GLOW 212A G 6A SWITCH AND U Y
62
GND-E
PLUG 48 CB2 810 RECEPTACLE N W
51A 400F ALT. AUX
15A
GND-N
OIL PRES.
820 POWER SHUNT
SWITCH/
212B
51C 11A 7A FIELD
SENDER CB1 WINDINGS
50A 20A 11C 41
S I GND-S
*54 G
STARTING
S MOTOR
AMMETER WK OIL
PRESSURE
G GND-T SWITCH - +
+- GAUGE 90-MIN
+B 50 ALTERNATOR
WATER ENGINE
130-80
190-120
+ -
* 64
GND-M
SENSOR 220-MAX
SENSOR
B
BATTERY 51
212E IG
*69 *94 * 844A 2 TURNS INTERPOLE COILS
60A
60 *93 841 1
3 11C
DIODE
AND
WELDING GENERATOR
TO TO * 60F 842 842 2 3 TURNS
INLINE CONNECTORS
Y X PLUG P5
W.F.M.
CONTROL
G B W PANEL
#8 LEAD WIRE FEED
NEGATIVE CV
608
OUTPUT TERMINAL
609
PANEL #2 HEAVY LEAD
BRUSH HOLDER
A
M21293

212C
212D
44
58
59
61
54
93
57
*
B-BLACK OR R-RED OR
GRAY PINK
IDLER/ENGINE PROTECTION P.C. Bd. 1 J5 Y-YELLOW
400D Y
600B
4 TRANSFORMER 48 U
610
B1 B2 B3 B4 N
SLIP RINGS
- ALTERNATOR
610
IDLER +
60A 55 +
602B
SOLENOID 610A
GLOW SLIP RING
844 212E B NEAREST
602
*57 R TO IRON
41
600
41 G

600A
ENGINE *212D 7A 3
42 X
53 *58 HOT LINE HOT LOAD Y
GLOW HOUR *61 15A 4
IGNITION 602A 5 42
PLUG START METER SWITCH ENGINE FUSE 6 W
RHEOSTAT
10A LAMP IDLER
56 *844 214 215 REMOTE CONTROL
52 *93 212A 60C SWITCH
51C 51A TEMPERATURE 6A SWITCH AND U Y
43
GND-E
S I WATER SWITCH/SENDER 810 RECEPTACLE N W
TEMPERATURE CB2 ALT. AUX
50A *44 15A POWER
GAUGE G SHUNT
W 11A 7A WINDINGS
G FIELD
CB1
+ - 20A 41
60 AMMETER 820 SELECTOR SERIES FIELD
212B GND-T - +
GND-M
GND-N SWITCH
STARTING 200 *54
G WK 11B 90-MIN
S
MOTOR
OIL
S I OIL PRESSURE GND-S GROUND 130-80
190-120
+ -
B 50 SWITCH/SENDER SCREW 240-160
GAUGE TO IDLER / ENGINE
+
D+ 11C
*59 INTERPOLE COILS
PROTECTION P.C.Bd.
51 DIODE
B+ ALTERNATOR
CURRENT TRANSFORMER WELDING GENERATOR AND
*844A REED MOV
*60A GND-B
GND-A SWITCH BRUSH POSITION SHOWN AS
POSITIVE VIEWED FROM CONTROL PANEL
GROUND GROUND GROUND SCREW NEAR NEGATIVE
INLINE CONNECTORS
Y X W.F.M. PLUG P5
CONTROL
G B PANEL
W #8 LEAD WIRE FEED
NEGATIVE CV
608
OUTPUT TERMINAL
609
PANEL #2 HEAVY LEAD
BRUSH HOLDER
A
M21684


B-BLACK OR R-RED OR
25
34
17
9
61 GRAY PINK
NOTE: LEADS 70A & 70B ARE
GLOW PLUGS 51B
212D 55 LEFT OPEN AND WIRE 121110 9 8 7 6 5 4 3 2 1
J5 Y-YELLOW
58 844A TIED INTO HARNESS. RPM CONTROL
70A 400D Y
69 400E W
600B
94 48 U
52B 88
44 * 57 ACTUATOR
610
N
87
86 54
60E SLIP RINGS ALTERNATOR -
610
ENGINE *
56 56
60F 64 + +
602B
FAILURE SLIP RING 610A
1
10
18
26
ENGINE HOUR METER 1 2 3
LAMP NEAREST
602
+ - 58 *87 *86 *88 TO IRON
START HARNESS BEHIND * 61 841A
* J8 P8 W R
CONTROL PANEL 230 VOLT - 600
841 1
41 41 G
*52B START RELAY TEMP. SWITCH 115 VOLT GFCI RECEPTACLE
7A 21 2
600A
* 212D RECEPTACLE 3
42 X Y
400D
50A
52A 212C IGNITION * 44 841B 400F 15A
602A
4
5 42 N W
55 * SWITCH WATER HOT LINE HOT LOAD FUSE 6 W U Y
53 TEMP. SENDER RHEOSTAT
TEMP
212E
51B * 43 S I
400E
GAUGE 214 215 REMOTE CONTROL
GND-M WHITE LINE WHITE LOAD
6A SWITCH AND
GLOW 62 212A G U Y
GND-E
810 RECEPTACLE N W
48
PLUG 51A ALT. AUX
GND-N
OIL PRES.
820
SHUNT
212B
SWITCH/ POWER
51C 11A 7A FIELD
SENDER CB1 WINDINGS
50A 20A CB2
41
S I 15A
*54
GND-S
200 SERIES FIELD
GND-T
G 820 SELECTOR
STARTING AMMETER WK OIL G SWITCH - +
11C
S MOTOR PRESSURE
+- GAUGE 90-MIN
B
50 ALTERNATOR
WATER ENGINE
130-80
190-120
+ -
11B
+
L TEMP. SPEED 240-160
* 64
GND-M
SENSOR 220-MAX
B SENSOR
51
BATTERY
212E IG
*69 *94 * 844A 2 TURNS INTERPOLE COILS
60A
60 *93 841 1
3 11C
DIODE
AND
WELDING GENERATOR
TO TO * 60F 842
IDLER SWITCH
842 2
67A
3 TURNS
BRUSH POSITION SHOWN AS
INLINE CONNECTORS
Y X PLUG P5
W.F.M.
CONTROL
G B W PANEL
#8 LEAD WIRE FEED
NEGATIVE CV
608
OUTPUT TERMINAL
609
PANEL #2 HEAVY LEAD
BRUSH HOLDER
A
M21563

SCHEMATIC - COMPLETE MACHINE - (CODES 11110, 11111) (L12412)
L12412 ENGINEERING CONTROLLED CHANGE DETAIL: SLIP RINGS, CHANGED POSITIVE TO NEGATIVE
MANUFACTURER: No
CENTER OF CONTROL PANEL THIS LEAD PROVIDES FLASH BACK, LEFT SIDEOF ENGINE K924-5 REMOTE CONTROL
IDLER / ENGINE PROTECTION PC BOARD
(OPTIONAL)
12 VOLT - NORMALLY OFF FOR ALTERNATOR AND 55 AMP / 12 VOLT AMMETER SHOWS FULL
SENSES ALTERNATOR OUTPUT DISCHARGE WHILE PRESSING
RED ENGINE LOCATED BEHIND UPPER PORTION OF CONTROL PANEL ALTERNATOR GLOW PLUG
PROTECTION 60C J1-4 SCHEMATIC G4828-1 SWITCH GLOW PLUG SWITCH
61 59
LIGHT ENGINE J1-3 FLASH
SHUTDOWN BACK, RIGHT SIDEOF ENGINE BAT 53
N.C.
B3 55 WHITE IDLE SOLENOID BAT REMOTE CONTROL PLUG
RIGHT SIDEOF ENGINE PULL COIL TYPICAL CURRENT DRAW AND 51C
G
BY INJECTION PUMP J1-8 57 RED RESISTANCE: -40 TO 40 AMPS
N.O. HOLD COIL AMMETER
INJECTION GND-C 58 J1-9 FLYBACK BLACK HOLD COIL: 1A, 10-15 OHMS 51
PUMP DIODES 212E PULL COIL: 40A, LESS THAN .1 OHM 51G
+ - GLOW PLUGS
Y
SOLENOID ENGINE
RUNNING J1-2 212C 56 51A TYPICAL CURRENT X
58H
APPROXIMATE 10A
J1-1 212D IGNITION DRAW IS 40 +/- 3 AMPS
RESISTANCE: 3.3 OHMS CB4 50A W 25+/-1.25 OHMS EACH
SWITCH
TYPICAL CURRENT DRAW: 3.3A LOWER LEFT OF
BACK, LEFT SIDEOF ENGINE 212A SHOWN IN "OFF" CONTROL PANEL
RIGHT SIDEOF ENGINE S POSITION 50
BY OIL FILLER J1-6 44 43 I START
TEMPERATURE CCW
W G G SWITCH 64+/-6.4 OHMS MAX
FUEL PUMP ENGINE GAUGE BACK, BOTTOM
TEMPERATURE SWITCH / SENDER
APPROXIMATE PROTECTION LOWER LEFT OF 52 OF MACHINE
RESISTANCE: 3-4 OHMS CIRCUITS (SEE SWITCH CLOSES SENDER OPERATION: 212B CONTROL PANEL STARTER
+
AT 230v+/-6vF 140vF -> 134+/-13.5 OHMS

BELOW FOR SOLENOID BATTERY

TYPICAL CURRENT DRAW: 3A 194vF -> 51.2+/-4.3 OHMS RHEOSTAT
LOGIC)
60 + 93 J1-10 212vF -> 38.5+/-3 OHMS SENDER IS APPROX.
STARTER 12.6 VOLTS MIN
HOUR METER BACK, TOPOF ENGINE 500 OHMS AT 70vF REMOTE CONTROL BOX
S MOTOR AT REST
CENTER OF J1-5 J1-7 54 200 I OIL PRESSURE 14-14.5 VOLTS
GAUGE
CONTROL PANEL UNUSED J2-1 WK G G WHILE RUNNING
LOWER LEFT OF
J2-2 CONTROL PANEL
B1 REVERSE VOLTAGE OIL PRESSURE SWITCH / SENDER
PROTECTION DIODE SWITCH CLOSES SENDER OPERATION:
60A IDLE AT 6+/-2 PSI 0 PSI -> 10+/-5 OHMS
AUX LOAD SENSING SOLENOID 40PSI -> 105+/-5 OHMS
B4
CIRUITS 80 PSI -> 187+/-5 OHMS FLYBACK DIODE PREVENTS
(SEE BELOW B5 UNUSED VOLTAGE SPIKES IN SHUNT FIELD
WELD LOAD SENSING THE P10 PLUG IS ONLY ON UNITS WITHOUT
J2-3 J2-4 B2 FOR LOGIC) B6 FROM DAMAGING LOCAL/REMOTE
ENGINE PROTECTION CIRCUIT LOGIC THE WIRE FEED MODULE. THE WIRE FEED P10 TOGGLE SWITCH WHEN SWITCHED
MODULE HAS A HARNESS THAT PLUGS
ON NEWER BOARDS, DIRECTLY INTO J5. 12 11 10 9 8 7 6 5 4 3 2 1
1. UPON RECIEVING POWER FROM THE SHOWN IN "AUTO J1 BECOMES J31, J2 BECOMES J32, JUMPER PLUG IS FOR CONNECTION
IGNITION SWITCH, THE FUEL SOLENOID, 844 GND-B
IDLE" POSITION B5 AND B6 TERMINALS ARE DELETED. J5 TO WIRE FEED MODULE
FUEL PUMP AND HOUR METER ARE IDLER SWITCH 48
400D
ENERGIZED.
400E JUMPER PLUG ISWIRE-TIED UP
DC EXCITER BEHIND LOCAL / REMOTE SWITCH ON
2. ENGINE PROTECTION IS BYPASSED 610 RIGHT SIDEOF MACHINE (ASVIEWED
FOR ONE MINUTE TO ALLOW OIL 15A
WINDING SPEC: ALT-241-3A
+ 610A
+ 610 FROM CONTROL PANEL)
20A 40.5 - 42.5 OHMS AT 25C
PRESSURE BUILDUP. ENGINE MUST BE CB1 CB3 AC AC DIODE N U W Y
STARTED WITHIN ONE MINUTE OF EXCITER REVOLVING LOWER, RIGHT SIDEOF CONTROL PANEL
11A FIELD (ROTOR)
TURNING IGNITION SWITCH ON OR THE - 600C
- 600B
FUEL SOLENOID, FUEL PUMP AND HOUR SLIP RINGS 21 600A
METER WILL TURN OFF. AFTER ONE 400F 115 VOLT GFCI 7A TOP, RIGHT PORTION
NEGATIVE SLIP RING FUSE
RECEPTACLE
MINUTE, THE IGNITION SWITCH MUST BE IS NEAREST TO IRON 15A EXCITER CIRCUIT OF CONTROL PANEL N U W Y
CYCLED OFF AND BACK ON TO START 215
LOWER, RHEOSTAT
HOT LINE HOT LOAD
LEAD 21A TO 21B CCW

ENGINE. RIGHT OF 64+/-6.4 OHMS MAX
230 VOLT WINDING SPEC: ALT-214-2B
CONTROL 214 602B
RECEPTACLE .488 OHMS MAX AT 25C
3. AFTER ENGINE STARTS, FLASHING GND-E PANEL 42 41
CURRENT IS SUPPLIED TO THE ENGINE 602A
6A 810 115 VOLT CIRCUIT
ALTERNATOR. GND-T 15A J8
11C LEAD 810 TO 820
GND-S CB2 EXCITER STATOR WINDING SPEC: ALT-214-2C 6 4 5 3 1 2
4. AFTER ONE MINUTE, TIMER IS TIMED 820 (ALTERNATOR) P9
.230 OHMS MAX AT 25C
OUT. IF OIL PRESSURE IS LOW, IN-LINE BOLTED CONNECTION JUMPER PLUG IS
COOLANT TEMPERATURE IS HIGH OR 41 600 WIRE-TIED UPBEHIND
BEHIND CONTROL PANEL 115 VOLT CIRCUIT G
ALTERNATOR IS NOT CHARGING, THE 11B 602 42 LOCAL / REMOTE
LEAD 820 TO 830
ENGINE WILL SHUT DOWN AND THE GENERATOR LEAD BLOCK Y SWITCH ON RIGHT
WINDING SPEC: ALT-214-2D
ENGINE PROTECTION LIGHT WILL COME 844A SHOWN AS VIEWED WITH .424 OHMS MAX AT 25C X SIDEOF MACHINE
ON. TOP, LEFT PORTION ENGINE IN THIS DIRECTION W
IDLE SOLENOID CIRUIT LOGIC OF CONTROL PANEL REMOTE
MOUNTED TO NEGATIVE
RECEPTACLE
1. WHEN THE ENGINE IS RUNNING IN HIGH IDLE SELECTOR SWITCH SERIES FIELD SHUNT LOCAL / REMOTE BRUSH HOLDER
OR UNDER LOAD, THE SOLENOID IS NOT - + FIELD SWITCH DIODE AND MOV ASSEMBLY
ENERGIZED. 90-MIN
130-80 - SHOWN IN LOCAL
2. IF NO AUXILIARY CURRENT DRAW OR WELD
+ FJW-5AP
POSITION
THIS CIRCUIT USES THE
190-120 COIL PAIR: RESIDUAL MAGNETISM OF
LOAD IS SENSED FOR 15 SECONDS AND THE 240-160 25.2 - 26.7 THE GENERATOR TO FLASH
IDLER SWITCH IS OPEN (AUTO), THE PULL AND INTERPOLE OHMS EACH THE EXCITE THE ROTOR
220-MAX
HOLD COIL OF THE IDLER SOLENOID ARE COILS WHICH IN TURN PROVIDES
ENERGIZED. THE PULL COIL IS DE-ENERGIZED THE EXCITATION FOR THE
AFTER HALF A SECOND. GENERATOR
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS 3. IF AN AUXILIARY CURRENT DRAW OR WELD BACK OF OUTPUT STUD
WELDING
LOAD IS SENSED OR THE IDLER SWITCH IS CLOSED BRUSH POSITION SHOWN AS

RESISTOR: OHMS/WATTS (HIGH), THE IDLE SOLENOID IS DE-ENERGIZED. REED SWITCH

SWITCH CLOSES
VIEWED FROM CONTROL PANEL GENERATOR
CONNECTOR PIN NUMBERS: WITH FLOW OF
EX. 12 PIN CONNECTOR LEAD COLOR CODE:
B-BLACK OR GRAY
LABELS: WELDING CURRENT
GND-A
_ +
1 2 6
G-GREEN NEGATIVE OUTPUT POSITIVE OUTPUT PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
COMMON TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
R-RED OR PINK TERMINAL TERMINAL UNLESS OTHERWISE SPECIFIED TOLERANCE
U-BLUE FRAME GROUND TYPICAL OCV (WARM MACHINE):

MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION
ON 2 PLACE DECIMALS IS ± .02
REFERENCE:
EQUIPMENT TYPE: CLASSIC 300D PERKINS 404C-22 PAGE ___ 1
1 OF ___
7 12 ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: DM / DFM L12020 DOCUMENT DOCUMENT
W-WHITE 94-99.0 VOLTS AT MAX RHEOSTAT UNDER LEFT DOOR SUBJECT: MACHINE SCHEMATIC
LATCH EARTH GROUND ON ALL ANGLES IS ± .5 OF A DEGREE NUMBER: REVISION:
Y-YELLOW 44-54.5 VOLTS AT MIN RHEOSTAT MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: J.STAPP SCALE:
VIEW OF CONNECTOR ON PC BOARD N-BROWN
WITH PUBLISHED STANDARDS.
NA
MATERIAL
UF APPROVAL
DATE: 09/21/2006
PROJECT
CRM22115-FZ L12412 C
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
APPROVED:
DO NOT SCALE THIS DRAWING DISPOSITION: NUMBER:

ENGINEERING CONTROLLED CHANGE DETAIL: Released A.05 from X

L12265
MANUFACTURER: No JUMPERPLUGISBEHINDLOWER
94 20
12 VOLT SUPPLY 11
RIGHTSIDEOFCONTROLPANEL
87 1
LOWERRIGHTOFCONTROLPANEL
RPM CONTROL POTENTIOMETER
10,000 +/- 1,000 OHMS MAX GLOW PLUG
AMMETER SHOWS FULL
DISCHARGE WHILE PRESSING
K924-5 REMOTE CONTROL
(OPTIONAL)
ENGINE BUTTON GLOW PLUG SWITCH
RATED VOLTAGE: 12V 2 86 2 TURN POT COUNTERCLOCKWISE TO
SPEED
RATED CURRENT: 22mA MAX SENSOR 93 17 ENGINE CONTROL UNIT (ECU) CCW REDUCE RESISTANCE AND SUBSEQUENTLY 53
REDUCE RPM BY UP TO 150RPM GLOW PLUGS
BACK, RIGHT LOCATEDBEHINDUPPERPORTIONOFCONTROLPANEL 3 88 3
60A RATED VOLTAGE: 12V BACK, LEFTSIDEOFENGINE 51C
SIDEOFENGINE 4 TYPICAL CURRENT
RATED CURRENT: 4.5A(MAX.)-TERMINAL #15 ALTERNATOR DRAW IS 40 AMPS
LEAKAGE CURRENT 10micro A (MAX.)-TERMINAL #16 40 AMP / 12 VOLT
26 64 L REMOTE CONTROL PLUG
69 13 G
SENSOR OPERATION: SENSES ALTERNATOR OUTPUT IG
-4vF -> 18.80 kOHMS WATER
TEMP. FLASHES ALTERNATOR B
104vF -> 1.14 kOHMS 212E
212vF -> .16 kOHMS SENSOR
16 51B
-40 TO 40 AMPS Y
BACK, LEFT 60 IGNITION AMMETER
51 STARTER BACK, BOTTOM X
RATED VOLTAGE: 12V
SIDEOFENGINE
1 9 15 212D
SWITCH
51A
- 50 SOLENOID OFMACHINE
RATED CURRENT: 2A 10 17 SHOWN IN "OFF" + + 25+/-1.25 OHMS EACH
BATTERY W
COIL RESISTENCE: 57 34 POSITION
18 25
2.8 +/- .28 OHMS AT 20vC
ENERGIZED FOR RUN
12 VOLT 26 34 BACK, LEFTSIDEOFENGINE 212A STARTER 12.6 VOLTS MIN
ACTUATOR SUPPLY S I MOTOR AT REST
DE-ENERGIZED FOR STOP 50A
28 44 43 14-14.5 VOLTS
ACTUATOR CONTROLS RPM BACK, RIGHT TEMPERATURE CCW
MECHANICAL STOP WILL SHUT SIDEOFENGINE W G G WHILE RUNNING
DOWN THE ENGINE AT 115%
56 18 GAUGE START 64+/-6.4 OHMS MAX
TEMPERATURE SWITCH / SENDER LOWERLEFTOF
OF RATED SPEED. BUTTON
ENGINE ECU CONNECTOR DETAIL 212B CONTROL PANEL
SWITCH CLOSES SENDER OPERATION: RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY
PROTECTION 140vF -> 134+/-13.5 OHMS
COLOR: RED
LIGHT 61 9 AT 230v+/-6vF 62 OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED

12 VOLT 194vF -> 51.2+/-4.3 OHMS SENDER IS APPROX. WHEN THE IGNITION SWITCH IS "ON" AND THE ECU
CENTEROF THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING THE ENGINE 212vF -> 38.5+/-3 OHMS 500 OHMS AT 70vF
RHEOSTAT
NORMALLY OFF SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT
CONTROLPANEL 841A PROTECTION LIGHT IN A CODED SEQUENCE, SEE CHART FOR FAULT FRONT, LEFTSIDEOFENGINE 212C
S DOWN DUE TO A FAULT (EVEN IF THAT CONDITION
CODES AND CORRECTIVE MEASURES. WHEN THE ENGINE IS SHUT 27 54 200 I OIL PRESSURE DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING REMOTE CONTROL BOX
HOUR METER
+ 58 6
DOWN DUE TO A FAULT, THE IGNITION SWITCH WILL NEED TO BE
TURNED OFF THEN BACK ON TO RESTART THE ENGINE. WK G G
GAUGE
OUT OF FUEL), THE IGNITION SWITCH WILL NEED TO BE
LOWERLEFTOF 52A
CENTEROF OIL PRESSURE SWITCH / SENDER CONTROLPANEL
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
CONTROLPANEL 31 1 19 30 32 7 12
SWITCH CLOSES SENDER OPERATION: STARTER THE P10 PLUG IS ONLY ON UNITS
CONNECT TO AT 6+/-2 PSI 0 PSI -> 10+/-5 OHMS RELAY WITHOUT THE WIRE FEED MODULE.
CONNECT TO 40PSI -> 105+/-5 OHMS THE WIRE FEED MODULE HAS A
60F 60E GROUND FOR 70A70BGROUND FOR
1600RPM, LEAVE 80 PSI -> 187+/-5 OHMS WIRE-TIEDTOHARNESS HARNESS THAT PLUGS DIRECTLY
800RPM
UNCONNECTED 52B BEHINDCONTROLPANEL P10 INTO J5.
844A
FOR 1800RPM 55
BOTHOPENLEADSAREWIRE-TIEDINSIDETHEHARNESSBEHINDCONTROLPANEL 12 11 10 9 8 7 6 5 4 3 2 1 FLYBACK DIODE PREVENTS
841B VOLTAGE SPIKES IN SHUNT FIELD
J5 FROM DAMAGING LOCAL/REMOTE
400D 48
TOGGLE SWITCH WHEN SWITCHED
400E
GND-B JUMPER PLUG IS FOR CONNECTION
610
20A 20A 15A
+ 610A
+ 610
TO WIRE FEED MODULE
40.5 - 42.5 OHMS AT 25C
CB2 CB1 CB3 AC AC DIODE N U W Y JUMPERPLUGISWIRE-TIEDUP
IDLER SWITCH EXCITER REVOLVING LOWER, RIGHTSIDEOFCONTROLPANEL BEHINDLOCAL/ REMOTESWITCHON
11A FIELD (ROTOR)
SHOWN IN "AUTO 11
- 600C
-
600B RIGHTSIDEOFMACHINE(ASVIEWED
IDLE" POSITION 400F SLIP RINGS 21 600A FROMCONTROL PANEL)
4A 7A FUSE
POSITIVE SLIP RING
115 VOLT 15A
IS NEAREST TO IRON EXCITER CIRCUIT N U W Y
RECEPTACLE 215 RHEOSTAT
LOWER, LEAD 21A TO 21B CCW
GND-S RIGHTOF 64+/-6.4 OHMS MAX
CONTROL 214 602B
GND-E PANEL 42 41
602A
841 844 6A 810 115 VOLT CIRCUIT
J8 JUMPERPLUGIS
CB4 LEAD 810 TO 820 WIRE-TIEDUP
15A EXCITER STATOR WINDING SPEC: ALT-214-2C 6 4 5 3 1 2 BEHINDLOCAL /
820 (ALTERNATOR) .230 OHMS MAX AT 25C P9 REMOTESWITCH

GND-T IN-LINE BOLTED CONNECTION 41 ONRIGHTSIDEOF
BEHIND CONTROL PANEL 115 VOLT CIRCUIT 600
11C
602 42 G MACHINE
11B LEAD 820 TO 830
WITH AC AUXILIARY POWER, GENERATOR LEAD BLOCK WINDING SPEC: ALT-214-2D Y
LOCATEDBEHINDUPPERLEFT ROUTING DIRECTIONS OF THESE SHOWN AS VIEWED WITH .424 OHMS MAX AT 25C X
PORTIONOFCONTROLPANEL LEADS DOES NOT MATTER 2 TURNS ENGINE IN THIS DIRECTION W
REMOTE
SENSOR GROUNDS LEAD RECEPTACLE DIODE AND MOV ASSEMBLY
ON SENSE OF WELD OR CURRENT SENSING PC BOARD SERIES FIELD SHUNT
SELECTOR SWITCH LOCAL / REMOTE MOUNTEDTONEGATIVE
AUXILIARY LOAD SCHEMATIC S25973 - + FIELD SWITCH BRUSHHOLDER
4 90-MIN
DRIVER 130-80 - SHOWN IN LOCAL
3
CIRCUITS
+ FJW-5AP
POSITION
842 2 67B
12 VOLT SUPPLY 240-160 25.2 - 26.7 THE GENERATOR TO FLASH
1 220-MAX INTERPOLE OHMS EACH THE EXCITE THE ROTOR
COILS WHICH IN TURN PROVIDES
THE EXCITATION FOR THE
LIGHT CODE FAILURE DETECTED POSSIBLE CAUSE - CORRECTIVE MEASURE 3 TURNS GENERATOR
LONG 1, SHORT 1 RPM IS OVER 115% OF RATED RPM (2070 RPM) ACTUATOR IS STUCK - REMOVE ACTUATOR AND VERIFY PLUNGER PULLS IN WHEN ENERGIZED
LOW OIL - CHECK OIL LEVEL ON DIPSTICK
LONG 1, SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND FAULTY OIL PRESSURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS RUNNING BRUSH POSITION SHOWN AS WELDING
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED - CHECK
BROKEN OR LOOSE BELT - INSPECT
"L" TERMINAL IS GROUNDED ON ALTERNATOR 67A COMPONENT VALUE UNITS:
LONG 1, SHORT 3
FOR 1 SECOND
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE SHORTED TO GROUND - CHECK
FAULTY ALTERNATOR - CHECK
AMOUNT OR QUALITY OF COOLANT INCORRECT - CHECK
_ + CAPACITOR: MFD/VOLTS
LONG 1, SHORT 4
HIGH WATER TEMPERATURE DETECTED FOR 1
FAULTY WATER TEMPERATURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING NEGATIVE OUTPUT
RESISTOR: OHMS/WATTS
SECOND POSITIVE OUTPUT
LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED - CHECK TERMINAL TERMINAL
LONG 1, SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS TYPICAL OCV (WARM MACHINE): CONNECTOR PIN NUMBERS:
0 RPM IS DETECTED AND 12V IS DETECTED FAULTY RPM SENSOR - CHECK FOR GOOD CONNECTION 94-99.0 VOLTS AT MAX RHEOSTAT
LONG 2, SHORT 1 LEAD COLOR CODE: LABELS: EX. 12 PIN CONNECTOR
FROM "L" TERMINAL ON ALTERNATOR FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU 44-54.5 VOLTS AT MIN RHEOSTAT
FAULTY ACTUATOR - CHECK FOR PROPER COIL RESISTANCE B-BLACK OR GRAY 1 2 6
LONG 2, SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT UNDERLEFTDOOR
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK G-GREEN
COMMON
LONG 2, SHORT3 NOT ENABLED FOR LINCOLN PRODUCTS R-RED OR PINK

LONG 2, SHORT4 -50C WATER TEMPERATURE DETECTED
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE U-BLUE FRAME GROUND 7 12
LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN - CHECK FOR CONTINUITY W-WHITE
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE EARTH GROUND LATCH
LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED Y-YELLOW
LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK VIEW OF CONNECTOR ON PC BOARD
N-BROWN
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN - CHECK FOR CONTINUITY
0 VOLTS DETECTED FROM "L" TERMINAL ON
LONG 2, SHORT 6 BROKEN OR LOOSE BELT - INSPECT
ALTERNATOR FOR 1 SECOND
PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
UNLESS OTHERWISE SPECIFIED TOLERANCE
LONG 2, SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR
INCORRECT BATTERY - INSPECT
REFERENCE:
EQUIPMENT TYPE: CLASSIC 300D (KUBOTA V2203M) PAGE ___ 1
1 OF ___
ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: DM L12020 DOCUMENT DOCUMENT
LONG 2, SHORT 8
LESS THAN 4 VOLTS TO RPM SENSOR AND/OR
ACTUATOR SENSED BY ECU FAULTY ECU - CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: J.STAPP SCALE:
SUBJECT: MACHINE SCHEMATIC NUMBER: REVISION:
WITH PUBLISHED STANDARDS. MATERIAL
UF APPROVAL PROJECT
CRM35580 L12265 A
DO NOT SCALE THIS DRAWING APPROVED: NONE DISPOSITION: DATE: 06/08/2004 NUMBER:

SCHEMATIC - COMPLETE MACHINE - (CODES 11243, 11244) (L12265-1)
ENGINEERING CONTROLLED CHANGE DETAIL: New

L12265-1
94 20
12 VOLT SUPPLY 11
87 1
AMMETER SHOWS FULL
(OPTIONAL)
SPEED
69 13 G
104vF -> 1.14 kOHMS 212E
16 51B
-40 TO 40 AMPS Y
51 BACK, BOTTOM X
RATED VOLTAGE: 12V
SIDEOFENGINE
1 9 15 212D
SWITCH
51A
- 50 STARTER OFMACHINE
RATED CURRENT: 2A 10 17 SHOWN IN "OFF" + + 25+/-1.25 OHMS EACH
SOLENOID BATTERY W
18 25
2.8 +/- .28 OHMS AT 20vC
ENERGIZED FOR RUN
28 44 43 14-14.5 VOLTS
COLOR: RED OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED
AT 230v+/-6vF 62
LIGHT 61 9 194vF -> 51.2+/-4.3 OHMS

12 VOLT SENDER IS APPROX. WHEN THE IGNITION SWITCH IS "ON" AND THE ECU RHEOSTAT
NORMALLY OFF CENTEROF THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING THE ENGINE 212vF -> 38.5+/-3 OHMS 500 OHMS AT 70vF SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT
CODES AND CORRECTIVE MEASURES. WHEN THE ENGINE IS SHUT S I OIL PRESSURE DOWN DUE TO A FAULT (EVEN IF THAT CONDITION
27 54 200 DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING REMOTE CONTROL BOX
HOUR METER
+ 58 6
GAUGE
LOWERLEFTOF 52A
CONTROLPANEL 31 1 19 30 327 12
60F 60E GROUND FOR 70A 70B GROUND FOR
800RPM
844A
FOR 1800RPM 55
400D 48
400E
GND-B JUMPER PLUG IS FOR CONNECTION
610
20A 15A
+ 610A + 610
TO WIRE FEED MODULE
40.5 - 42.5 OHMS AT 25C
CB1 CB3 AC AC DIODE N U W Y JUMPERPLUGISWIRE-TIEDUP
IDLER SWITCH EXCITER REVOLVING LOWER, RIGHTSIDEOFCONTROLPANEL BEHINDLOCAL/ REMOTESWITCHON
11A FIELD (ROTOR)
SHOWN IN "AUTO - 600C
- 600B RIGHTSIDEOFMACHINE(ASVIEWED
IDLE" POSITION 400F SLIP RINGS 21 600A FROMCONTROL PANEL)
7A FUSE
POSITIVE SLIP RING
HOT LINE HOT LOAD IS NEAREST TO IRON 15A EXCITER CIRCUIT N U W Y
115 VOLT GFCI 215 RHEOSTAT
GND-S LOWER, LEAD 21A TO 21B CCW
RECEPTACLE 64+/-6.4 OHMS MAX
WHITE LINE WHITE LOAD RIGHTOF WINDING SPEC: ALT-214-2B
230 VOLT CONTROL 214 602B
GND-E PANEL 42 41
GND-T 602A
841 844 6A 810 115 VOLT CIRCUIT
J8 JUMPERPLUGIS
CB4 LEAD 810 TO 820 WIRE-TIEDUP
15A EXCITER STATOR WINDING SPEC: ALT-214-2C 6 4 5 3 1 2 BEHINDLOCAL /
(ALTERNATOR) P9
820 .230 OHMS MAX AT 25C REMOTESWITCH

IN-LINE BOLTED CONNECTION 41 ONRIGHTSIDEOF
11C
602 42 G MACHINE
11B LEAD 820 TO 830
REMOTE
4 90-MIN
3
CIRCUITS
+ FJW-5AP
POSITION
842 2 67B
1 3 TURNS 220-MAX INTERPOLE OHMS EACH THE EXCITE THE ROTOR
LIGHT CODE FAILURE DETECTED POSSIBLE CAUSE - CORRECTIVE MEASURE
GENERATOR
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED - CHECK VIEWED FROM CONTROL PANEL GENERATOR
LONG 1, SHORT 3
FOR 1 SECOND
LONG 1, SHORT 4
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK G-GREEN COMMON

N-BROWN
REFERENCE:
1 OF ___
ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: Maglietta L12265 DOCUMENT DOCUMENT
LONG 2, SHORT 8
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: N. TAYLOR SCALE:
NONE
MATERIAL
NA APPROVAL
03/11/2005
PROJECT
CRM34902 L12265-1 A
APPROVED:
DO NOT SCALE THIS DRAWING DISPOSITION: DATE: NUMBER:

SCHEMATIC - COMPLETE MACHINE - (CODES 11248, 11249, 11280, 11281) (L12561)
L12561 ENGINEERING CONTROLLED CHANGE DETAIL: ADDED "ON NEWER BOARDS..."

MANUFACTURER: No
CENTER OF CONTROL PANEL THIS LEAD PROVIDES FLASH BACK, LEFT SIDEOF ENGINE
IDLER / ENGINE PROTECTION PC BOARD
(OPTIONAL)
12 VOLT - NORMALLY OFF FOR ALTERNATOR AND 65 AMP / 12 VOLT AMMETER SHOWS FULL
SENSES ALTERNATOR OUTPUT DISCHARGE WHILE PRESSING
RED ENGINE LOCATED BEHIND UPPER PORTION OF CONTROL PANEL ALTERNATOR GLOW PLUG
PROTECTION 60C J1-4 SCHEMATIC G4828-1 SWITCH GLOW PLUG SWITCH
61 59
LIGHT ENGINE J1-3 D+
SHUTDOWN BACK, RIGHT SIDEOF ENGINE 53
N.C. B+
B3 55 WHITE IDLE SOLENOID REMOTE CONTROL PLUG
RIGHT SIDEOF ENGINE PULL COIL TYPICAL CURRENT DRAW AND 51C
G
BY INJECTION PUMP J1-8 57 RED RESISTANCE: -40 TO 40 AMPS
INJECTION GND-C 58 J1-9 FLYBACK BLACK HOLD COIL: 1A, 10-15 OHMS
PUMP DIODES 212E PULL COIL: 40A, LESS THAN .1 OHM 51
+ - GLOW PLUGS
Y
SOLENOID ENGINE
RUNNING J1-2 212C 56 51A TYPICAL CURRENT X
58H
APPROXIMATE 10A
RESISTANCE: 3.3 OHMS CB4 50A W 25+/-1.25 OHMS EACH
SWITCH
BYOIL FILLER J1-6 44 43 I START
TEMPERATURE CCW
W G G SWITCH 64+/-6.4 OHMS MAX
FUEL PUMP ENGINE GAUGE BACK, BOTTOM
+
BELOW FOR AT 230v+/-6vF 140vF -> 134+/-13.5 OHMS SOLENOID

TYPICAL CURRENT DRAW: 3A 194vF -> 51.2+/-4.3 OHMS BATTERY RHEOSTAT
LOGIC)
HOUR METER BACK, TOPOF ENGINE 500 OHMS AT 70vF REMOTE CONTROL BOX
S MOTOR AT REST
GAUGE
LOWER LEFT OF
J2-2 CONTROL PANEL
B4
400D
ENERGIZED.
+ 610A
20A 40.5 - 42.5 OHMS AT 25C
PRESSURE BUILDUP. ENGINE MUST BE CB1 CB3 AC AC DIODE N U W Y
STARTED WITHIN ONE MINUTE OF EXCITER REVOLVING LOWER, RIGHT SIDEOF CONTROL PANEL
11A FIELD (ROTOR)
- 600B
METER WILL TURN OFF. AFTER ONE 400F 115 VOLT GFCI 7A TOP, RIGHT PORTION
POSITIVE SLIP RING FUSE
MINUTE, THE IGNITION SWITCH MUST BE RECEPTACLE 15A OF CONTROL PANEL

IS NEAREST TO IRON 215 EXCITER CIRCUIT N U W Y
CYCLED OFF AND BACK ON TO START HOT LINE HOT LOAD
LOWER, CCW RHEOSTAT
LEAD 21A TO 21B
ENGINE. RIGHT OF 64+/-6.4 OHMS MAX
CONTROL 214 602B
3. AFTER ENGINE STARTS, FLASHING GND-E PANEL 42 41
CURRENT IS SUPPLIED TO THE ENGINE 602A
6A 810 115 VOLT CIRCUIT
ALTERNATOR. GND-T 15A J8
11C LEAD 810 TO 820
GND-S CB2 EXCITER STATOR WINDING SPEC: ALT-214-2C 6 4 5 3 1 2
LEAD 820 TO 830
MOUNTED TO NEGATIVE
RECEPTACLE
ENERGIZED. 90-MIN
+ FJW-5AP
POSITION
220-MAX
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS 3. IF AN AUXILIARY CURRENT DRAW OR WELD BACK OF OUTPUT STUD
WELDING
LOAD IS SENSED OR THE IDLER SWITCH IS CLOSED

BRUSH POSITION SHOWN AS

RESISTOR: OHMS/WATTS (HIGH), THE IDLE SOLENOID IS DE-ENERGIZED. REED SWITCH
SWITCH CLOSES
CONNECTOR PIN NUMBERS: WITH FLOW OF
EX. 12 PIN CONNECTOR LEAD COLOR CODE:
B-BLACK OR GRAY
LABELS: WELDING CURRENT
GND-A
_ +
1 2 6
G-GREEN NEGATIVE OUTPUT POSITIVE OUTPUT PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
R-RED OR PINK TERMINAL TERMINAL UNLESS OTHERWISE SPECIFIED TOLERANCE
U-BLUE FRAME GROUND TYPICAL OCV (WARM MACHINE):

REFERENCE:
1 OF ___
7 12 ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: DFM L12412 DOCUMENT DOCUMENT
W-WHITE 94-99.0 VOLTS AT MAX RHEOSTAT UNDER LEFT DOOR SUBJECT: MACHINE SCHEMATIC
Y-YELLOW 44-54.5 VOLTS AT MIN RHEOSTAT MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: N. TAYLOR SCALE:
NA
MATERIAL
UF APPROVAL PROJECT
CRM36948 L12561 B
DO NOT SCALE THIS DRAWING APPROVED:
DISPOSITION: DATE: 11/12/2004 NUMBER:

L13096 ENGINEERING CONTROLLED CHANGE DETAIL: New

MANUFACTURER: No
CENTER OF CONTROL PANEL
12 VOLT - NORMALLY OFF IDLER / ENGINE PROTECTION PC BOARD
THIS LEAD PROVIDES FLASH
FOR ALTERNATOR AND
BACK, LEFT SIDEOF ENGINE
65 AMP / 12 VOLT AMMETER SHOWS FULL
RED ENGINE
PROTECTION 60C 61 J1-4
LOCATED BEHIND UPPER PORTION OF CONTROL PANEL
SCHEMATIC G4828-1
J1-3
SENSES ALTERNATOR OUTPUT
59
ALTERNATOR
D+
GLOW PLUG
SWITCH
GLOW PLUG SWITCH (OPTIONAL)
LIGHT ENGINE
BACK, RIGHT SIDEOF ENGINE 53
N.C. SHUTDOWN B+
B3 55 WHITE IDLE SOLENOID
RIGHT SIDEOF ENGINE PULL COIL TYPICAL CURRENT DRAW AND 51C REMOTE CONTROL PLUG
BY INJECTION PUMP J1-8 57 RED RESISTANCE: -40 TO 40 AMPS G
INJECTION GND-C 58 J1-9 FLYBACK BLACK HOLD COIL: 1A, 10-15 OHMS
PUMP DIODES 212E PULL COIL: 40A, LESS THAN .1 OHM 51
+ - GLOW PLUGS
SOLENOID ENGINE Y
58H RUNNING J1-2 212C 56 51A TYPICAL CURRENT
APPROXIMATE 10A X
RESISTANCE: 3.3 OHMS CB4 50A
SWITCH W 25+/-1.25 OHMS EACH
BY OIL FILLER J1-6 44 43 I START
W G TEMPERATURE
FUEL PUMP G SWITCH CCW
ENGINE GAUGE BACK, BOTTOM 64+/-6.4 OHMS MAX
AT 230v+/-6vF 140vF -> 134+/-13.5 OHMS SOLENOID +
BELOW FOR BATTERY

TYPICAL CURRENT DRAW: 3A 194vF -> 51.2+/-4.3 OHMS

LOGIC)
RHEOSTAT
HOUR METER BACK, TOPOF ENGINE 500 OHMS AT 70vF
S MOTOR AT REST REMOTE CONTROL BOX
GAUGE
LOWER LEFT OF
J2-2 CONTROL PANEL
B4
400D
ENERGIZED.
+ 610A
20A CB2 40.5 - 42.5 OHMS AT 25C
PRESSURE BUILDUP. ENGINE MUST BE CB1 AC AC DIODE N U W Y
EXCITER REVOLVING
STARTED WITHIN ONE MINUTE OF LOWER, RIGHT SIDEOF CONTROL PANEL
11A 7A FIELD (ROTOR)
- 600B
METER WILL TURN OFF. AFTER ONE 400F 115 VOLT GFCI TOP, RIGHT PORTION
POSITIVE SLIP RING FUSE
RECEPTACLE 6A
MINUTE, THE IGNITION SWITCH MUST BE OF CONTROL PANEL
IS NEAREST TO IRON 15A

810 215 EXCITER CIRCUIT N U W Y

CYCLED OFF AND BACK ON TO START HOT LINE HOT LOAD
LOWER, CCW RHEOSTAT
LEAD 21A TO 21B
ENGINE. GND-E RIGHT OF 64+/-6.4 OHMS MAX
WINDING SPEC: ALT-214-2B
CONTROL 214 602B
230 VOLT .488 OHMS MAX AT 25C
3. AFTER ENGINE STARTS, FLASHING 6A PANEL 42 41
RECEPTACLE 602A
CURRENT IS SUPPLIED TO THE ENGINE 810
820 115 VOLT CIRCUIT
ALTERNATOR. GND-T J8
11C LEAD 810 TO 820
GND-S EXCITER STATOR WINDING SPEC: ALT-214-2C 6 4 5 3 1 2
LEAD 820 TO 830
MOUNTED TO NEGATIVE
RECEPTACLE
ENERGIZED. 90-MIN
+ FJW-5AP
POSITION
220-MAX
COMPONENT VALUE UNITS: 3. IF AN AUXILIARY CURRENT DRAW OR WELD BACK OF OUTPUT STUD
CAPACITOR: MFD/VOLTS LOAD IS SENSED OR THE IDLER SWITCH IS CLOSED BRUSH POSITION SHOWN AS WELDING
(HIGH), THE IDLE SOLENOID IS DE-ENERGIZED. REED SWITCH

RESISTOR: OHMS/WATTS SWITCH CLOSES
WITH FLOW OF
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR LEAD COLOR CODE: LABELS:
WELDING CURRENT
GND-A
_ +
1 2 6 B-BLACK OR GRAY NEGATIVE OUTPUT POSITIVE OUTPUT
G-GREEN TERMINAL TERMINAL
R-RED OR PINK UNLESS OTHERWISE SPECIFIED TOLERANCE
U-BLUE FRAME GROUND

TYPICAL OCV (WARM MACHINE): MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE:
1 OF ___
7 12 94-99.0 VOLTS AT MAX RHEOSTAT UNDER LEFT DOOR ON 2 PLACE DECIMALS IS ± .02
W-WHITE 44-54.5 VOLTS AT MIN RHEOSTAT SUBJECT: MACHINE SCHEMATIC
Y-YELLOW MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: D. BENDER SCALE:
WITH PUBLISHED STANDARDS. MATERIAL APPROVAL PROJECT L13096 A
VIEW OF CONNECTOR ON PC BOARD N-BROWN NA CRM37529
DO NOT SCALE THIS DRAWING APPROVED: NA DISPOSITION: DATE: 10/05/2006 NUMBER:

ENGINEERING CONTROLLED CHANGE DETAIL: REVISED 115 VOLT GFCI RECEPTACLE GRAPHICS
L13097
94 20
12 VOLT SUPPLY 11
87 1
AMMETER SHOWS FULL
(OPTIONAL)
SPEED
69 13 G
104vF -> 1.14 kOHMS 212E
16 51B
-40 TO 40 AMPS Y
51 BACK, BOTTOM X
RATED VOLTAGE: 12V
SIDEOFENGINE
1 9 15 212D
SWITCH
51A
- 50 STARTER OFMACHINE
RATED CURRENT: 2A 10 17 SHOWN IN "OFF" + SOLENOID
+ 25+/-1.25 OHMS EACH
BATTERY W
18 25
2.8 +/- .28 OHMS AT 20vC
ENERGIZED FOR RUN
28 44 43 14-14.5 VOLTS
COLOR: RED OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED

LIGHT 61 9 AT 230v+/-6vF 62
12 VOLT 194vF -> 51.2+/-4.3 OHMS SENDER IS APPROX. WHEN THE IGNITION SWITCH IS "ON" AND THE ECU
CENTEROF THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING THE ENGINE 212vF -> 38.5+/-3 OHMS 500 OHMS AT 70vF
RHEOSTAT
NORMALLY OFF SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT
S DOWN DUE TO A FAULT (EVEN IF THAT CONDITION
CODES AND CORRECTIVE MEASURES. WHEN THE ENGINE IS SHUT 27 54 200 I OIL PRESSURE DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING REMOTE CONTROL BOX
HOUR METER
+ 58 6
GAUGE
LOWERLEFTOF 52A
CONTROLPANEL 31 1 19 30 7 12
32
60F 60E GROUND FOR 70A 70BGROUND FOR
800RPM
844A
FOR 1800RPM 55
400D 48
400E
GND-B WINDING SPEC: ALT-241-3A JUMPER PLUG IS FOR CONNECTION
610
40.5 - 42.5 OHMS AT 25C + TO WIRE FEED MODULE
20A
CB1
15A
CB2
+ 610A 610 602B
EXCITER REVOLVING AC AC DIODE N U W Y JUMPERPLUGISWIRE-TIEDUP
IDLER SWITCH FIELD (ROTOR) LOWER, RIGHTSIDEOFCONTROLPANEL BEHINDLOCAL/ REMOTESWITCHON
400F 11A 7A
SHOWN IN "AUTO 400D - 600C
IDLE" POSITION SLIP RINGS 21 600A FROMCONTROL PANEL)
6A POSITIVE SLIP RING FUSE
810 15A EXCITER CIRCUIT RHEOSTAT N U W Y
HOT LINE HOT LOAD IS NEAREST TO IRON 215
115 VOLT GFCI LOWER, LEAD 21A TO 21B CCW 64+/-6.4 OHMS MAX
GND-E RIGHTOF
RECEPTACLE WINDING SPEC: ALT-214-2B 602B
230 VOLT CONTROL 214 .488 OHMS MAX AT 25C
6A RECEPTACLE PANEL 42 41
602A
841 844 GND-S 810 115 VOLT CIRCUIT
J8 JUMPERPLUGIS
GND-T
LEAD 810 TO 820 WIRE-TIEDUP
EXCITER STATOR WINDING SPEC: ALT-214-2C 6 4 5 3 1 2 BEHINDLOCAL /
820 820 (ALTERNATOR) .230 OHMS MAX AT 25C P9 REMOTESWITCH

IN-LINE BOLTED CONNECTION 41 ONRIGHTSIDEOF
11C
602 42 G MACHINE
11B LEAD 820 TO 830
REMOTE
4 90-MIN
3
CIRCUITS
+ FJW-5AP
POSITION
842 2 67B
1 220-MAX INTERPOLE OHMS EACH THE EXCITE THE ROTOR
3 TURNS GENERATOR
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED - CHECK
LONG 1, SHORT 3
FOR 1 SECOND
LONG 1, SHORT 4
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK G-GREEN COMMON

N-BROWN
REFERENCE:
1 OF ___
LONG 2, SHORT 8
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: D. BENDER SCALE:
WITH PUBLISHED STANDARDS. MATERIAL
UF APPROVAL PROJECT
CRM37535 L13097 B
DO NOT SCALE THIS DRAWING APPROVED: NONE DISPOSITION: DATE: 04/13/2007 NUMBER:


L13672
MANUFACTURER: No AMMETER SHOWS FULL
THIS LEAD PROVIDES FLASH BACK, LEFT SIDEOF ENGINE
CENTER OF CONTROL PANEL IDLER / ENGINE PROTECTION PC BOARD
LOCATED BEHIND UPPER PORTION OF CONTROL PANEL
FOR ALTERNATOR AND
SENSES ALTERNATOR OUTPUT 65 AMP / 12 VOLT
ALTERNATOR
GLOW PLUG
SWITCH
GLOW PLUG SWITCH
12 VOLT - NORMALLY OFF
(OPTIONAL)
ENGINE J1-3 59 D+
RED ENGINE 60C 61 J1-4 SCHEMATIC G4828-1 BACK, RIGHT SIDEOF ENGINE 53
PROTECTION N.C. SHUTDOWN B+
B3 55 WHITE IDLE SOLENOID
LIGHT PULL COIL 51C
TYPICAL CURRENT DRAW AND
GHT SIDEOF ENGINE J1-8 57 RED RESISTANCE: -40 TO 40 AMPS
YINJECTION PUMP GND-C 58 J1-9 FLYBACK BLACK HOLD COIL: 1A, 10-15 OHMS REMOTE CONTROL PLUG
INJECTION DIODES 212E PULL COIL: 40A, LESS THAN .1 OHM 51
+ - GLOW PLUGS G
ENGINE
PUMP
RUNNING J1-2 212C 56 51A TYPICAL CURRENT
SOLENOID 10A
J1-1 212D IGNITION DRAW IS 40 +/- 3 AMPS Y
APPROXIMATE CB4 50A
SWITCH
RESISTANCE: 3.3 OHMS LOWER LEFT OF X
TYPICAL CURRENT DRAW: 3.3A S POSITION 50
W 25+/-1.25 OHMS EACH
J1-6 44 43 I START
W G TEMPERATURE
G SWITCH
ENGINE GAUGE BACK, BOTTOM
PROTECTION LOW ER LEFT OF 52 OF MACHINE
SWITCH CLOSES SENDER OPERATION: 212B STARTER CCW
CIRCUITS (SEE +
140vF -> 134+/-13.5 OHMS CONTROL PANEL
64+/-6.4 OHMS MAX
BELOW FOR AT 230v+/-6vF SOLENOID
CENTER OF CONTROL PANEL 194vF -> 51.2+/-4.3 OHMS BATTERY
LOGIC)
HOUR METER BACK, TOPOF ENGINE 500 OHMS AT 70vF
MOTOR AT REST
S RHEOSTAT
J1-5 J1-7 54 200 I OIL PRESSURE 14-14.5 VOLTS

GAUGE WHILE RUNNING
UNUSED J2-1 WK G G REMOTE CONTROL BOX
LOWER LEFT OF
J2-2 CONTROL PANEL
B4
1. UPON RECIEVING POWER FROM THE MODULE HAS A HARNESS THAT PLUGS
IGNITION SWITCH, THE FUEL SOLENOID, 844 GND-B SHOWN IN "AUTO J1 BECOMES J31, J2 BECOMES J32, JUMPER PLUG IS FOR CONNECTION
FUEL PUMP AND HOUR METER ARE IDLE" POSITION B5 AND B6 TERMINALS ARE DELETED. J5 TO WIRE FEED MODULE
IDLER SWITCH 48
ENERGIZED. 400D
2. ENGINE PROTECTION IS BYPASSED DC EXCITER BEHIND LOCAL / REMOTE SWITCH ON
610 RIGHT SIDEOF MACHINE (ASVIEWED
FOR ONE MINUTE TO ALLOW OIL
15A
+ 610A
PRESSURE BUILDUP. ENGINE MUST BE 20A 40.5 - 42.5 OHMS AT 25C
CB2 N U W Y
STARTED WITHIN ONE MINUTE OF CB1 EXCITER REVOLVING AC AC DIODE
TURNING IGNITION SWITCH ON OR THE LOWER, RIGHT SIDEOF CONTROL PANEL
11A 7A FIELD (ROTOR)
FUEL SOLENOID, FUEL PUMP AND HOUR - 600C
- 600B
METER WILL TURN OFF. AFTER ONE SLIP RINGS 21 600A
400F 115 VOLT GFCI POSITIVE SLIP RING FUSE TOP, RIGHT PORTION
MINUTE, THE IGNITION SWITCH MUST BE 6A
RECEPTACLE IS NEAREST TO IRON 15A OF CONTROL PANEL
CYCLED OFF AND BACK ON TO START 810 EXCITER CIRCUIT N U W Y
215
ENGINE. LOWER, RHEOSTAT
HOT LINE HOT LOAD
LEAD 21A TO 21B CCW

GND-E RIGHT OF
WINDING SPEC: ALT-214-2B 64+/-6.4 OHMS MAX

3. AFTER ENGINE STARTS, FLASHING WHITE LINE WHITE LOAD
CONTROL 214 602B
230 VOLT .488 OHMS MAX AT 25C
CURRENT IS SUPPLIED TO THE ENGINE 6A RECEPTACLE PANEL 42 41
ALTERNATOR. 602A
820 810 115 VOLT CIRCUIT
GND-T J8
11C LEAD 810 TO 820
4. AFTER ONE MINUTE, TIMER IS TIMED GND-S EXCITER STATOR WINDING SPEC: ALT-214-2C 6 4 5 3 1 2
OUT. IF OIL PRESSURE IS LOW, 820 (ALTERNATOR) .230 OHMS MAX AT 25C P9
COOLANT TEMPERATURE IS HIGH OR JUMPER PLUG IS
IN-LINE BOLTED CONNECTION 41 600 WIRE-TIED UPBEHIND
ALTERNATOR IS NOT CHARGING, THE BEHIND CONTROL PANEL 115 VOLT CIRCUIT
602 42 G LOCAL / REMOTE
ENGINE WILL SHUT DOWN AND THE 11B LEAD 820 TO 830
GENERATOR LEAD BLOCK Y SWITCH ON RIGHT
ENGINE PROTECTION LIGHT WILL COME SHOWN AS VIEWED WITH WINDING SPEC: ALT-214-2D
ON. 844A TOP, LEFT PORTION ENGINE IN THIS DIRECTION .424 OHMS MAX AT 25C X W SIDEOF MACHINE
MOUNTED TO NEGATIVE
RECEPTACLE
ENERGIZED. 90-MIN
+ FJW-5AP
POSITION
220-MAX
COMPONENT VALUE UNITS: 3. IF AN AUXILIARY CURRENT DRAW OR WELD BACK OF OUTPUT STUD
CAPACITOR: MFD/VOLTS LOAD IS SENSED OR THE IDLER SWITCH IS CLOSED BRUSH POSITION SHOWN AS WELDING
(HIGH), THE IDLE SOLENOID IS DE-ENERGIZED. REED SWITCH VIEWED FROM CONTROL PANEL GENERATOR
SWITCH CLOSES
WITH FLOW OF
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR LEAD COLOR CODE: LABELS:
WELDING CURRENT
GND-A
_ +
1 2 6 B-BLACK OR GRAY NEGATIVE OUTPUT POSITIVE OUTPUT
G-GREEN TERMINAL TERMINAL
R-RED OR PINK TYPICAL OCV (WARM MACHINE):
MANUFACTURING TOLERANCE PER E2056 CONTROL:
CLEVELAND SCALE:
U-BLUE
UNLESS OTHERWISE SPECIFIED TOLERANCE: EQUIPMENT TYPE: CLASSIC 300D (PERKINS 1
1 OF ___
PAGE ___
7 12 FRAME GROUND 94-99.0 VOLTS AT MAX RHEOSTAT UNDER LEFT DOOR ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: C. Kocsis
W-WHITE 44-54.5 VOLTS AT MIN RHEOSTAT
IF PRINTED
SUBJECT: MACHINE SCHEMATIC
DOCUMENT DOCUMENT
LATCH EARTH GROUND ON ALL ANGLES IS ± .5 OF A DEGREE @ A2 SIZE NUMBER: REVISION:
Y-YELLOW MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: D. BENDER
-
UNITS: MATERIAL
NA
APPROVAL
1/11/2008
PROJECT
CRM37573
REFERENCE:
L13672 A
APPROVED: INCH
DO NOT SCALE THIS DRAWING DISPOSITION: DATE: NUMBER: L13096


L13351
JUMPERPLUGISBEHINDLOWER
MANUFACTURER: No
RIGHTSIDEOFCONTROL PANEL LOWERRIGHTOFCONTROL PANEL
AMMETER SHOWS FULL
12 VOLT SUPPLY 11 87 1 GLOW PLUG DISCHARGE WHILE PRESSING
(OPTIONAL)
94 20 10,000 +/- 1,000 OHMS MAX GLOW PLUG SWITCH
ENGINE BUTTON
SPEED
BACK, RIGHT LOCATEDBEHINDUPPERPORTIONOFCONTROL PANEL 3 88 3
LEAKAGE CURRENT 10micro A (MAX.)-TERMINAL #16 40 AMP / 12 VOLT REMOTE CONTROL PLUG
26 64 L
69 13 G
104vF -> 1.14 kOHMS 212E Y
212vF -> .16 kOHMS SENSOR -40 TO 40 AMPS
60 16 51B
BACK, LEFT IGNITION AMMETER X
51 BACK, BOTTOM
SIDEOFENGINE SWITCH -
RATED VOLTAGE: 12V
RATED CURRENT: 2A
1
10
9
17
15 212D
SHOWN IN "OFF"
51A
+
50 STARTER
SOLENOID
+ OFMACHINE W 25+/-1.25 OHMS EACH
POSITION BATTERY
COIL RESISTENCE: BACK, RIGHT 57 34 18 25
2.8 +/- .28 OHMS AT 20vC SIDEOFENGINE 12 VOLT FRONT, RIGHTSIDE BACK, LEFTSIDE 212A STARTER 12.6 VOLTS MIN
26 34
ENERGIZED FOR RUN SUPPLY OFENGINE OFENGINE MOTOR AT REST
DE-ENERGIZED FOR STOP ACTUATOR S I
28 44 43 50A 14-14.5 VOLTS
ACTUATOR CONTROLS RPM TEMPERATURE
CCW
DOWN THE ENGINE AT 115% G WHILE RUNNING 64+/-6.4 OHMS MAX
56 18 GAUGE START
OF RATED SPEED. TEMPERATURE TEMPERATURE
LOWERLEFTOF BUTTON
ENGINE ECU CONNECTOR DETAIL SWITCH SENSOR
212B CONTROL PANEL RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY
PROTECTION SWITCH CLOSES SENDER OPERATION:
COLOR: RED LIGHT AT 110v+/-3vC 90vC -> 51.2+/-4.3 OHMS 62 OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED
61 9
RHEOSTAT
12 VOLT WHEN THE IGNITION SWITCH IS "ON" AND THE ECU

NORMALLY OFF CENTEROF THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING THE
SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT
CONTROL PANEL 841A ENGINE PROTECTION LIGHT IN A CODED SEQUENCE, SEE CHART FRONT, LEFTSIDEOFENGINE 212C
S DOWN DUE TO A FAULT (EVEN IF THAT CONDITION REMOTE CONTROL BOX
FOR FAULT CODES AND CORRECTIVE MEASURES. WHEN THE
27 54 200 I OIL PRESSURE DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING
HOUR METER
+ 58 6
ENGINE IS SHUT DOWN DUE TO A FAULT, THE IGNITION
WK G G
GAUGE
SWITCH WILL NEED TO BE TURNED OFF THEN BACK ON LOWERLEFTOF 52A
CENTEROF TO RESTART THE ENGINE.
OIL PRESSURE SWITCH / SENDER CONTROL PANEL
CONTROL PANEL 31 1 19 30 32 7 12
CONNECT TO 40PSI -> 105+/-5 OHMS
60F 60E GROUND FOR 70A 70BGROUND FOR THE WIRE FEED MODULE HAS A
800RPM
UNCONNECTED 52B BEHINDCONTROL PANEL P10 INTO J5.
844A
FOR 1800RPM 55
BOTHOPENLEADSAREWIRE-TIEDINSIDETHEHARNESSBEHINDCONTROL PANEL 12 11 10 9 8 7 6 5 4 3 2 1 FLYBACK DIODE PREVENTS
400D 48
400E
GND-B WINDING SPEC: ALT-241-3A JUMPER PLUG IS FOR CONNECTION
610
40.5 - 42.5 OHMS AT 25C TO WIRE FEED MODULE
20A 15A + 610A + 610 602B
CB1 CB2 N U W Y
EXCITER REVOLVING AC AC DIODE JUMPERPLUGISWIRE-TIEDUP
IDLER SWITCH FIELD (ROTOR) LOWER, RIGHTSIDEOFCONTROL PANEL BEHINDLOCAL/ REMOTESWITCHON
400F 11A 7A
SHOWN IN "AUTO 400D - 600C
IDLE" POSITION SLIP RINGS 21 600A FROMCONTROLPANEL)
6A POSITIVE SLIP RING FUSE
810 15A EXCITER CIRCUIT RHEOSTAT N U W Y
HOT LINE HOT LOAD IS NEAREST TO IRON 215
115 VOLT GFCI LOWER, LEAD 21A TO 21B CCW 64+/-6.4 OHMS MAX
GND-E RIGHTOF
RECEPTACLE WINDING SPEC: ALT-214-2B 602B
230 VOLT CONTROL 214 .488 OHMS MAX AT 25C
6A RECEPTACLE PANEL 42 41
602A
841 844 GND-S 810 115 VOLT CIRCUIT
J8 JUMPERPLUGIS
GND-T
LEAD 810 TO 820 WIRE-TIEDUP
EXCITER STATOR 6 4 5 3 1 2
WINDING SPEC: ALT-214-2C BEHINDLOCAL/

820 820 (ALTERNATOR) .230 OHMS MAX AT 25C P9 REMOTESWITCH
IN-LINE BOLTED CONNECTION 41 600 ONRIGHTSIDEOF
11C BEHIND CONTROL PANEL 115 VOLT CIRCUIT G MACHINE
11B LEAD 820 TO 830 602 42
LOCATEDBEHINDUPPERLEFTROUTING DIRECTIONS OF THESE SHOWN AS VIEWED WITH .424 OHMS MAX AT 25C X
PORTIONOFCONTROL PANELLEADS DOES NOT MATTER 2 TURNS ENGINE IN THIS DIRECTION W DIODE AND MOV ASSEMBLY
REMOTE
SENSOR GROUNDS LEAD RECEPTACLE MOUNTEDTONEGATIVE
ON SENSE OF WELD OR CURRENT SENSING PC BOARD SERIES FIELD SHUNT BRUSHHOLDER
SELECTOR SWITCH LOCAL / REMOTE
AUXILIARY LOAD SCHEMATIC S25973 - + FIELD SWITCH THIS CIRCUIT USES THE
4 90-MIN
130-80 SHOWN IN LOCAL RESIDUAL MAGNETISM OF
3 DRIVER
CIRCUITS
+ - FJW-5AP
POSITION THE GENERATOR TO FLASH
190-120 COIL PAIR: THE EXCITE THE ROTOR
842 2 67B
12 VOLT SUPPLY 240-160 25.2 - 26.7 WHICH IN TURN PROVIDES
1 220-MAX INTERPOLE OHMS EACH THE EXCITATION FOR THE
COILS GENERATOR
LONG 1, SHORT 1 RPM IS OVER 115% OF RATED RPM (2070 RPM) ACTUATOR IS STUCK - REMOVE ACTUATOR AND VERIFY PLUNGER PULLS IN WHEN ENERGIZED 3 TURNS
LONG 1, SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND FAULTY OIL PRESSURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS RUNNING COMPONENT VALUE UNITS:
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED - CHECK BRUSH POSITION SHOWN AS WELDING
"L" TERMINAL IS GROUNDED ON ALTERNATOR
BROKEN OR LOOSE BELT - INSPECT VIEWED FROM CONTROL PANEL GENERATOR CAPACITOR: MFD/VOLTS
LONG 1, SHORT 3 LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE SHORTED TO GROUND - CHECK
FOR 1 SECOND
FAULTY ALTERNATOR - CHECK 67A RESISTOR: OHMS/WATTS
LONG 1, SHORT 4
SECOND
FAULTY WATER TEMPERATURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING
_ + CONNECTOR PIN NUMBERS:
LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED - CHECK
NEGATIVE OUTPUT POSITIVE OUTPUT LEAD COLOR CODE: LABELS: EX. 12 PIN CONNECTOR
LONG 1, SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS
TERMINAL TERMINAL
LONG 2, SHORT 1
0 RPM IS DETECTED AND 12V IS DETECTED FAULTY RPM SENSOR - CHECK FOR GOOD CONNECTION B-BLACK OR GRAY 1 2 6
FROM "L" TERMINAL ON ALTERNATOR FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU TYPICAL OCV (WARM MACHINE):
94-99.0 VOLTS AT MAX RHEOSTAT G-GREEN COMMON
FAULTY ACTUATOR - CHECK FOR PROPER COIL RESISTANCE
R-RED OR PINK
LONG 2, SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT 44-54.5 VOLTS AT MIN RHEOSTAT
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK

U-BLUE FRAME GROUND
LONG 2, SHORT3 NOT ENABLED FOR LINCOLN PRODUCTS UNDERLEFTDOOR 7 12
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE W-WHITE
LONG 2, SHORT4 -50C WATER TEMPERATURE DETECTED EARTH GROUND LATCH
LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN - CHECK FOR CONTINUITY Y-YELLOW
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE N-BROWN VIEW OF CONNECTOR ON PC BOARD
LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED
LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK

LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN - CHECK FOR CONTINUITY PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
ALTERNATOR FOR 1 SECOND MANUFACTURING TOLERANCE PER E2056 CONTROL:
FAULTY ALTERNATOR - CHECK CLEVELAND SCALE:
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE
EQUIPMENT TYPE: CLASSIC 300D KUBOTA PAGE ___ 1
1 OF ___
LONG 2, SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: Maglietta
FAULTY ALTERNATOR - CHECK IF PRINTED DOCUMENT DOCUMENT
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: D. BENDER
@ A2 SIZE SUBJECT: MACHINE SCHEMATIC NUMBER: REVISION:
LONG 2, SHORT 8
ACTUATOR SENSED BY ECU FAULTY ECU - CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU WITH PUBLISHED STANDARDS. UNITS: MATERIAL
NA
APPROVAL PROJECT REFERENCE:
L13351 A
DO NOT SCALE THIS DRAWING APPROVED: - INCH DISPOSITION: DATE: 11/16/2007 NUMBER: CRM37569 L13097

WIRING DIAGRAM - WIRE FEED MODULE OPTION - (L9259)
WIRE FEED MODULE - WIRING DIAGRAM

ELECTRICAL SYMBOLS PER E1537 LEAD COLOR CODE
FLASHING 1 Y CONTROL BOARD
B-BLACK R-RED
MOLEX CONNECTORS LEADS
G-GREEN U-BLUE 2 W 218 1
J1 J2 J3 J4 N-BROWN W-WHITE
1 1 5 1 4 1 3 Y-YELLOW 3 503 219 2
SHUNT P1 J1
CONNECTOR CAVITY NUMBERING TO 4 602
FIELD
SEQUENCE VIEWED FROM RHEOSTAT
10 8 4 6 5 509 634 1
2 6 5 COMPONENT SIDE OF BOARD.
CONNECTS TO + 6 610 667 2
ENGINE WELDER 115V
N.A. LEADS 31, 32 AND 602 DO NOT GO INSIDE WIRE FEED MODULE BOX. DC 7 2 3
RECEPTACLE J5
N.B. COMPONENTS VIEWED FROM REAR
- 8 600 4 4
9 621 5
1 2 3 4
10 GND 633 6
5 6 7 8
115V 11 31 75A 7
9 10 11 12
AC
12 32 76 8
P5 P5
N.A. 77 9
CONNECTOR CAVITY NUMBERING
SEQUENCE VIEWED FROM GND 1 GND 75 10
LEAD SIDE OF CONNECTOR P2 J2
CC/CV SWITCH S1 31 2 31
510 602
SHOWN IN CV MODE 32 501 1
32 3
CV CONTROL
609 4 609 509 2
77A R501 75 610A
10K 503A 610A 5 610A 503A 3
510 6 510 631 4
76A
501 7 501 630 5
609 501 503A 8 503A 503 6

P4 J4
602 9 602
REMOTE CONNECTOR J6 P6
W 1
J 31
115 VAC 75 610A 2
A 32 75 1
76 Y 3
GROUND B GND 76 2
C 2A 77 600 4
CONTACTOR 77 3
4A 608 5
D
2 4 2
E 77B 610 6
4 5 4
REMOTE F 76B
75A 7
G 75A 75A 6
P7 J7 510 8
AMPHENOL 1
77 P3 J3
4A 2
2A 76B
4
77B
POS
218 219
76 NEG
LOCAL/REMOTE SWITCH S2 - +
SHOWN IN LOCAL MODE 621 667
300 AMP
SHUNT
77A 76A
633
WELDER 608 609
CR4
666
634
+ + +
250
R502
CC + CC - TO NEG CV - 25W
BRUSH HOLDER CONTACTOR C501 C502 C503 CR3
622 630 631
CONTACTOR
30000 MFD
EACH
75 VOLT
A
L9259

SCHEMATIC - WIRE FEED MODULE OPTION - (G2562)

SCHEMATIC - IDLER (CODES 10545, 10546, 10657, 10658, 10911, 10927) - (L10826)

SCHEMATIC - IDLER (CODES 11110 THRU 11475 PERKINS ENGINE ONLY) - (G4828)

SCHEMATIC - CURRENT SENSOR PC BD (KUBOTA ENGINE ONLY) - (S25973)

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SVM194-A

CLASSIC® 300 D & 300 G

Safety Depends on You

Lincoln arc welding and cutting

equipment is designed and built

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

1.h. To avoid scalding, do not remove the

wipe it up and do not start engine until fumes

2.d.4. Connect the work cable to the workpiece as close as

CLASSIC® 300D & 300G

ELECTRIC SHOCK can kill. ARC RAYS can burn.

FUMES AND GASES

your head out of the fume. Use enough

electrode holders connected to two welders because voltage

5.e. Read and understand the manufacturerʼs instructions for this

5.f. Also see item 1.b.

CLASSIC® 300D & 300G

WELDING and CUTTING CYLINDER may explode

explosion. 7.a. Use only compressed gas cylinders

area as practical. Work cables connected to the building the equipment.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

CLASSIC® 300D & 300G

PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de

Pour votre propre protection lire et observer toutes les instructions

PRÉCAUTIONS DE SÛRETÉ POUR

enrouler le câble-électrode autour de nʼimporte quelle partie du

talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

CLASSIC® 300D & 300G

Electromagnetic Compatibility (EMC)

Installation and Use

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

f) equipment used for calibration or measurement

CLASSIC® 300D & 300G

Electromagnetic Compatibility (EMC)

Methods of Reducing Emissions

Maintenance of the Welding Equipment

Earthing of the Workpiece

Screening and Shielding

CLASSIC® 300D & 300G

RETURN TO MAIN MENU

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Aʼs

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Bʼs

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Cʼs

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Dʼs

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-337, P-379, P-498, P-507

CLASSIC® 300D & 300G

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.2

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.3

Pre-Operation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.4

Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5

Polarity Control & Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5

Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6

Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6

CLASSIC® 300D & 300G

TECHNICAL SPECIFICATIONS - CLASSIC® 300D