Professional Documents
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Hobart Welding Class 3oo
Hobart Welding Class 3oo
CLASSIC 300 D
®
May, 2006
For Machines with Code Numbers 10545, 10546, 10657, 10658, 10911 and 10927
OPERATOR’S MANUAL
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, 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 before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
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.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
3.f. Maintain the electrode holder, work clamp, welding cable and 5.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace coming from degreasing, cleaning or spraying operations.
damaged insulation. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
3.g. Never dip the electrode in water for cooling. products.
3.h. Never simultaneously touch electrically “hot” parts of 5.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage especially in confined areas, to insure breathing air is safe.
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
3.i. When working above floor level, use a safety belt to protect equipment and the consumables to be used, including the
yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
3.j. Also see Items 6.c. and 8. your welding distributor or from the manufacturer.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact • A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
iv iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
Pour votre propre protection lire et observer toutes les instructions zones où l’on pique le laitier.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv- 6. Eloigner les matériaux inflammables ou les recouvrir afin de
antes: prévenir tout risque d’incendie dû aux étincelles.
Sûreté Pour Soudage A L’Arc 7. Quand on ne soude pas, poser la pince à une endroit isolé de
1. Protegez-vous contre la secousse électrique: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours 8. S’assurer que la masse est connectée le plus prés possible
tout contact entre les parties sous tension et la peau nue de la zone de travail qu’il est pratique de le faire. Si on place
ou les vétements mouillés. Porter des gants secs et sans la masse sur la charpente de la construction ou d’autres
trous pour isoler les mains. endroits éloignés de la zone de travail, on augmente le risque
b. Faire trés attention de bien s’isoler de la masse quand on de voir passer le courant de soudage par les chaines de lev-
soude dans des endroits humides, ou sur un plancher age, câbles de grue, ou autres circuits. Cela peut provoquer
metallique ou des grilles metalliques, principalement dans des risques d’incendie ou d’echauffement des chaines et des
les positions assis ou couché pour lesquelles une grande câbles jusqu’à ce qu’ils se rompent.
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble 9. Assurer une ventilation suffisante dans la zone de soudage.
de soudage et la machine à souder en bon et sûr état Ceci est particuliérement important pour le soudage de tôles
defonctionnement. galvanisées plombées, ou cadmiées ou tout autre métal qui
d.Ne jamais plonger le porte-électrode dans l’eau pour le produit des fumeés toxiques.
refroidir.
e. Ne jamais toucher simultanément les parties sous tension 10. Ne pas souder en présence de vapeurs de chlore provenant
des porte-électrodes connectés à deux machines à souder d’opérations de dégraissage, nettoyage ou pistolage. La
parce que la tension entre les deux pinces peut être le chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
total de la tension à vide des deux machines. du solvant pour produire du phosgéne (gas fortement toxique)
f. Si on utilise la machine à souder comme une source de ou autres produits irritants.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de 11. Pour obtenir de plus amples renseignements sur la sûreté,
soudage. voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
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
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, LES MACHINES À SOUDER À
donc:
TRANSFORMATEUR ET À
a. Utiliser un bon masque avec un verre filtrant approprié REDRESSEUR
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc. 1. Relier à la terre le chassis du poste conformement au code de
b. Porter des vêtements convenables afin de protéger la l’électricité et aux recommendations du fabricant. Le dispositif
peau de soudeur et des aides contre le rayonnement de de montage ou la piece à souder doit être branché à une
l‘arc. bonne mise à la terre.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables. 2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres 3. Avant de faires des travaux à l’interieur de poste, la debranch-
de l’huile, tels que les gants en cuir, chemise épaisse, pan- er à l’interrupteur à la boite de fusibles.
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
v v
Thank You to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi TABLE OF CONTENTS vi
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
General Description ...............................................................................................A-2
Design Features ....................................................................................................A-2
Pre-Operation Installation ......................................................................................A-3
Safety Precautions ..........................................................................................A-3
Exhaust Spark Arrester ...................................................................................A-3
Location/Ventilation.........................................................................................A-3
Machine Grounding.........................................................................................A-3
Lift Bail ............................................................................................................A-3
Trailers ............................................................................................................A-4
Polarity Control and Cable Sizes ....................................................................A-4
Pre-Operation Service ...........................................................................................A-4
Oil....................................................................................................................A-4
Fuel .................................................................................................................A-4
Cooling System ...............................................................................................A-4
Engine Break-in, Battery Charging..................................................................A-5
________________________________________________________________________
Operation .........................................................................................................Section B
Engine Operation...................................................................................................B-1
Starting The Perkins 104-22 Engine ...............................................................B-1
Stopping the engine ........................................................................................B-1
Welder Operation...................................................................................................B-2
Duty Cycle.......................................................................................................B-2
Control of Welding Current..............................................................................B-2
Idler Operation ................................................................................................B-2
Auxiliary Power ...............................................................................................B-3
________________________________________________________________________
Accessories .....................................................................................................Section C
Optional Features (Field Installed) ........................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
General Instructions ..............................................................................................D-1
Cooling System .....................................................................................................D-1
Bearings ................................................................................................................D-1
Commutator and Brushes .....................................................................................D-1
Idler Maintenance..................................................................................................D-2
Nameplates ...........................................................................................................D-2
Purging Air from Fuel System................................................................................D-2
Engine Service Chart ....................................................................................D-3, D-4
GFCI Receptacle Testing and Reseting Procedure (Optional)..............................D-5
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
Welder Troubleshooting ........................................................................................E-2
Electronic Idler Troubleshooting Guide...........................................................E-3,E-4
Engine Troubleshooting Guide .....................................................................E-5, E-6
________________________________________________________________________
Diagrams ..........................................................................................................Section F
Wiring Diagram (Classic 300 D) ......................................................................F-1,F-2
Connection Diagram ..............................................................................................F-3
Dimension Print......................................................................................................F-4
________________________________________________________________________
Parts List ......................................................................................................P337 Series
A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS - CLASSIC 300D
INPUT - DIESEL ENGINE
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
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
High Idle (1800 RPM)-No Load @ 96.6 Volts 0.45 gal/hr ( 1.70 ltrs/hr)
CLASSIC 300D
A-2 INSTALLATION A-2
GENERAL DESCRIPTION
DESIGN FEATURES
The Classic® 300 D is a heavy duty, engine driven,
Control Panel
DC arc welding power source, capable of providing
constant current output for stick welding or DC TIG Both the engine and the welder controls are located
welding. This welder is wound with all copper coils, on one recessed panel at the exciter end of the
rated at 300 amps/32 Volts, and provides other machine. The welder controls consist of a five step
Classic features such as improved door latches and “Current Range Selector” switch and a “Fine Current
stainless hinges. With the addition of the optional Adjustment” rheostat. The welder is equipped with a
K623-1 Wire Feed Module™, the Classic 300 D will “Start” button, an “Ignition” switch, an “Idler” control
provide constant voltage output for running the LN-7, switch, and a “Glow Plug” button for easier cold
LN-23P, or LN-25 wire feeders. (The Wire Feed weather starting.
Module is factory installed on the K1643-2). The
The control panel also contains an engine tempera-
optional K924-4 or K924-5 Remote Control Kit (Both
ture gauge, a battery charging ammeter, an oil pres-
field installed) See Section C for description.
sure gauge, two three prong grounding type recepta-
cles and four circuit breakers for auxiliary power.
The Classic 300 D has Diesel Engine Protection. In
the event of sudden low oil pressure or high coolant All Copper Windings - For long life and dependable
temperature, the engine immediately shuts down. operation.
The Classic 300 D has a current range of 40-350 DC
amps with output ratings as follows: Engine Idler - The Classic 300 D is equipped with an
electronic automatic engine idler. It automatically
increases and decreases engine speed when start-
ing and stopping welding or using auxiliary
RATED OUTPUT DUTY CYCLE power. A built-in time delay permits changing elec-
trodes before the engine slows to its low idle speed.
250A @ 30V 100% The “Idler” control switch on the panel locks the idler
300A @ 32V 60% in high idle position when desired.
CLASSIC 300D
A-3 INSTALLATION A-3
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 manufacturer’s 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
starting, operating and maintenance instructions, .06”(1.6mm) thick, which shall extend not more than
and parts lists. 5.90”(150mm) beyond the equipment on all side.s.
------------------------------------------------------------------------ ----------------------------------------------------------------------
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
------------------------------------------------------------------------ connected with a #8 or larger copper wire to a solid
See additional warning information at the earth ground such as a metal water pipe going into
front of this operator’s manual. the ground for at least ten feet and having no insulat-
----------------------------------------------------------- ed 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
Exhaust Spark Arrester
grounding 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.
qualify as a spark arrester. When required by local
regulations, a suitable spark arrester must be installed WARNING
and properly maintained.
• 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 when lifting.
• Do not lift this machine using
for specific recommendations. lift bale if it is equipped with a
------------------------------------------------------------------------ heavy accessory such as trail-
Location / Ventilation er or gas cylinder.
FALLING • Do not lift machine if lift bale is
Always operate the welder with the doors closed. damaged.
Leaving the doors open changes the designed air flow
EQUIPMENT can • Do not operate machine while
and may cause overheating.
cause injury. suspended from 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.
CLASSIC 300D
A-4 INSTALLATION A-4
TRAILER (See Optional Features) RECOMMENDED COPPER CABLE SIZES
Cables Sizes for Combined Length
If the user adapts a non-Lincoln trailer, he must 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 • Stop engine while fueling.
operated or serviced. • Do not smoke when fueling.
• Keep sparks and flame away
4. Typical conditions of use, i.e., travel speed, rough- from tank.
ness of surface on which the trailer will be operated;
• Do not leave unattended while
environmental conditions, likely maintenance.
fueling.
DIESEL FUEL • Wipe up spilled fuel and allow
5. Conformance with federal, state and local laws. (1) can cause fire.
(1) Consult your federal, state and local laws regarding specific
fumes to clear before starting
requirements for use on public highways. engine.
• Do not overfill tank, fuel
VEHICLE MOUNTING expansion may cause over-
flow.
Improperly mounted concentrated loads may cause DIESEL FUEL ONLY
unstable vehicle handling and tires or other compo- ------------------------------------------------------------------------
nents to fail. Oil
• Only transport this equipment on serviceable vehi-
cles which are rated and designed for such loads. This unit is supplied from the factory with the engine
• Distribute, balance and secure loads so vehicle is
crankcase filled with a high quality SAE 10W/30 oil.
stable under conditions of use.
This oil should be acceptable for most typical ambient
• Do not exceed maximum rated loads for compo-
temperatures. Consult the engine operation manual
nents such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of for specific engine manufacturer’s recommendations.
vehicle. Upon receipt of the welder, check the engine dipstick
• Follow vehicle manufacturer’s instruction. 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 the Engine Operator’s manual. Make sure the fuel
With the engine off, route the electrode and work valves on the sediment bowl and the water separator
cables through the strain relief bracket on the base are in the open positions.
and connect to the studs located below the fuel tank
mounting rail. (See size recommendations below.)
For positive polarity, connect the electrode cable to
Cooling System
the terminal marked “+”. For Negative polarity, con-
nect the electrode cable to the “-” stud. These con-
The radiator has been filled at the factory with a 50-50
nections should be checked periodically and tightened
mixture of ethylene glycol antifreeze and water.
if necessary.
Check the radiator level and add a 50-50 solution as
needed (see engine manual or antifreeze container for
When welding at a considerable distance from the
alternate antifreeze recommendations).
welder, be sure you use ample sized welding cables.
CLASSIC 300D
A-5 INSTALLATION A-5
2. Set the welder controls for an output cur- To prevent BATTERY DISCHARGE, if you have an
rent and voltage within the welder rating ignition switch, turn it off when engine is not
and duty cycle. Note that any attempt to running.
exceed the welder rating or duty cycle for
any period of time will result in catastrophic • To prevent BATTERY BUCKLING, tighten nuts on
damage to the generator and voids the battery clamp until snug.
------------------------------------------------------------------------
warranty.
The Classic 300 D is equipped with a wet charged
3. Periodically shut off the engine and check
battery. The charging current is automatically regulat-
the crankcase oil level.
ed when the battery is low (after starting the engine)
to a trickle current when the battery is fully charged.
CLASSIC 300D
B-1 OPERATION B-1
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 manufacturer’s 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:
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• 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
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or longer glow plug operation.
vent exhaust outside.
WARNING
------------------------------------------------------------------------
MOVING PARTS can injure. Under NO conditions should ether or other
• Do not operate with doors open or starting 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 operator’s manual.
At the end of each day’s 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 tank to minimize moisture condensation in the tank.
the doors open changes the designed air flow and can Also, running out of fuel tends to draw dirt into the fuel
cause overheating. system.
CLASSIC 300D
B-2 OPERATION B-2
WELDER OPERATION Range Selector” to the 190-120 position and then
adjust the “Fine Current Adjustment” for 175 amps.
WARNING When a forceful “digging” arc is required, usually for
vertical and overhead welding, use a higher “Current
ELECTRIC SHOCK can kill. Range Selector” setting and lower open circuit volt-
• Do not touch electrically live parts or age. For example: to obtain 175 amps and a forceful
electrode with skin or wet clothing.
arc, set the “Current Range Selector” to the 240-160
• Insulate yourself from work and ground.
position and the “Fine Current Adjustment” setting to
FUMES & GASES can be dangerous. get 175 amps.
• Keep your head out of the fumes.
• Use ventilation or exhaust to remove Some arc instability may be experienced with EXX10
fumes from breathing zone. electrodes when trying to operate with long arc tech-
niques at settings at the lower end of the open circuit
voltage range.
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
CAUTION
DO NOT attempt to set the “Current Range Selector”
between the five points designated on the nameplate.
------------------------------------------------------------------------
ARC RAYS can burn.
• Wear eye, ear, and body protection.
These switches have a spring loaded cam which
almost eliminates the possibility of setting this switch
between the designated points.
Duty Cycle
Idler Operation
The NEMA output rating of the Classic 300 D is 300
amperes at 32 arc volts on a 60% duty cycle (consult Start the engine with the “Idler” switch in the “High”
Specifications in this manual for alternate ratings). position. Allow it to run at high idle speed for several
Duty cycle is based on a ten minute period; thus, the minutes to warm the engine. See Specifications for
welder can be loaded at rated output for six minutes operating speeds.
out of every ten minute period.
The idler is controlled by the “Idler” toggle switch on
Control of Welding Current the welder control panel. The switch has two posi-
tions as follows:
CAUTION
1. In the “High” position, the idler solenoid acti-
DO NOT TURN THE “CURRENT RANGE SELEC- vates, and the engine goes to high idle speed. The
TOR” WHILE WELDING because the current may speed is controlled by the governor.
arc between the contacts and damage the switch.
------------------------------------------------------------------------ 2. In the “Auto” / position, the idler oper-
ates as follows:
The “Current Range Selector” provides five overlap-
ping current ranges. The “Fine Current Adjustment” a. When welding or drawing power for lights or tools
adjusts the current from minimum to maximum within (approximately 100-150 watts minimum) from the
each range. Open circuit voltage is also controlled by receptacles, the idler solenoid activates and the
the “Fine Current Adjustment” permitting control of the engine operates at high idle speed.
arc characteristics.
b. When welding ceases or the power load is turned
A high open circuit voltage setting provides the soft off, a preset time delay of about 15 seconds
“buttering” arc with best resistance to pop-outs pre- starts. This time delay cannot be adjusted.
ferred for most welding. To get this characteristic, set
the “Current Range Selector” to the lowest setting that c. If the welding or power load is not re-started
still provides the current you need and set the “Fine before the end of the time delay, the idler sole-
Current Adjustment” near maximum. For example: to noid deactivates and reduces the engine to low
obtain 175 amps and a soft arc, set the “Current idle speed.
CLASSIC 300D
B-3 OPERATION B-3
Auxiliary Power
CLASSIC 300D
C-1 ACCESSORIES C-1
OPTIONAL FEATURES (Field Installed) Remote Control Kit (K924-4) - Contains switch,
receptacle, remote control rheostat, and 100 ft
GENERAL OPTIONS (30.5m) cable for adjusting the OCV at the welding
site.(For Codes below 10911.)
Power Plug Kit (K802D) - A power plug kit for the TIG OPTIONS
auxiliary power receptacles is available. (Provides a
plug for each receptacle.) TIG Module (K930-2) - Provides high frequency and
shielding gas control for AC and DC GTAW (TIG)
GFCI Receptacle Kit (K1690-1) - Includes one UL welding applications. Its compact case is designed for
approved 115V ground fault circuit interrupter duplex easy carrying, complete with a handle. High frequen-
type receptacle with cover and installation instruc- cy bypass is built in.The K938-1 Contactor Kit must
tions. Replaces the factory installed 115V duplex be field installed in the TIG Module when used with a
receptacle. Each receptacle of the GFCI duplex is ZR-10. Additionally, the K936-3 control cable is
rated at 20 amps. Maximum total current from the required if remote control is used. If remote control is
GFCI duplex is limited to 20 amps. See the MAINTE- not used the K936-4 control cable is required.
NANCE section for detailed information on testing and
resetting the GFCI receptacle. PTA-26V TIG Torch K1783-9-Air cooled 200 amp-
torch equipped with valve for gas flow control. 25Ft.
Spark Arrestor Kit (K903-1) - Includes a heavy gage 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.
CLASSIC 300D
C-2 ACCESSORIES C-2
Wire Feed Module (K623-1) - Provides constant SG Control Module K488-The interface between the
voltage (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.
CLASSIC 300D
D-1 MAINTENANCE D-1
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 neces- and the detailed maintenance and troubleshooting in
sary to remove safety guards to perform the engine manufacturer’s manual.
required maintenance. Remove guards only
when necessary and replace them when the Cooling System
maintenance requiring their removal is com-
The Classic 300 D is equipped with a pressure radia-
plete. Always use the greatest care when work-
tor. Keep the radiator cap tight to prevent loss of
ing near moving parts.
coolant. Clean and flush the cooling system periodi-
cally to prevent clogging the passage and overheating
Do not put your hands near the engine cooling the engine. When antifreeze is needed, always use
blower fan. If a problem cannot be corrected by the permanent type. Capacity = 9.5 qts (9.0 Ltrs.).
following the instructions, take the machine to
the nearest Lincoln Field Service Shop. Bearings
-----------------------------------------------------------------------
ELECTRIC SHOCK can kill. 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.
• Use in open, well ventilated areas or
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
• Keep away from moving parts.
------------------------------------------------------------------------ WARNING
See additional warning information at
Uncovered rotating equipment can be dangerous.
front of this operator’s manual.
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 cur- Commutators and slip rings require little attention.
rent control through its entire range frequently. Good However, if they are black or appear uneven, have
practice is to turn the handle from maximum to mini- them cleaned by an experienced maintenance man
mum setting twice each morning before starting to using fine sandpaper or a commutator stone. Never
weld. use emery cloth or paper for this purpose.
CAUTION
Before doing electrical work on the idler printed Priming
circuit board, disconnect the battery. Lever
------------------------------------------------------------------------ FIGURE D.1
When installing a new battery or using a jumper bat-
tery to start the engine, be sure the battery polarity is 2. For Engines Equipped with a mechanical fuel pump:
connected properly. The correct polarity is negative Operate the priming lever on the fuel lift pump until
ground. Damage to the engine alternator and the fuel, free of air, flows from the vent point. Tighten
printed circuit board can result from incorrect connec- the vent screw. If the pump is at the point of maxi-
tion. mum lift, it will not be possible to operate the prim-
ing lever. If this occurs, turn the crankshaft one
1. The solenoid plunger must work freely and not revolution.
bind. Dust the plunger about once a year with For Engines Equipped with an electric fuel pump:
graphite powder. Operate the electric fuel pump by turning the
“Ignition” switch “ON” until fuel, free of air, flows
2. Proper operation of the idler requires good ground- from the vent point. Tighten the vent screw.
ing of the printed circuit board, reed switch, and
battery. 3. Contact your Perkins Engine repair facility if prob-
lems persist.
3. Idler solenoid is activated for high idle.
Nameplates
ENGINE SERVICE
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE-(20 / 50 HOURS)
EVERY 100 HOURS OR 3 MONTHS
EVERY 200 HOURS OR 6 MONTHS
EVERY 400 HOURS OR 12 MONTHS
EVERY 600 HOURS OR 18 MONTHS
ENGINE SERVICE (NOTE 2)
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
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
CLASSIC 300D
D-4 MAINTENANCE D-4
ENGINE SERVICE
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE-(20 / 50 HOURS)
EVERY 100 HOURS OR 3 MONTHS
EVERY 200 HOURS OR 6 MONTHS
EVERY 400 HOURS OR 12 MONTHS
EVERY 600 HOURS OR 18 MONTHS
ENGINE SERVICE (NOTE 2)
CLASSIC 300D
D-5 MAINTENANCE D-5
CLASSIC 300D
E-1 TROUBLESHOOTING E-1
TROUBLESHOOTING
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CLASSIC 300D
E-2 TROUBLESHOOTING E-2
WELDER TROUBLESHOOTING
TROUBLE CAUSES WHAT TO DO
c. Field circuit may have variable c. Check field current with ammeter to
resistance connection or discover varying current. This
intermittent open circuit due to applies to both the main generator
loose connection or broken wire. and exciter.
2. Welder starts but fails a. Generator or exciter brushes a. Be sure that all brushes bear on the
to generate current. may be loose or missing. commutator and have proper spring
tension.
d. Exciter may have lost excitation. d. Flash fields. (1) Check flashing
diode at 5 o’clock brushholder in
generator.
e. Series field and armature circuit e. Check circuit with ringer or voltmeter.
may be open-circuited.
3. Welding arc is loud and a. Current setting may be too high. a. Check setting and current output with ammeter.
spatters excessively
b. Polarity may be wrong. b. Check polarity. Try reversing polarity or try an
electrode of the opposite polarity.
4. Welding current too great or too a. Exciter output low causing low output a. Check exciter field circuit.
small compared to indication on compared to dial indication.
the dial.
b. Operating speed too low or too high. b. Adjust speed with screw stops at throttle linkage.
(High idle - 1800 RPM, Low idle - 1375 RPM)
5. Arc continuously pops out. a. “Current Range Selector” switch may be a. Set the switch at the center of the current range
set at an intermediate position. desired.
CLASSIC 300D
E-3 TROUBLESHOOTING E-3
Open Closed
12 VDC 0 VDC
Open Closed
2. Replace Idler
P.C. Board
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CLASSIC 300D
E-4 TROUBLESHOOTING E-4
To Check: Short the Red Lead Engine Does Not Pick Up Speed
on P.C. Board to Welder Frame.
1. Check Continuity of Idler Solenoid Coil
(8.5-9.0 ohms) and Replace as
Required.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CLASSIC 300D
E-5 TROUBLESHOOTING E-5
ENGINE TROUBLESHOOTING
TROUBLE CAUSES WHAT TO DO
1. Engine does not start Faulty Ignition switch and or Injector pump solenoid Correct the connection and contact.
Insufficient charging or complete discharge of the battery Charge.
Lack of fuel Supply fuel.
Air mixed in the fuel system Bleed air (To be done by qualified personnel only)
Clogged fuel filter Replace.
Irregular and faulty fuel supply (Injector pump trouble) Repair in an authorized service shop.
Glow plug not heated Breakage of the glow plug; replace.
Improper viscosity of the lubricating oil Inspect and replace.
Clogged air cleaner Clean or replace.
No compression Repair in a service shop.
Engine protection light is ON 60 second start period elapsed, Turn ignition switch
OFF & ON - See #4 Below.
2. Irregular running of the engine Air mixed in the fuel system Bleed air (To be done by qualified personnel only)
Uneven fuel injection (Faulty fuel injector pump) Repair in an authorized service shop.
Clogged fuel filter Replace.
Defective governor Check and correct.
Engine itself defective Repair in an authorized service shop.
3. Engine stops during operation Lack of fuel in the fuel tank Supply fuel and bleed air (To be done by qualified personnel only)
and the Engine Protection light Clogged fuel filter Replace.
does not turn on. Air mixed in the fuel system Bleed air (To be done by qualified personnel only)
Faulty function of the engine Repair in a service shop.
4. Engine stops during operation a. Overheat of the Engine
and the Engine Protection light Lack of Coolant Supply coolant. Inspect leakage and correct.
does turn on. Loose or slipping fan belt Remove oil, dust, etc. and tighten.
Damaged fan belt Replace.
Clogged radiator Flush the radiator.
Clogged radiator fin Clean.
Dust or scale clogged in the cooling water passage Flush the system.
Faulty function of the thermostat Inspect or replace thermostat.
Lack of lubricating oil. Add oil.
Overloading Decrease the load.
Faulty Idler/Engine Protection P.C. Board Replace.
b. Loss of Engine Oil Pressure
Lack of engine oil Supply oil up to the specified level.
Fault in the Oil Pressure Switch Replace the switch.
Oil leakage from the lubricating system Inspect and retighten.
Clogged oil filter Replace with new one.
Oil too light Drain and refill with proper grade.
Faulty Idler/Engine Protection P.C. Board Replace.
5. White or Blue Smoke Excess engine oil Inspect and correct the level.
Too low viscosity of the engine oil Inspect and replace the oil with proper grade.
Faulty injection timing Repair in a service shop.
6. Dark Grey Smoke Unsuitable fuel Inspect and replace with correct grade.
Excess injection Inspect and adjust (in a service shop).
Faulty function of the engine Repair in a service shop.
Overloading Reduce the load.
Clogged air cleaner Clean.
7. Faulty Charging Loose fan belt Correct the tension.
Faulty wiring Inspect and correct.
Faulty battery Repair.
Worn out alternator brush Replace.
8. Starter Motor does not run Loose or damaged wiring Inspect and tighten.
Drained voltage from battery Charge the battery.
Damaged starter motor (including solenoid) Repair in a service shop.
9. Engine Protection Light not Broken Light Bulb Replace the bulb.
coming on (after the ignition Faulty light wiring (to GND or P.C. Board) Correct.
switch has been in the ON Faulty Idler/Engine Protection P.C. Board Replace.
position for more than 60
seconds with the engine
not started).
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CLASSIC 300D
F-1
+
B
CURRENT
EXC CR2 REED WELDER
+ W TRANSFORMER RELAY LEAD BLOCK
51
W N
R U
-W
+Y
G
GROUND N
TO ENGINE (GROUND SCREW NEAR POSITIVE
GROUND ENGINE GAUGES)
NEGATIVE
CLASSIC 300D
TO BASE (CC-) (CC+) & (CV+ WITH W.F.M.)
DIAGRAMS
X 12 11 10 9 8 7 6 5 4 3 2 1
SEE B Y POTENTIOMETER
*
BELOW R
W
P11 ** SEE BELOW INLINE PLUG
600 CONNECTORS (P5)
41 R Y X
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
#8 LEAD
602 WIRE FEED MODULE INSTALLED. CONNECT W
6 TO CASE B CONNECT TO POS. & NEG. POS. WIRE FEED
W OUTPUT TERMINALS
P8 NEG.
A REMOTE SWITCH WIRED
SWITCH FOR LOCAL OR RESISTORS
THIS WAY ON EARLIER
REMOTE CONTROL SHOWN NEGATIVE CV
{ MODULE
IN LOCAL POSITION. UNITS #2 HEAVY LEAD
OUTPUT TERMINAL
PANEL
MACHINE NOT RUNNING, REMOVE PLUG "P9" ON MACHINE FROM CONNECTOR "J8". 608
* WITH
THEN CONNECT PLUG "P8" ON REMOTE CONTROL TO CONNECTOR "J8" ON MACHINE. 609
A WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISPOSE OF THE REMOTE CONTROL CONNECT TO NEG.
* * IFUNCONNECTED PLUG "P10" (IF ONE IS ON THE MACHINE). FASTEN THE NEW PLUG "P11"
POTENTIOMETER BOX 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 250 AMP
CONTROL KIT TO CONNECTOR "J5" ON THE MACHINE. MUST NOT BE RUNNING
THERMOSTAT * 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 ASSEMBLY
WILL RESULT IF THE RED AND BLACK LEADS ARE CONNECTED IN THE CLASSIC 300D. 7-13-2001G
L10877
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
F-1
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
CLASSIC 300D WIRING DIAGRAM (FOR CODES 10911 AND ABOVE)
F-2
+
B
ALTERNATOR CURRENT
EXC CR2 REED WELDER
+ W TRANSFORMER RELAY LEAD BLOCK
51
W N
51G R U
-W
GND-M +Y
G
GROUND N
TO ENGINE (GROUND SCREW NEAR NEGATIVE POSITIVE
GROUND ENGINE GAUGES)
CLASSIC 300D
TO BASE (CC-) (CC+) & (CV+ WITH W.F.M.)
DIAGRAMS
Y X INLINE PLUG
CONNECTORS (P5)
W.F.M.
G
CONTROL
PANEL
CONNECT W
TO CASE B
#8 LEAD
CONNECT TO POS. & NEG. POS. WIRE FEED
RESISTORS
OUTPUT TERMINALS NEG.
NEGATIVE CV
{ MODULE
OUTPUT TERMINAL #2 HEAVY LEAD
PANEL
608
REMOTE CONTROL 609
POTENTIOMETER BOX CONNECT TO NEG.
BRUSH HOLDER
#2 HEAVY LEAD
L11865
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2
F-3 DIAGRAMS F-3
Y X
G B W
CV "WIRE" CONTROL POT
RESISTORS CCW
ORANGE
RED
CABLE CONNECTION TABLE
PIN LEAD COLOR
E RED
F ORANGE
G BLUE
REMOTE CONTROL BOX CONNECT TO CASE C WHITE JUMPER
D WHITE JUMPER
S26097
CLASSIC 300D
F-4
S10766-6, -8, -9, AND -10, ADDED DIMENSION L AND NOTE N.C.
A
24.00 A
A
A
A
NOTES: CONTROL PANEL
A
37.12
N.C. DIMENSION TO TOP OF
EXHAUST ELBOW OR G
RAINCAP.
A
A
A
A
A
A
CLASSIC 300D
A
J A H A
DIAGRAMS
A
A
B
S10766-8 CLASSIC 300D 65.00 57.70 8.70 27.94 12.82 41.66 3.25 45.5
C
PART NO. WELDER A B C D F G H J K L
S10766
F-4
● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.
French ● Ne laissez ni la peau ni des vête- ● Gardez à l’écart de tout matériel ● Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
German ● Berühren Sie keine stromführenden ● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec- ● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or
● Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
● Los humos fuera de la zona de res- Spanish
● Desconectar el cable de ali- ● No operar con panel abierto o
piración.
● Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux French
● Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
● Vermeiden Sie das Einatmen von ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
● Mantenha seu rosto da fumaça. ● Não opere com as tampas removidas. ● Mantenha-se afastado das partes
● Use ventilação e exhaustão para ● Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. ● Não opere com os paineis abertos ATENÇÃO
● Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• World's Leader in Welding and Cutting Products •
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