SVM194-A
October, 2009
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
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.
SERVICE MANUAL
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
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ii
ii
SAFETY
ELECTRIC SHOCK can kill.
ARC RAYS can burn.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases.When welding, keep
• AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical ven-
tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
cautions are also required when welding on galvanized
steel.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo-
sure level should be checked upon installation and periodi-
cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
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
CLASSIC® 300D & 300G
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can cause fire or
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
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjcent areas. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available.
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
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
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
6.c. When not welding, make certain no part of the electrode
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
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
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
welding area.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until
they fail.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
6.h. Also see item 1.c.
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
CLASSIC® 300D & 300G
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iv
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SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRÉCAUTIONS DE SÛRETÉ
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
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible de
la zone de travail quʼil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dʼautres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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 nʼimporte quelle partie du
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
quʼun verre blanc afin de se protéger les yeux du rayon-
nement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-
er à lʼinterrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
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
CLASSIC® 300D & 300G
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v
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SAFETY
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
CLASSIC® 300D & 300G
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vi
vi
SAFETY
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-
1
tions.
_________________________
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
CLASSIC® 300D & 300G
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I
I
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Aʼs
Classic® 300D Perkins 104-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.1
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.2
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Bʼs
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.2
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.4
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Cʼs
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.2
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C.4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Dʼs
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D.2
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D.4
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-337, P-379, P-498, P-507
Classic® 300D Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-507
Classic® 300D Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-507
CLASSIC® 300D & 300G
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A1.1
A1.1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.3
Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6
CLASSIC® 300D & 300G
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A1.2
A1.2
INSTALLATION
TECHNICAL SPECIFICATIONS - CLASSIC® 300D
INPUT - DIESEL ENGINE
Make/Model
Description
Speed (RPM)
Displacement
Starting
System
Capacities
Perkins
4 cylinder
4 Cycle
High Idle 1800
Low Idle 1350
Full Load 1725
135.6 cu. in
(2.2 L)
12VDC batteries
(2) & Starter
Fuel: 15 gal.
57 L
104-22 Diesel
Engine
32.7 HP @
1800 RPM
(Water Cooled)
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
(1)
WELDING OUTPUT*
OPEN CIRCUIT
VOLTAGE
OUTPUT RANGE
AUXILIARY POWER
Current/Voltage/Duty Cycle
AMPS
40-350A
115/230 VAC
3000 Watts, 60 Hz.
26 Amps @ 115V
13 Amps @ 230V
250A / 30V / 100%
300A / 32V / 60%
98 Max.
220A-MAX.
160-240A
120-240A
120-190A
80-130A
@ 1800 RPM
Min.-90A
(2)
PHYSICAL DIMENSIONS
HEIGHT
WIDTH
DEPTH
WEIGHT
1354 lbs.
K1643-1
45.50 in.
1156 mm
24.00 in.
610 mm
65.00 in.
1651 mm
(616 kg)
1354 lbs.
K1643-2
(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
High Idle (1800 RPM)-No Load @ 96.6 Volts
50 Amps @ 22 Volts
0.28 gal/hr ( 1.06 ltrs/hr)
0.45 gal/hr ( 1.70 ltrs/hr)
0.51 gal/hr ( 1.93 ltrs/hr)
0.58 gal/hr ( 2.19 ltrs/hr)
0.70 gal/hr ( 2.65 ltrs/hr)
0.85 gal/hr ( 3.21 ltrs/hr)
1.05 gal/hr ( 3.97 ltrs/hr)
1.31 gal/hr ( 4.95 ltrs/hr)
1.68 gal/hr ( 6.35 ltrs/hr)
100 Amps @ 24 Volts
150 Amps @ 26 Volts
200 Amps @ 28 Volts
250 Amps @ 30 Volts
300 Amps @ 32 Volts
350 Amps @ 34 Volts
CLASSIC® 300D & 300G
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A1.3
A1.3
INSTALLATION
DESIGN FEATURES
GENERAL DESCRIPTION
Control Panel
®
The Classic 300 D is a heavy duty, engine driven, DC
arc welding power source, capable of providing con-
stant current output for stick welding or DC TIG weld-
ing. This welder is wound with all copper coils, rated at
300 amps/32 Volts, and provides other Classic® fea-
tures such as improved door latches and stainless
hinges. With the addition of the optional K623-1 Wire
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
Range Selector” switch and
a
“Fine Current
Adjustment” rheostat. The welder is equipped with a
“Start” button, an “Ignition” switch, an “Idler” control
switch, and a “Glow Plug” button for easier cold weath-
er starting.
™
Feed Module , the Classic® 300 D will provide con-
stant voltage output for running the LN-7, LN-23P, or
LN-25 wire feeders. (The Wire Feed Module is factory
installed on the K1643-2). The optional K924-4 or
K924-5 Remote Control Kit (Both field installed) See
Section C for description.
The control panel also contains an engine temperature
gauge, a battery charging ammeter, an oil pressure
gauge, two three prong grounding type receptacles
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
temperature, the engine immediately shuts down. The
Classic® 300 D has a current range of 40-350 DC
amps with output ratings as follows:
All Copper Windings - For long life and dependable
operation.
Engine Idler - The Classic® 300 D is equipped with
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-
trol switch on the panel locks the idler in high idle posi-
tion when desired.
RATED OUTPUT
DUTY CYCLE
250A @ 30V
300A @ 32V
100%
60%
Auxiliary Power - 3.0 kVA of nominal 115/230V, 60Hz,
AC. Output voltage is maintained within 10% at all
loads up to rated capacity. (See Optional Features
in Section C for Power Plug Kit.)
These units are also capable of providing 3 kVA of
115/230 volts of 60 cycle AC auxiliary power.
Welder Enclosure - The complete welder is rubber
The Classic® 300 D uses the Perkins 104-22 industri-
al water-cooled diesel engine.
mounted on a rugged steel “C” channel base.
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.
CLASSIC® 300D & 300G
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A1.4
A1.4
INSTALLATION
PRE-OPERATION INSTALLATION
WARNING
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SUR-
FACES.
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, the surface
shall be covered with a steel plate at least .06”(1.6mm)
thick, which shall extend not more than 5.90”(150mm)
beyond the equipment on all sides.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
----------------------------------------------------------------------
Machine Grounding
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
According to the United States National Electrical
Code, the frame of this portable generator is not
required to be grounded and is permitted to serve as
the grounding means for cord connected equipment
plugged into its receptacle.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• 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
extent to which such requirements may apply to your
particular situation and follow them explicitly. A
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
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
ground such as a metal water pipe going into the
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
electrical equipment.
------------------------------------------------------------------------
See additional warning information at the
front of this operatorʼs manual.
-----------------------------------------------------------
Exhaust Spark Arrester
Some federal, state or local laws may require that
engines be equipped with exhaust spark arresters
when they are operated in certain locations where
unarrested sparks may present a fire hazard. The
standard muffler included with this welder does not
qualify as a spark arrester. When required by local reg-
ulations, a suitable spark arrester must be installed
and properly maintained.
Lift Bail
A lift bail is provided for lifting with a hoist.
WARNING
FALLING EQUIPMENT can cause injury.
• Lift only with equipment of
CAUTION
adequate lifting capacity.
• Be sure machine is stable
when lifting.
Use of an incorrect arrester may lead to engine damage
or performance loss. Contact the engine manufacturer for
specific recommendations.
• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trail-
er or gas cylinder.
------------------------------------------------------------------------
Location / Ventilation
• Do not lift machine if lift bale is damaged.
Always operate the welder with the doors closed.
Leaving the doors open changes the designed air flow
and may cause overheating.
• Do not operate machine while 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 & 300G
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A1.5
A1.5
INSTALLATION
RECOMMENDED COPPER CABLE SIZES
TRAILER
Cables Sizes for Combined Length
of Electrode Plus Work Cable
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 dam-
age the welding equipment. Some of the factors to be
considered are as follows:
Amps
250
Duty Cycle
100%
Up to 200ft.(61m) 200 to 250ft.
(61 to 76m)
1
1/0
2/0
300
60%
1/0
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
stress to the framework.
READ the engine operating and maintenance instruc-
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
being moved and when standing by itself while
being operated or serviced.
WARNING
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
4. Typical conditions of use, i.e., travel speed, rough-
ness of surface on which the trailer will be operated;
environmental conditions, likely maintenance.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
fumes to clear before starting
engine.
DIESEL FUEL
(1)
5. Conformance with federal, state and local laws.
can cause fire.
(1)
Consult your federal, state and local laws regarding specific
requirements for use on public highways.
• Do not overfill tank, fuel
expansion may cause over-
flow.
VEHICLE MOUNTING
Improperly mounted concentrated loads may cause
unstable vehicle handling and tires or other compo-
nents to fail.
DIESEL FUEL ONLY
------------------------------------------------------------------------
• Only transport this equipment on serviceable vehi-
cles which are rated and designed for such loads.
• Distribute, balance and secure loads so vehicle is
stable under conditions of use.
Oil
This unit is supplied from the factory with the engine
crankcase filled with a high quality SAE 10W/30 oil.
This oil should be acceptable for most typical ambient
temperatures. Consult the engine operation manual
for specific engine manufacturerʼs recommendations.
Upon receipt of the welder, check the engine dipstick to
be sure the oil is at the “full” mark. DO NOT overfill.
• Do not exceed maximum rated loads for compo-
nents such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of
vehicle.
• Follow vehicle manufacturerʼs instruction.
----------------------------------------------------------------------------
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
valves on the sediment bowl and the water separator
are in the open positions.
With the engine off, route the electrode and work
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-
itive polarity, connect the electrode cable to the termi-
nal marked “+”. For Negative polarity, connect the
electrode cable to the “-” stud. These connections
should be checked periodically and tightened if neces-
sary.
Cooling System
The radiator has been filled at the factory with a 50-50
mixture of ethylene glycol antifreeze and water. Check
the radiator level and add a 50-50 solution as needed
(see engine manual or antifreeze container for alter-
nate antifreeze recommendations).
When welding at a considerable distance from the
welder, be sure you use ample sized welding cables.
CLASSIC® 300D & 300G
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A1.6
A1.6
INSTALLATION
Battery Charging
ENGINE BREAK-IN
WARNING
Lincoln Electric selects high quality, heavy-duty indus-
trial engines for the portable welding machines we
offer. While it is normal to see a small amount of
crankcase oil consumption during initial operation,
excessive oil use, wetstacking (oil or tar like substance
at the exhaust port), or excessive smoke is not normal.
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes
away.
BATTERY ACID can burn eyes and
skin.
Larger machines with a capacity of 350 amperes and
higher, which are operated at low or no-load conditions
for extended periods of time are especially susceptible
to the conditions described above. To accomplish suc-
cessful engine break-in, most diesel-powered equip-
ment needs only to be run at a reasonably heavy load
within the rating of the welder for some period of time
during the engineʼs early life. However, if the welder is
subjected to extensive light loading, occasional moder-
ate to heavy loading of the engine may sometimes be
necessary. Caution must be observed in correctly
loading a diesel/generator unit.
• Wear gloves and eye protection and be
careful when boosting, charging or work-
ing 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
battery clamp. When reinstalling, connect the
negative cable last.
1. Connect the welder output studs to a suitable resis-
tive load bank. Note that any attempt to short the
output studs by connecting the welding leads
together, direct shorting of the output studs, or con-
necting the output leads to a length of steel will
result in catastrophic damage to the generator and
voids the warranty.
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.
Use correct polarity - Negative Ground.
2. Set the welder controls for an output current and
voltage within the welder rating and duty cycle.
Note that any attempt to exceed the welder rating or
duty cycle for any period of time will result in cata-
strophic damage to the generator and voids the
warranty.
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
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.
CLASSIC® 300D & 300G
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B1.1
B1.1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.2
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.2
Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.3
CLASSIC® 300D & 300G
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B1.2
B1.2
OPERATION
7. Allow the engine to run at high idle speed for sev-
eral minutes to warm the engine. Stop the engine
and recheck the oil level, after allowing sufficient
time for the oil to drain into the pan. If the level is
down, fill it to the full mark again. The engine con-
trols were properly set at the factory and should
require no adjusting when received.
ENGINE OPERATION
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
COLD WEATHER STARTING:
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
about -15°F (-26°C), it maybe desirable to install cold-
starting aides.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
Note: Extreme cold weather staring may require longer
glow plug operation.
• Use in open, well ventilated areas or
vent exhaust outside.
WARNING
------------------------------------------------------------------------
MOVING PARTS can injure.
Under NO conditions should ether or other starting
fluids be used!
• Do not operate with doors open or
guards off.
------------------------------------------------------------------------
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
Stopping the Engine
1. Turn the “IGNITION” switch to “OFF”
See additional warning information at the
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
tank to minimize moisture condensation in the tank.
Also, running out of fuel tends to draw dirt into the fuel
system.
-----------------------------------------------------------
Operate the welder with the doors closed. Leaving the
doors open changes the designed air flow and can
cause overheating.
When hauling the welder between job sites, close the
fuel feed valve beneath the fuel tank.
Starting the Classic® 300D Perkins 104-22
Diesel Engine
If the fuel supply is cut off or runs out while the fuel
pump is operating, air may be entrapped in the fuel dis-
tribution system. If this happens, bleeding of the fuel
system may be necessary. Use qualified personnel to
tion of this manual.
1. Turn the “IDLER” switch to “HIGH”.
2. Turn the “IGNITION” switch to “ON”.
3. Press the Glow Plug button for 20 to 30 seconds.
(maximum 60 seconds).
4. Press the Start button. When the engine starts
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.
CLASSIC® 300D & 300G
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B1.3
B1.3
OPERATION
When a forceful “digging” arc is required, usually for
vertical and overhead welding, use a higher “Current
Range Selector” setting and lower open circuit voltage.
For example: to obtain 175 amps and a forceful arc,
set the “Current Range Selector” to the 240-160 posi-
tion and the “Fine Current Adjustment” setting to get
175 amps.
WELDER OPERATION
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground.
Some arc instability may be experienced with EXX10
electrodes when trying to operate with long arc tech-
niques at settings at the lower end of the open circuit
voltage range.
FUMES & GASES can be dangerous.
•
•
Keep your head out of the fumes.
Use ventilation or exhaust to remove
fumes from breathing zone.
CAUTION
DO NOT attempt to set the “Current Range Selector”
between the five points designated on the nameplate.
------------------------------------------------------------------------
WELDING SPARKS can cause fire or
explosion.
•
Keep flammable material away.
These switches have a spring loaded cam which
almost eliminates the possibility of setting this switch
between the designated points.
ARC RAYS can burn.
Wear eye, ear, and body protection.
•
Idler Operation
Duty Cycle
Start the engine with the “Idler” switch in the “High”
position. Allow it to run at high idle speed for several
operating speeds.
The NEMA output rating of the Classic® 300 D is 300
amperes at 32 arc volts on a 60% duty cycle (consult
Specifications in this manual for alternate ratings).
Duty cycle is based on a ten minute period; thus, the
welder can be loaded at rated output for six minutes
out of every ten minute period.
The idler is controlled by the “Idler” toggle switch on the
welder control panel. The switch has two positions as
follows:
Control of Welding Current
1. In the “High”
position, the idler solenoid acti-
vates, and the engine goes to high idle speed. The
speed is controlled by the governor.
CAUTION
DO NOT TURN THE “CURRENT RANGE SELEC-
TOR” WHILE WELDING because the current may
arc between the contacts and damage the switch.
------------------------------------------------------------------------
The “Current Range Selector” provides five overlap-
ping current ranges. The “Fine Current Adjustment”
adjusts the current from minimum to maximum within
each range. Open circuit voltage is also controlled by
the “Fine Current Adjustment” permitting control of the
arc characteristics.
2. In the “Auto”
/
position, the idler oper-
ates as follows:
a. When welding or drawing power for lights or tools
(approximately 100-150 watts minimum) from the
receptacles, the idler solenoid activates and the
engine operates at high idle speed.
b. When welding ceases or the power load is turned
off, a preset time delay of about 15 seconds
starts. This time delay cannot be adjusted.
A high open circuit voltage setting provides the soft
“buttering” arc with best resistance to pop-outs pre-
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
Current Adjustment” near maximum. For example: to
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.
c. If the welding or power load is not re-started
before the end of the time delay, the idler solenoid
deactivates and reduces the engine to low idle
speed.
CLASSIC® 300D & 300G
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B1.4
B1.4
OPERATION
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.
CLASSIC® 300D & 300G
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C1.1
C1.1
TABLE OF CONTENTS - ACCESSORIES SECTION
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1
Wire Feed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1.3
CLASSIC® 300D & 300G
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C1.2
C1.2
ACCESSORIES
OPTIONAL FEATURES (Field Installed)
Remote Control Kit (K924-4) - Contains switch,
receptacle, remote control rheostat, and 100 ft (30.5m)
cable for adjusting the OCV at the welding site.(For
Codes below 10911.)
GENERAL OPTIONS
WARNING
Remote Control Kit (K924-5) - Contains remote con-
trol rheostat and 100 ft. (30.5 m) cable for adjusting
the OCV at the welding site. (For Codes 10911 and
above.)
Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly. The use of an arc welder
for pipe thawing is not approved by the CSA, nor is
it recommended or supported by Lincoln Electric.
------------------------------------------------------------------------
Remote Control Kit (K2464-1) - Contains remote
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
for each receptacle.)
TIG OPTIONS
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
carrying, complete with a handle. High frequency
bypass is built in.The K938-1 Contactor Kit must be
field installed in the TIG Module when used with a ZR-
10. Additionally, the K936-3 control cable is required if
remote control is used. If remote control is not used the
K936-4 control cable is required.
GFCI Receptacle Kit (K1690-1) - Includes one UL
approved 115V ground fault circuit interrupter duplex
type receptacle with cover and installation instructions.
Replaces the factory installed 115V duplex receptacle.
Each receptacle of the GFCI duplex is rated at 20
amps. Maximum total current from the GFCI duplex is
for detailed information on testing and resetting the
GFCI receptacle.
PTA-26V TIG Torch K1783-9-Air cooled 200 amptorch
equipped with valve for gas flow control. 25Ft. length.
Spark Arrestor Kit (K903-1) - Includes a heavy gage
steel, approved spark arrestor, clamp and adapter for
mounting to the muffler exhaust pipe.
Magnum Parts Kit For PTA-26V TIG Torch KP509
Remote Control Cable (K936-4) - Control cable for
connecting the K930-2 TIG Module to a ZR-10 not
equipped with a K892-1 Remote Kit. 9-Socket to a
grounded 115 V plug and a 6 pin MS-connector.
(Contains circuits 31, 32, and ground)
K953-1 TRAILER - Two-wheeled trailer with optional fender
and light package. For highway use, consult applicable feder-
al, state, and local laws regarding possible additional require-
ments. There is a choice of 2 hitches, a fender & a light pack-
age.
K953-1 Trailer
Arc Start Switch K814
Contactor Kit K938-1
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-1 Fender & Light Kit
K965-1 Cable Rack
Control Cable Extension K937-45-Cable is 45Ft. in
length.
OIL DRAIN KIT K1586-1 - Includes ball valve, hose
and clamp.
Water Valve Kit K844-1-For use with a water-cooled
TIG torch. Installs inside TIG Module.
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.
CLASSIC® 300D & 300G
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C1.3
C1.3
ACCESSORIES
Wire Feed Module (K623-1) - Provides constant volt-
age (CV) output with improved arc stability for
Innershield welding. Excellent for MIG welding.
Recommended wire feeders are the LN-7, LN-23P and
LN-25. (Factory installed on the K1643-2).
SG Control Module K488-The interface between the
power source and the spool gun. Provides control of
wire speed and gas flow.
Input Cable K691-10.-For Lincoln engine drives with
14-pin MS-type connection, separate 115V NEMA
receptacle and output stud connections. 10 ft.
length.
LN-25 Wire Feeder K449-Portable CC/CV unit for
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.
Magnum® 350 Innershield Gun (for LN-25)K126-2-
For self-shielded wire with 15 ft. (4.5m) cable. For
.062-3/32” (1.6-2.8mm) wire.
)
Magnum® 200 MIG Gun (for LN-25 K497-3-With
15 ft. (4.5m) cable. For .025 (0.6m) wire.
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.
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C1.4
C1.4
NOTES
CLASSIC® 300D & 300G
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D1.1
D1.1
TABLE OF CONTENTS - MAINTENANCE SECTION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1
GFCI Receptacle Testing & Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.6
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.7
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D1.2
D1.2
MAINTENANCE
MAINTENANCE
4. When necessary, remove the sediment bowl, if so
equipped, from beneath the fuel tank and clean out
any accumulated dirt and water.
WARNING
Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. In some cases, it may be necessary
to remove safety guards to perform required
maintenance. Remove guards only when neces-
sary and replace them when the maintenance
requiring their removal is complete. Always use
the greatest care when working near moving
parts.
5. Follow the engine service schedule in this manual
and the detailed maintenance and troubleshooting in
the engine manufacturerʼs manual.
Cooling System
The Classic® 300 D is equipped with a pressure radi-
ator. Keep the radiator cap tight to prevent loss of
coolant. Clean and flush the cooling system periodical-
ly to prevent clogging the passage and overheating the
engine. When antifreeze is needed, always use the
permanent type. Capacity = 9.5 qts (9.0 Ltrs.).
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
the nearest Lincoln Field Service Shop.
-----------------------------------------------------------------------
ELECTRIC SHOCK can kill.
Bearings
This welder is equipped with a double-shielded ball
bearing having sufficient grease to last indefinitely
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
of grease one inch wide, one inch long, and one inch
high weighs approximately one half ounce. Over-
greasing is far worse than insufficient greasing.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• 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
grease.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
Commutator and Brushes
• Stop engine before servicing.
• Keep away from moving parts.
WARNING
------------------------------------------------------------------------
See additional warning information at
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-
front of this operatorʼs manual.
-----------------------------------------------------------
ing armature when stoning the commutator.
General Instructions
------------------------------------------------------------------------
Shifting of the commutator brushes may result in:
- Change in machine output
1. Blow out the welder and controls with an air hose at
least once every two months. In particularly dirty loca-
tions, this cleaning may be necessary once a week.
Use low pressure air to avoid driving dirt into the insu-
lation.
- Commutator damage
- Excessive brush wear
Periodically inspect the commutator, slip rings, and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
2. “Current Range Selector” contacts should not be
greased. To keep the contacts clean, rotate the current
control through its entire range frequently. Good prac-
tice is to turn the handle from maximum to minimum
setting twice each morning before starting to weld.
3. Put a drop of oil on the “Current Range Selector”
shaft at least once every month.
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D1.3
D1.3
MAINTENANCE
Replace brushes when they wear within 1/4” of the pig-
tail. A complete set of replacement brushes should be
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-
tator as the armature rotates at full speed until contact
is made across the full face of the brushes. After ston-
ing, blow out the dust with low pressure air.
Purging Air from Fuel System (Perkins
104-22 Engine)
WARNING
Keep fuel clear of open flames or arcs, allow
engine to cool before working on the fuel system.
Wipe up any spilled fuel and do not start engine
until fumes clear.
To seat slip ring brushes, position the brushes in place.
Then slide one end of a piece of fine sandpaper
between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres-
sure on top of the brushes, pull the sandpaper around
the circumference of the rings - in direction of rotation
only - until brushes seat properly. In addition, stone slip
ring with a fine stone. Brushes must be seated 100%.
------------------------------------------------------------------------
If the engine is running rough and you suspect air has
been trapped in the fuel system, (e.g. the engine was
allowed to run out of fuel) perform the following steps
using qualified personnel:
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
Lever
circuit board, disconnect the battery.
------------------------------------------------------------------------
When installing a new battery or using a jumper battery
to start the engine, be sure the battery polarity is con-
nected properly. The correct polarity is negative
ground. Damage to the engine alternator and the print-
ed circuit board can result from incorrect connection.
FIGURE D1.3
2. For Engines Equipped with a mechanical fuel pump:
Operate the priming lever on the fuel lift pump until
fuel, free of air, flows from the vent point. Tighten
the vent screw. If the pump is at the point of maxi-
mum lift, it will not be possible to operate the prim-
ing lever. If this occurs, turn the crankshaft one
revolution.
1. The solenoid plunger must work freely and not bind.
Dust the plunger about once a year with graphite
powder.
For Engines Equipped with an electric fuel pump:
Operate the electric fuel pump by turning the
“Ignition” switch “ON” until fuel, free of air, flows
from the vent point. Tighten the vent screw.
2. Proper operation of the idler requires good ground-
ing of the printed circuit board, reed switch, and bat-
tery.
3. Contact your Perkins Engine repair facility if prob-
lems persist.
3. Idler solenoid is activated for high idle.
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.
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D1.4
D1.4
MAINTENANCE
FOR CODES 10658 AND BELOW
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)
MAINTENANCE ITEM
Coolant level
TYPE OR QUANTITY
I
I
I
Concentration of antifreeze
Coolant (NOTE 3)
50/50 Water/Ethylene Glycol
R
9.5qrts, (9.0L)
Engine oil level (NOTE 1)
Engine oil (NOTE 1 & 3)
Engine oil filter
R
R
C
R
R
C
8.7qrts, (8.2L) (including filter)
Perkins #140517000
Drain water separator & fuel strainer
Fuel filter canister
R
Perkins #1300366120
I
Tension of alternator drive belt
Alternator drive belt wear
Alternator drive belt
I
R
Perkins # 080109080
C
C
I
Air filter (earlier check may be req'd.)
Air filter element
R
Donaldson #P181050 or Nelson #70206N
Check and adjust idle speed
Tighten cylinder head
Valve clearances
I
I
I
I
Intake .008", exhaust .008"
Electrical systems
All nuts and bolts for tightness
Injector performance
Leaks or engine damage
Battery
I
I
Contact Perkins
BCI Group 24
I
I = Inspect
NOTES:
(1) Consult Engine Operators Manual for oil recommendations.
C = Clean
R = Replace
(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.
If necessary use shorter periods.
5/06
S20919-2
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D1.5
D1.5
MAINTENANCE
FOR CODES 10911 AND ABOVE
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)
MAINTENANCE ITEM
Coolant level
Concentration of antifreeze
Coolant (NOTE 3)
Engine oil level (NOTE 1)
Engine oil (NOTE 1 & 3)
Engine oil filter
Drain water separator & fuel strainer
Fuel filter canister
TYPE OR QUANTITY
I
I
50/50 Water/Ethylene Glycol
9.5qrts., 9.0L
I
R
R R
R R
C C
8.7qrts, 8.2L (including filter)
Perkins #140517000
R
I
Perkins #26560017
I
Tension of alternator drive belt
Alternator drive belt wear
Alternator drive belt
R
Perkins #080109080
C C
I
Air filter (earlier check may be req'd.)
Air filter element
Check and adjust idle speed
Tighten cylinder head
Valve clearances
Electrical systems
All nuts and bolts for tightness
Injector performance
R
Donaldson #P181050, Nelson #70206N
I
I
I
I
Intake .008", exhaust .008"
Contact Perkins
I
I
I
Leaks or engine damage
Battery
I = Inspect
Notes:
(1) Consult Engine Operators Manual for oil recommendations.
C = Clean
R = Replace
(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.
S25557
If necessary use shorter periods.
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D1.6
D1.6
MAINTENANCE
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.
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D1.7
D1.7
MAINTENANCE
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)
7. Welding Generator & Coupling (2 of 2)
8. Solenoid Assembly
9. Roof & Doors
10. Alternator Brush Holder
11. Generator Brush Holder
FIGURE D1.7 - MAJOR COMPONENT LOCATION
3
9
2
1
4
8
5
7
11
6
10
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D1.8
D1.8
NOTES
CLASSIC® 300D & 300G
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A2.1
A2.1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2.2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2.3
Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2.5
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A2.2
A2.2
INSTALLATION
TECHNICAL SPECIFICATIONS - CLASSIC® 300D PERKINS
INPUT - DIESEL ENGINE
Make/Model
Description
Speed (RPM)
Displacement
Starting
System
Capacities
4 Cylinder
4 Cycle
135.6 cu. in
(2.2 ltrs)
12VDC battery
Fuel: 15 gal.
57 L.
(Group 24, 650
cold crank amps)
2.0 KW Starter
55 A. Alternator
w/ built in reg.
Naturally Aspirated High Idle 1800
Water-Cooled
Diesel Engine
Low Idle 1400
Full Load 1725
Bore x Stroke
Oil: 8.45 Qts.
8 L.
Perkins
404C-22
Cast Iron Cylinder,
Block/Crankcase
3.43” x 3.64”
32.7HP @1800 RPM (For Codes 11111
and Below)
Coolant: 9.5 Qts.
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
Fine Adjustments in each Range
40-350 Amps
220-Max.
VOLTS @ RATED AMPS
CYCLE
300 Amp DC Welder
All Copper Windings
30V @ 250A
32V @ 300A
100%
60%
160-240
120-190
Pure DC Power Generator
99V DC Max. OCV @ 1800RPM
80-130
Min.-90
RATED OUTPUT @ 104°F(40°C) - GENERATOR
(1)
Auxiliary Power
3,000 Watts Continuous, 60 Hz AC
26 Amps @ 115V
13 Amps @ 230V
(2)
PHYSICAL DIMENSIONS
MODEL
HEIGHT
WIDTH
DEPTH
WEIGHT
K1643-3 CSA
w/o Wire Feed Module
(Codes 11110, 11248,
11280)
1354 lbs.
(616 kg)
45.5 in.
24.00 in.
65.0 in.
(1156 mm)
(610 mm)
(1651 mm
K1643-4 CSA
w/ Wire Feed Module
(Codes 11111, 11249,
11281)
1389lbs.
(630 kg)
* Based on a 10 min. period.
(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.
(2)
Height to top of exhaust elbow.
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A2.3
A2.3
INSTALLATION
All Copper Windings - For long life and dependable
GENERAL DESCRIPTION
operation.
The Classic® 300D Perkins is a heavy duty, engine dri-
ven, DC arc welding power source, capable of provid-
ing constant current output for stick welding or DC TIG
welding. This welder is wound with all copper coils,
rated at 300 amps/32 Volts, and provides other
Classic® features such as improved door latches and
stainless hinges. With the addition of the optional
Engine Idler - The Classic® 300D Perkins is
equipped with an electronic automatic engine idler. It
automatically increases and decreases engine speed
when starting and stopping welding or using auxil-
iary power. A built-in time delay permits changing
electrodes before the engine slows to its low idle
speed. The “Idler” control switch on the panel locks the
idler in high idle position when desired.
™
K623-1 Wire Feed Module , the Classic® 300D
Perkins will provide constant voltage output for running
the LN-7, LN-23P, or LN-25 wire feeders. (The Wire
Feed Module is factory installed on the K1643-4). The
optional K924-5 Remote Control Kit, provides a remote
control rheostat for remote fine current and open circuit
Auxiliary Power - 3.0 KVA of nominal 115/230V, 60Hz,
AC. Output voltage is maintained within 10% at all
Section C for Power Plug Kit.)
GFCI Receptacle - One UL approved 115V ground
fault circuit interrupter duplex type receptacle is stan-
information on testing and resetting the GFCI recepta-
cle.
The Classic® 300D Perkins has an Electronic Engine
Protection System. In the event of sudden low oil pres-
sure or high coolant temperature, the engine immedi-
ately shuts down. The Classic® 300D Perkins has a
current range of 40-350 DC amps with output ratings
as follows:
Welder Enclosure - The complete welder is rubber
mounted on a rugged steel “C” channel base.
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 (-).
RATED OUTPUT
250A @ 30V
300A @ 32V
DUTY CYCLE
Cranking System - A 12 volt electric starter is stan-
100%
60%
dard.
Air Cleaner - Heavy duty two stage dry type.
Muffler - A muffler and stainless steel exhaust outlet
These units are also capable of providing 3 KVA of
115/230 volts of 60 cycle AC auxiliary power.
elbow are standard.
Engine Hour Meter - A meter to record hours of oper-
The Classic® 300D Perkins uses the Perkins 404C-22
industrial water-cooled diesel engine.
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.
DESIGN FEATURES
Control Panel
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
standard.
Range Selector” switch and
a
“Fine Current
Adjustment” rheostat. The welder is equipped with a
“Start” button, an “Ignition” switch, an “Idler” control
switch, and a “Glow Plug” button for easier cold weath-
er starting.
Remote Control - The Remote / Local Switch and
Receptacle are standard.
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.
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A2.4
A2.4
INSTALLATION
PRE-OPERATION INSTALLATION
WARNING
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SUR-
FACES.
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
Where there is a combustible surface directly under sta-
tionary or fixed electrical equipment, the surface shall be
covered with a steel plate at least .06”(1.6mm) thick,
which shall extend not more than 5.90”(150mm) beyond
the equipment on all sides.
--------------------------------------------------------------------------------
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
MACHINE GROUNDING
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
According to the United States National Electrical
Code, the frame of this portable generator is not
required to be grounded and is permitted to serve as
the grounding means for cord connected equipment
plugged into its receptacle.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• 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
extent to which such requirements may apply to your
particular situation and follow them explicitly. A
------------------------------------------------------------------------
MOVING PARTS can injure.
machine grounding stud marked with the symbol
is
• Do not operate with doors open or
guards off.
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
ground such as a metal water pipe going into the
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
electrical equipment.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at the
front of this operatorʼs manual.
-----------------------------------------------------------
EXHAUST SPARK ARRESTER
Some federal, state or local laws may require that
engines be equipped with exhaust spark arresters
when they are operated in certain locations where
unarrested sparks may present a fire hazard. The
standard muffler included with this welder does not
qualify as a spark arrester. When required by local
regulations, a suitable spark arrester must be installed
and properly maintained.
LIFT BAIL
A lift bail is provided for lifting with a hoist.
WARNING
• Lift only with equipment of adequate
lifting capacity.
• Be sure machine is stable when lifting.
• Do not lift this machine using lift bail if
it is equipped with a heavy accessory
such as trailer or gas cylinder.
CAUTION
FALLING
EQUIPMENT can
cause injury.
• Do not lift machine if lift bail is
damaged.
• Do not operate machine while
suspended from lift bail.
----------------------------------------------------------------------------
Use of an incorrect arrester may lead to engine damage
or performance loss. Contact the engine manufacturer for
specific recommendations.
------------------------------------------------------------------------
LOCATION / VENTILATION
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:
Always operate the welder with the doors closed.
Leaving the doors open changes the designed air flow
and may cause overheating.
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.
1. Design capacity of trailer vs. weight of Lincoln equip-
ment and likely additional attachments.
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A2.5
A2.5
INSTALLATION
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
PRE-OPERATION SERVICE
CAUTION
3. Proper placement of the equipment on the trailer to
ensure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.
READ the engine operating and maintenance instruc-
tions supplied with this machine.
WARNING
4. Typical conditions of use, i.e., travel speed, rough-
ness of surface on which the trailer will be operat-
ed; environmental conditions, likely maintenance.
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
(1)
5. Conformance with federal, state and local laws.
• Do not leave unattended while
fueling.
(1)
Consult your federal, state and local laws regarding specific
requirements for use on public highways.
• Wipe up spilled fuel and allow
fumes to clear before starting
engine.
• Do not overfill tank, fuel expan-
sion may cause overflow.
VEHICLE MOUNTING
DIESEL FUEL
can
WARNING
cause fire
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
-------------------------D---I--E---S--E---L----F---U---E---L----O---N---L--Y---------
• Only transport this Equipment on serviceable
vehicles 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
crankcase filled with a high quality SAE 10W/30 oil.
This oil should be acceptable for most typical ambient
temperatures. Consult the engine operation manual
for specific engine manufacturerʼs recommendations.
Upon receipt of the welder, check the engine dipstick to
be sure the oil is at the “full” mark. DO NOT overfill.
• Do not exceed maximum rated loads for compo-
nents such as suspension, axles and tires.
• Use appropriate nuts bolts and lockwashers to
attach the equipment base to the metal bed or
frame of vehicle.
• Follow vehicle manufacturerʼs instructions.
------------------------------------------------------------------------
FUEL
Fill the fuel tank with the grade of fuel recommended in
the Engine Operatorʼs manual. Make sure the fuel
valve on the water separator is in the open position.
POLARITY CONTROL AND CABLE SIZES
With the engine off, route the electrode and work
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-
itive polarity, connect the electrode cable to the termi-
nal marked “+”. For Negative polarity, connect the
electrode cable to the “-” stud. These connections
should be checked periodically and tightened if neces-
sary.
COOLING SYSTEM
The radiator has been filled at the factory with a 50-50
mixture of ethylene glycol antifreeze and water. Check
the radiator level and add a 50-50 solution as needed
(see engine manual or antifreeze container for alter-
nate antifreeze recommendations).
When welding at a considerable distance from the
welder, be sure you use ample sized welding cables.
RECOMMENDED COPPER CABLE SIZES
Cables Sizes for Combined Length
of Electrode Plus Work Cable
Amps
250
Duty Cycle
100%
Up to 200ft.(61m) 200 to 250ft.
(61 to 76m)
1
1/0
2/0
300
60%
1/0
CLASSIC® 300D & 300G
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A2.6
A2.6
INSTALLATION
BATTERY CHARGING
WARNING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes
away.
BATTERY ACID can burn eyes and
skin.
• Wear gloves and eye protection and be
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
battery clamp. When reinstalling, connect the
negative cable last.
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.
Use correct polarity - Negative Ground.
• 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
battery clamp until snug.
------------------------------------------------------------------------
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.
When replacing, jumping or otherwise connecting the
battery to the battery cables, the proper polarity must
be observed. This system is NEGATIVE GROUND.
CLASSIC® 300D & 300G
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B2.1
B2.1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2.2
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2.2
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2.3
Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2.3
Idler Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2.4
CLASSIC® 300D & 300G
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B2.2
B2.2
OPERATION
7. Allow the engine to run at high idle speed for sev-
eral minutes to warm the engine. Stop the engine
and recheck the oil level, after allowing sufficient
time for the oil to drain into the pan. If the level is
down, fill it to the full mark again. The engine con-
trols were properly set at the factory and should
require no adjusting when received.
ENGINE OPERATION
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
COLD WEATHER STARTING:
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
about -15°F (-26°C), it maybe desirable to install cold-
starting aides.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
Note: Extreme cold weather staring may require longer
glow plug operation.
• Use in open, well ventilated areas or
vent exhaust outside.
WARNING
------------------------------------------------------------------------
MOVING PARTS can injure.
Under NO conditions should ether or other starting
fluids be used!
• Do not operate with doors open or
guards off.
------------------------------------------------------------------------
HIGH ALTITUDE OPERATION:
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
The engine will run correctly up to an altitude of 600m
(2000ft.). If the engine is to be operated permanently at
an altitude above this, the fuel consumption and
exhaust emissions may be excessive.
See additional warning information at the
front of this operatorʼs manual.
------------------------------------------------------------
Contact the Perkins Application Department for any
engine adjustments that may be required.
Operate the welder with the doors closed. Leaving the
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
water separator located on the fuel rail. Refill the fuel
tank to minimize moisture condensation in the tank.
Also, running out of fuel tends to draw dirt into the fuel
system.
1. Turn the “IDLER” switch to “HIGH”.
2. Turn the “IGNITION” switch to “ON”.
3. Press the Glow Plug button for 20 to 30 seconds.
(maximum 60 seconds).
4. Press the Start button. When the engine starts
running, release both buttons. If the engine fails to
start in 20 seconds, wait 30 seconds and repeat
the above procedure.
When hauling the welder between job sites, close the
fuel feed valve on the separator located on the fuel rail.
If the fuel supply is cut off or runs out while the fuel
pump is operating, air may be entrapped in the fuel dis-
tribution system. If this happens, bleeding of the fuel
system may be necessary. Use qualified personnel to
tion of this manual.
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.
CLASSIC® 300D & 300G
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B2.3
B2.3
OPERATION
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
cycle is based on a ten minute period; thus, the welder can
be loaded at rated output for six minutes out of every ten
minute period.
ENGINE BREAK-IN
Lincoln Electric selects high quality, heavy-duty industrial
engines for the portable welding machines we offer.
While it is normal to see a small amount of crankcase oil
consumption during initial operation, excessive oil use,
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
higher, which are operated at low or no-load conditions for
extended periods of time are especially susceptible to the
conditions described above. To accomplish successful
engine break-in, most diesel-powered equipment needs
only to be run at a reasonably heavy load within the rating
of the welder for some period of time during the engineʼs
early life. However, if the welder is subjected to extensive
light loading, occasional moderate to heavy loading of the
engine may sometimes be necessary. Caution must be
observed in correctly loading a diesel/generator unit.
CAUTION
DO NOT TURN THE “CURRENT RANGE SELECTOR”
WHILE WELDING because the current may arc between
the contacts and damage the switch.
-------------------------------------------------------------------------------
The “Current Range Selector” provides five overlapping cur-
rent ranges. The “Fine Current Adjustment” adjusts the cur-
rent from minimum to maximum within each range. Open cir-
cuit voltage is also controlled by the “Fine Current
Adjustment” permitting control of the arc characteristics.
A high open circuit voltage setting provides the soft “butter-
ing” arc with best resistance to pop-outs preferred 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 Current Adjustment” near maxi-
mum.
1. Connect the welder output studs to a suitable resis-
tive load bank. Note that any attempt to short the
output studs by connecting the welding leads togeth-
er, direct shorting of the output studs, or connecting
the output leads to a length of steel will result in cat-
astrophic damage to the generator and voids the
warranty.
For example: to 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.
2. Set the welder controls for an output current and volt-
age within the welder rating and duty cycle. Note that
any attempt to exceed the welder rating or duty cycle
for any period of time will result in catastrophic dam-
age to the generator and voids the warranty.
3. Periodically shut off the engine and check the
crankcase oil level.
When a forceful “digging” arc is required, usually for vertical
and overhead welding, use a higher “Current Range
Selector” setting and lower open circuit voltage.
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.
WELDER OPERATION
DUTY CYCLE
Some arc instability may be experienced with EXX10 elec-
trodes when trying to operate with long arc techniques at set-
tings at the lower end of the open circuit voltage range.
WARNING
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and ground.
ELECTRIC SHOCK can kill.
CAUTION
DO NOT attempt to set the “Current Range Selector” between
the five points designated on the nameplate.
FUMES & GASES can be dangerous.
•
•
Keep your head out of the fumes.
Use ventilation or exhaust to remove
fumes from breathing zone.
--------------------------------------------------------------------------------
These switches have a spring loaded cam which almost elim-
inates the possibility of setting this switch between the des-
ignated points.
WELDING SPARKS can cause fire or
explosion.
•
Keep flammable material away.
ARC RAYS can burn.
Wear eye, ear, and body protection.
•
CLASSIC® 300D & 300G
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B2.4
B2.4
OPERATION
IDLER OPERATION
AUXILIARY POWER
Start the engine with the “Idler” switch in the “High”
position. Allow it to run at high idle speed for several
operating speeds.
If a GFCI receptacle is tripped, See the MAINTE-
NANCE section for detailed information on testing and
resetting the GFCI receptacle.
The AC auxiliary power, supplied as a standard, has a
rating of 3.0 KVA of 115/230 VAC (60 hertz).
The idler is controlled by the “Idler” toggle switch on the
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
receptacles are provided. The circuit is protected with
circuit breakers.
1. In the “High”
position, the idler solenoid deac-
tivates, and the engine goes to high idle speed. The
speed is controlled by the governor.
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 20 amps can be drawn
from the 115 volt GFCI receptacle. The total combined
load of all receptacles is not to exceed 3.0 KVA.
2. In the “Auto”
/
position, the idler oper-
ates as follows:
a. When welding or drawing power for lights or tools
(approximately 100 watts minimum) from the
receptacles, the idler solenoid deactivates and the
engine operates at high idle speed.
An optional power plug kit is available. When this kit is
specified, the customer is supplied with a plug for each
receptacle.
b. When welding ceases or the power load is turned
off, a preset time delay of about 15 seconds
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
Low Idle (1400 RPM)-No Load @ 45 Volts
High Idle (1800 RPM)-No Load @ 96.6 Volts
0.28 gal/hr ( 1.06 ltrs/hr)
0.42 gal/hr ( 1.59 ltrs/hr)
3000 Watts
0.59 gal/hr ( 2.23 ltrs/hr)
1.03 gal/hr ( 3.90 ltrs/hr)
1.37 gal/hr ( 5.19 ltrs/hr)
250 Amps @ 30 Volts
300 Amps @ 32 Volts
CLASSIC® 300D & 300G
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C2.1
C2.1
TABLE OF CONTENTS - ACCESSORIES SECTION
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2
Wire Feed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2.3
CLASSIC® 300D & 300G
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C2.2
C2.2
ACCESSORIES
TIG OPTIONS
OPTIONAL FEATURES (Field Installed)
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
a handle. High frequency bypass is built in.
Additionally, the K936-3 control cable is required if
remote control is used. If remote control is not used the
K936-4 control cable is required.
WARNING
Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly. The use of an arc welder
for pipe thawing is not approved by the CSA, nor is
it recommended or supported by Lincoln Electric.
------------------------------------------------------------------------
PTA-26V TIG Torch K1783-9
Air cooled 200 amp torch equipped with valve for gas
flow control. 25Ft. length.
Power Plug Kit K802D
Magnum Parts Kit For PTA-26V TIG Torch KP509
A power plug kit for the auxiliary power receptacles is
available. (Provides a plug for each receptacle.)
Control Cable K936-4 (required for TIG Module)
Control cable for connecting the K930-2 TIG Module.
Spark Arrestor Kit K903-1
Includes a heavy gage steel, approved spark arrestor,
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.
Attaches to the TIG torch for convenient finger control.
TRAILER K953-1
Contactor Kit K938-1 (required for TIG Module)
Provide “Cold” tungsten Tip when welding with the TIG
Module.
Two-wheeled trailer with optional fender and light package.
For highway use, consult applicable federal, state, and local
laws regarding possible additional requirements. There is a
choice of 2 hitches, a fender & a light package.
Control Cable Extension K937-45
Allows the TIG Module to be operated at distances up
to 200 ft. from the power source.Available in 45 ft.
(13.7m).
Ball Hitch K958-1
Lunette Eye Hitch K958-2
Fender & Light Kit K959-1
Cable Rack K965-1
Water Valve Kit K844-1
For use with a water-cooled TIG torch. Installs inside
TIG Module.
Service Indicator Kit K1858-1
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.
CLASSIC® 300D & 300G
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C2.3
C2.3
ACCESSORIES
WIRE FEEDER OPTIONS
Magnum Spool Gun K487-25
Wire Feed Module K623-1
Provides constant voltage (CV) output with improved
arc stability for Innershield welding. Excellent for MIG
welding. Recommended wire feeders are the LN-7,
LN-23P and LN-25. (Factory installed on the K1643-2).
Hand held semiautomatic wire feeder requires SG
Control Module. 25 ft. length.
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.
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.
Magnum® 350 Innershield Gun for LN-25 K126-2
For self-shielded wire with 15 ft. (4.5m) cable. For
.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
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.
CLASSIC® 300D & 300G
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C2.4
C2.4
NOTES
CLASSIC® 300D & 300G
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D2.1
D2.1
TABLE OF CONTENTS - MAINTENANCE SECTION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
GFCI Receptacle Testing & Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.6
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.7
CLASSIC® 300D & 300G
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D2.2
D2.2
MAINTENANCE
SAFETY PRECAUTIONS
4. Follow the engine service schedule in this manual
and the detailed maintenance and troubleshooting
in the engine manufacturerʼs manual.
WARNING
Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. In some cases, it may be necessary
to remove safety guards to perform required
maintenance. Remove guards only when neces-
sary and replace them when the maintenance
requiring their removal is complete. Always use
the greatest care when working near moving
parts.
COOLING SYSTEM
The Classic® 300D Perkins is equipped with a pres-
sure radiator. Keep the radiator cap tight to prevent
loss of coolant. Clean and flush the cooling system
periodically to prevent clogging the passage and over-
heating the engine. When antifreeze is needed, always
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
the nearest Lincoln Field Service Shop.
-----------------------------------------------------------------------
ELECTRIC SHOCK can kill.
This welder is equipped with a double-shielded ball
bearing having sufficient grease to last indefinitely
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
of grease one inch wide, one inch long, and one inch
high weighs approximately one half ounce. Over-
greasing is far worse than insufficient greasing.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
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
grease.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
COMMUTATOR AND BRUSHES
------------------------------------------------------------------------
MOVING PARTS can injure.
WARNING
• Do not operate with doors open or
guards off.
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-
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
ing armature when stoning the commutator.
front of this operatorʼs manual.
------------------------------------------------------------------------
-----------------------------------------------------------
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
least once every two months. In particularly dirty
locations, this cleaning may be necessary once a
week. Use low pressure air to avoid driving dirt into
the insulation.
Periodically inspect the commutator, slip rings, and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
2. “Current Range Selector” contacts should not be
greased. To keep the contacts clean, rotate the cur-
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.
3. Put a drop of oil on the “Current Range Selector”
shaft at least once every month.
CLASSIC® 300D & 300G
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D2.3
D2.3
MAINTENANCE
Replace brushes when they wear within 1/4” of the pig-
tail. A complete set of replacement brushes should be
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-
tator as the armature rotates at full speed until contact
is made across the full face of the brushes. After ston-
ing, blow out the dust with low pressure air.
PURGING AIR FROM FUEL SYSTEM
(PERKINS 404C-22 ENGINE)
WARNING
Keep fuel clear of open flames or arcs, allow
engine to cool before working on the fuel system.
Wipe up any spilled fuel and do not start engine
until fumes clear.
To seat slip ring brushes, position the brushes in place.
Then slide one end of a piece of fine sandpaper
between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres-
sure on top of the brushes, pull the sandpaper around
the circumference of the rings - in direction of rotation
only - until brushes seat properly. In addition, stone slip
ring with a fine stone. Brushes must be seated 100%.
------------------------------------------------------------------------
If the engine is running rough and you suspect air has
been trapped in the fuel system, (e.g. the engine was
allowed to run out of fuel) perform the following steps
using qualified personnel:
1. Loosen by two or three turns, the vent screw
(Figure D2.3) 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
Lever
circuit board, disconnect the battery.
------------------------------------------------------------------------
When installing a new battery or using a jumper battery
to start the engine, be sure the battery polarity is con-
nected properly. The correct polarity is negative
ground. Damage to the engine alternator and the print-
ed circuit board can result from incorrect connection.
FIGURE D2.3
2. Operate the electric fuel pump by turning the
“Ignition” switch “ON” until fuel, free of air, flows
from the vent point. Tighten the vent screw.
3. Contact your Perkins Engine repair facility if prob-
lems persist.
1. Proper operation of the idler requires good ground-
ing of the printed circuit board, reed switch, and bat-
tery.
2. Idler solenoid is activated for low idle.
3. 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.
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D2.4
D2.4
MAINTENANCE
SERVICE DECAL FOR CODES 11249 AND BELOW
ENGINE SERVICE
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE-(20 / 50 HOURS)
EVERY 100 HOURS OR 3 MONTHS
EVERY 250 HOURS OR 6 MONTHS
EVERY 500 HOURS OR 12 MONTHS
EVERY 1000 HOURS
ENGINE SERVICE (NOTE 2)
MAINTENANCE ITEM
Coolant level
TYPE OR QUANTITY
I
I
50/50 Water/Ethylene Glycol
9.5qrts., 9.0L
Concentration of antifreeze
Coolant (NOTE 3)
R
R
I
Engine oil level (NOTE 1)
3)
R
R
Engine oil (NOTE 1 &
Engine oil filter
8.45Qrts, 8L (including filter)
Perkins #140517050
R
R
C
Drain water separator & fuel strainer
Fuel filter canister
R
Perkins #2656613
alternator drive belt
I
Tension of
I
Alternator drive belt wear
Alternator drive belt
Perkins #080109107
Donaldson #P821575
C
Air filter(earlier check may be req'd.)
nt
R
Air filter eleme
R
I
Renew the engine breather
Tighten cylinder head
Valve clearances
I
Intake .008", exhaust .08"
Contact Perkins
I
Electrical systems
I
All n
uts and bolts for tightness
I
I
Injector performance
Leaks or engine damage
Battery
I
I = Inspect
C = Clean
R = Replace
Notes:
erators Manual for oil recommendations.
(1) Consult Engine Op
(2) Consult Engine Op
d
erators Manual for a ditional maintenance schedule information.
(3) Fill slowly! Ensure correct quantity is used.
ons tobe carried out by trained personnel
Above operati
with reference to the workshop manual where necessary.
These preventive m
aintenance periods apply to average conditions of operation.
S2595C3
If necessary use s
h
eriods.
orter p
CLASSIC® 300D & 300G
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D2.6
D2.6
MAINTENANCE
GFCI RECEPTACLE TESTING AND RESET-
TING 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.
CLASSIC® 300D & 300G
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D2.7
D2.7
MAINTENANCE
1. Case Front Assembly
2. Engine Assembly
3. Radiator Assembly
4. Fuel Tank & Mounting
5. Base & Lift Bale Assembly
6. Exciter & Stator
7. Welding Generator & Coupling
8. Roof & Doors
9. Generator Brush Holder
FIGURE D2.7 - MAJOR COMPONENT LOCATION
3
8
1
4
2
5
7
9
6
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D2.8
D2.8
NOTES
CLASSIC® 300D & 300G
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A3.1
A3.1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.3
Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.5
Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.5
CLASSIC® 300D & 300G
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A3.2
A3.2
INSTALLATION
TECHNICAL SPECIFICATIONS - CLASSIC® 300D KUBOTA
INPUT - DIESEL ENGINE
Make/Model
Description
Speed (RPM)
Displacement
Starting
System
Capacities
4 Cylinder
4 Cycle
134.1 cu. in
(2.2 ltrs)
12VDC battery
Fuel: 15 gal.
57 L
Naturally Aspirated
Water-Cooled
Diesel Engine
(Group 24, 650
cold crank amps)
1.4 KW Starter
40 A. Alternator
w/ built in reg.
Kubota
High Idle 1800
Low Idle 1400
V2203M
Bore x Stroke
Oil: 8.0 Qts.
7.6 L
Cast Iron Cylinder, Full Load 1800
Block/Crankcase
3.43” x 3.64”
Coolant:
9.5 Qts.
9.0 L
32.5HP @1800 RPM
RATED OUTPUT @ 104°F(40°C) - WELDER
DESCRIPTION
RATED DC OUTPUT*
Duty
DC CURRENT RANGE
Fine Adjustments in each Range
40-350 Amps
220-Max.
VOLTS @ RATED AMPS
CYCLE
300 Amp DC Welder
All Copper Windings
30V @ 250A
32V @ 300A
100%
60%
160-240
120-190
Pure DC Power Generator
99V DC Max. OCV @ 1800RPM
80-130
Min.-90
RATED OUTPUT @ 104°F(40°C) - GENERATOR
(1)
Auxiliary Power
3,000 Watts Continuous, 60 Hz AC
26 Amps @ 115V
13 Amps @ 230V
(2)
PHYSICAL DIMENSIONS
MODEL
HEIGHT
WIDTH
DEPTH
WEIGHT
K1643-5 CSA@
With Out
1320 lbs.
(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.
(615 kg)
With Wire Feed Module
* Based on a 10 min. period.
(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.
(2)
Height to top of exhaust elbow.
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A3.3
A3.3
INSTALLATION
Engine Idler - The Classic® 300D is equipped with 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-
trol switch on the panel locks the idler in high idle posi-
tion when desired.
GENERAL DESCRIPTION
®
The CLASSIC 300D KUBOTA is a heavy duty, engine
driven, DC arc welding power source, capable of pro-
viding constant current output for stick welding or DC
TIG welding. This welder is wound with all copper coils,
rated at 300 amps/32 Volts, and provides other
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,
AC. Output voltage is maintained within 10% at all
in Section C for Power Plug Kit.)
™
K623-1 Wire Feed Module , the CLASSIC® 300D
KUBOTA will provide constant voltage output for run-
ning the LN-7, LN-23P, or LN-25 wire feeders. (The
Wire Feed Module is factory installed on the K1643-6).
The optional K924-5 Remote Control Kit, provides a
remote control rheostat for remote fine current and
description.
Welder Enclosure - The complete welder is rubber
mounted on a rugged steel “C” channel base.
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 (-).
The CLASSIC® 300D KUBOTA has an Electronic
Engine Protection System. In the event of sudden low
oil pressure or high coolant temperature, the engine
immediately shuts down. The CLASSIC® 300D KUB-
OTA has a current range of 40-350 DC amps with out-
put ratings as follows:
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.
RATED OUTPUT
DUTY CYCLE
250A @ 30V
300A @ 32V
100%
60%
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.
fault codes.
These units are also capable of providing 3 kVA of
115/230 volts of 60 cycle AC auxiliary power.
The CLASSIC® 300D KUBOTA uses the Kubota
V2203M industrial water-cooled diesel engine.
DESIGN FEATURES
Control Panel
High Idle RPM (OCV) Adjustment - A Potentiometer
is mounted on the Control Panel that allows the opera-
tor to adjust the high idle engine speed between 1650
and 1800 RPMʼS. This is to allow further adjustment of
the OCV. Total OCV adjustment range is about 15
volts.
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
Range Selector” switch and
a
“Fine Current
Adjustment” rheostat. The welder is equipped with a
“Start” button, an “Ignition” switch, an “Idler” control
switch, and a “Glow Plug” button for easier cold weath-
er starting.
Oil Drain Valve - A ball valve, hose and clamp are
standard.
Remote Control - The Remote/Local switch and
The control panel also contains an engine temperature
gauge, a battery charging ammeter, an oil pressure
gauge, two three prong grounding type receptacles
and circuit breakers for auxiliary power.
Receptacle are standard.
GFCI Receptacle - One UL approved 115V ground
fault circuit interupter duplex type receptacle is stan-
dard on codes 11243 and above. See MAINTENANCE
section for detailed information on testing and resetting
the GFCI receptacle.
All Copper Windings - For long life and dependable
operation.
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A3.4
A3.4
INSTALLATION
PRE-OPERATION INSTALLATION
WARNING
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under sta-
tionary or fixed electrical equipment, the surface shall be
covered with a steel plate at least .06”(1.6mm) thick,
which shall extend not more than 5.90”(150mm) beyond
the equipment on all side.
Do not attempt to use this equipment until you have
thoroughly read the engine manufacturerʼs manual sup-
plied with your welder. It includes important safety pre-
cautions, detailed engine starting, operating and mainte-
nance instructions, and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
--------------------------------------------------------------------------------
• 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
made for checking and maintaining the oil level at the normal
(FULL) oil capacity in the crankcase.
• Insulate yourself from work and ground
• Always wear dry insulating gloves.
--------------------------------------------------------------------------------
ENGINE EXHAUST can kill.
When operating the welder at an angle, the effective fuel
capacity will be slightly less than the amount specified.
• Use in open, well ventilated areas or vent
exhaust outside.
--------------------------------------------------------------------------------
MOVING PARTS can injure.
MACHINE GROUNDING
• Do not operate with doors open or guards
off.
According to the United States National Electrical Code, the
frame of this portable generator is not required to be grounded
and is permitted to serve as the grounding means for cord con-
nected equipment plugged into its receptacle.
• Stop engine before servicing.
• Keep away from moving parts.
--------------------------------------------------------------------------------
See additional warning information at the front
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
requirements may apply to your particular situation and follow
them explicitly. A machine grounding stud marked with the sym-
of this operatorʼs manual.
-----------------------------------------------------------------
EXHAUST SPARK ARRESTER
Some federal, state or local laws may require that engines be
equipped with exhaust spark arresters when they are oper-
ated in certain locations where unarrested sparks may pre-
sent a fire hazard. The standard muffler included with this
welder does not qualify as a spark arrester. When required
by local regulations, a suitable spark arrester must be
installed and properly maintained.
bol
is 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 earth ground such as
a metal water pipe going into the 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
electrical equipment.
CAUTION
LIFT BAIL
Use of an incorrect arrester may lead to engine damage or
performance loss. Contact the engine manufacturer for spe-
cific recommendations.
A lift bail is provided for lifting with a hoist.
--------------------------------------------------------------------------------
WARNING
LOCATION/VENTILATION
Always operate the welder with the doors closed. Leaving the
doors open changes the designed air flow and may cause
overheating.
• Lift only with equipment of ade-
quate lifting capacity.
• Be sure machine is stable when
lifting.
The welder should be located to provide an unrestricted flow of
clean, cool air. Also, locate the welder so that engine exhaust
fumes are properly vented to an outside area.
• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trailer
or gas cylinder.
ANGLE OF OPERATION
FALLING
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bale.
------------------------------------------------------------------------
• Do not lift machine if lift bale is
Engines are designed to run in the level condition which is
where the optimum performance is achieved. The maximum
angle of continuous operation is 20 degrees in all directions, 30
degrees Intermittent (less than 10 minutes continuous) in all
directions.
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A3.5
A3.5
INSTALLATION
RECOMMENDED COPPER CABLE SIZES
TRAILER
Cables Sizes for Combined Length
of Electrode Plus Work Cable
If the user adapts a non-Lincoln trailer, the user must
assume responsibility that the method of attachment
and usage does not result in a safety hazard nor dam-
age the welding equipment. Some of the factors to be
considered are as follows:
Amps
250
Duty Cycle
100%
Up to 200ft.(61m) 200 to 250ft.
(61 to 76m)
1
1/0
2/0
300
60%
1/0
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
PRE-OPERATION SERVICE
CAUTION
3. Proper placement of the equipment on the trailer to
ensure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.
READ the engine operating and maintenance instruc-
tions supplied with this machine.
------------------------------------------------------------------------
4. Typical conditions of use, i.e., travel speed, rough-
ness of surface on which the trailer will be operat-
ed; environmental conditions, likely maintenance.
WARNING
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
(1)
5. Conformance with federal, state and local laws.
(1)
Consult your federal, state and local laws regarding specific
requirements for use on public highways.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
VEHICLE MOUNTING
WARNING
DIESEL FUEL
fumes to clear before starting
engine.
• Do not overfill tank, fuel expan-
sion may cause overflow.
can
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
cause fire
-------------------------D---I--E---S--E---L----F---U---E---L----O---N---L--Y---------
• Only transport this Equipment on serviceable
vehicles 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
crankcase filled with a high quality SAE 10W/30 oil.
This oil should be acceptable for most typical ambient
temperatures. Consult the engine operation manual
for specific engine manufacturerʼs recommendations.
Upon receipt of the welder, check the engine dipstick to
be sure the oil is at the “full” mark. DO NOT overfill.
• Do not exceed maximum rated loads for compo-
nents such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of
vehicle.
• Follow vehicle manufactureʼs 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 valve on
the water separator is in the open position.
With the engine off, route the electrode and work
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-
itive polarity, connect the electrode cable to the termi-
nal marked “+”. For Negative polarity, connect the
electrode cable to the “-” stud. These connections
should be checked periodically and tightened if neces-
sary.
COOLING SYSTEM
The radiator has been filled at the factory with a 50-50
mixture of ethylene glycol antifreeze and water. Check
the radiator level and add a 50-50 solution as needed
(see engine manual or antifreeze container for alter-
nate antifreeze recommendations).
When welding at a considerable distance from the
welder, be sure you use ample sized welding cables.
CLASSIC® 300D & 300G
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A3.6
A3.6
INSTALLATION
Battery Charging
WARNING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes
away.
BATTERY ACID can burn eyes and
skin.
• Wear gloves and eye protection and be
careful when boosting, charging or work-
ing 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
battery clamp. When reinstalling, connect the
negative cable last.
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.
Use correct polarity - Negative Ground.
• 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
battery clamp until snug.
------------------------------------------------------------------------
The CLASSIC® 300D KUBOTA 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.
When replacing, jumping or otherwise connecting the
battery to the battery cables, the proper polarity must
be observed. This system is NEGATIVE GROUND.
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B3.1
B3.1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3.2
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3.2
Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3.3
Idler Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3.4
CLASSIC® 300D & 300G
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B3.2
B3.2
OPERATION
COLD WEATHER STARTING:
ENGINE OPERATION
With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
about -5°F (-20°C), it maybe desirable to install cold-
starting aides.
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine start-
ing, operating and maintenance instructions, and
parts lists.
Note: Extreme cold weather staring may require longer
glow plug operation.
-------------------------------------------------------
ELECTRIC SHOCK can kill.
WARNING
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
Under NO conditions should ether or other starting
fluids be used!
• Always wear dry insulating gloves.
-------------------------------------------------------
ENGINE EXHAUST can kill.
------------------------------------------------------------------------
• Use in open, well ventilated areas or
vent exhaust outside.
HIGH ALTITUDE OPERATION:
At higher altitudes, output derating may be necessary.
For maximum rating, derate the welder 4% for every
300 meters (984 ft.) above 1500 meters (4920 ft.).
--------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
Contact a Kubota Service Representative for any
engine adjustments that may be required.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at the
STOPPING THE ENGINE
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
cause overheating.
At the end of each dayʼs welding, check the crankcase
oil level, drain accumulated dirt and water from the
water separator 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.
STARTING THE CLASSIC® 300D KUBOTA V2203M
DIESEL ENGINE
When hauling the welder between job sites, close the
valve on the water separator.
1. Turn the “IDLER” switch to “HIGH”.
2. Turn the “IGNITION” switch to “ON”.
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
pump is operating, air may be entrapped in the fuel dis-
tribution system. If this happens, bleeding of the fuel
system may be necessary. Use qualified personnel to
tion of this manual.
4. Press the Glow Plug button and the Start button at the
same time. When the engine starts 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 “IGNI-
TION” switch to “OFF”.
ENGINE BREAK-IN
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.
7. Allow the engine to run at high idle speed for several
minutes to warm the engine. Stop the engine and
recheck the oil level, after allowing sufficient time for
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.
Lincoln Electric selects high quality, heavy-duty indus-
trial engines for the portable welding machines we
offer. While it is normal to see a small amount of
crankcase oil consumption during initial operation,
excessive oil use, wet stacking (oil or tar like substance
at the exhaust port), or excessive smoke is not normal.
CLASSIC® 300D & 300G
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B3.3
B3.3
OPERATION
DUTY CYCLE
Larger machines with a capacity of 350 amperes and
higher, which are operated at low or no-load conditions
for extended periods of time are especially susceptible
to the conditions described above. To accomplish suc-
cessful engine break-in, most diesel-powered equip-
ment needs only to be run at a reasonably heavy load
within the rating of the welder for some period of time
during the engineʼs early life. However, if the welder is
subjected to extensive light loading, occasional moder-
ate to heavy loading of the engine may sometimes be
necessary. Caution must be observed in correctly
loading a diesel/generator unit.
The NEMA output rating of the CLASSIC® 300D KUB-
OTA is 300 amperes at 32 arc volts on a 60% duty
cycle (consult Specifications in this manual for alternate
ratings). Duty cycle is based on a ten minute period;
thus, the welder can be loaded at rated output for six
minutes out of every ten minute period.
CONTROL OF WELDING CURRENT
CAUTION
1. Connect the welder output studs to a suitable
resistive load bank. Note that any attempt to short
the output studs by connecting the welding leads
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
voids the warranty.
DO NOT TURN THE “CURRENT RANGE SELEC-
TOR” WHILE WELDING because the current may
arc between the contacts and damage the switch.
------------------------------------------------------------------------
The “Current Range Selector” provides five overlap-
ping current ranges. The “Fine Current Adjustment”
adjusts the current from minimum to maximum within
each range. Open circuit voltage is also controlled by
the “Fine Current Adjustment” permitting control of the
arc characteristics.
2. Set the welder controls for an output current and
voltage within the welder rating and duty cycle.
Note that any attempt to exceed the welder rating
or duty cycle for any period of time will result in
catastrophic damage to the generator and voids
the warranty.
A high open circuit voltage setting provides the soft
“buttering” arc with best resistance to pop-outs pre-
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
Current Adjustment” near maximum. For example: to
obtain 175 amps and a soft arc, set the “Current
3. Periodically shut off the engine and check the
crankcase oil level.
WELDER OPERATION
WARNING
Range Selector” to the 190-120 position and then
adjust the “Fine Current Adjustment” for 175 amps.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground.
When a forceful “digging” arc is required, usually for
vertical and overhead welding, use a higher “Current
Range Selector” setting and lower open circuit voltage.
For example: to obtain 175 amps and a forceful arc,
set the “Current Range Selector” to the 240-160 posi-
tion and the “Fine Current Adjustment” setting to get
175 amps.
FUMES & GASES can be dangerous.
•
•
Keep your head out of the fumes.
Use ventilation or exhaust to remove
fumes from breathing zone.
Some arc instability may be experienced with EXX10
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.
CLASSIC® 300D & 300G
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B3.4
B3.4
OPERATION
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
operating speeds.
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 idler is controlled by the “Idler” toggle switch on
the welder control panel. The switch has two positions
as follows:
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.
1. In the “High”
position, the engine control unit
increases the engine to high idle speed.
2. In the “Auto”
/
position, the idler oper-
ates as follows:
An optional power plug kit is available. When this kit is
specified, the customer is supplied with a plug for each
receptacle.
a. When welding or drawing power for lights or tools
(approximately 100 watts minimum) from the recep-
tacles, the engine operates at high idle speed.
When the High Speed Adjustment knob is in the MIN
position, the frequency of the AC auxiliary output may
be reduced to approximately 55 Hertz. It is recom-
mended that the High Idle Speed Adjustment knob
should be in the MAX position when using the AC aux-
iliary output.
b. When welding ceases or the power load is turned
off, a preset time delay of about 15 seconds 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 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-
mation on testing and resetting the GFCI receptacle.
CLASSIC® 300D WITH KUBOTA V2203M DIESEL ENGINE
TYPICAL FUEL CONSUMPTION DATA
Low Idle (1400 RPM)-No Load
0.30 gal/hr ( 1.14 ltrs/hr)
0.46 gal/hr ( 1.74 ltrs/hr)
0.61 gal/hr ( 2.31 ltrs/hr )
1.01 gal/hr ( 3.82 ltrs/hr)
1.32 gal/hr ( 5.00 ltrs/hr)
High Idle (1800 RPM)-No Load
3,000 Watts
250 Amps @ 30 Volts
300 Amps @ 32 Volts
CLASSIC® 300D & 300G
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C3.1
C3.1
TABLE OF CONTENTS - ACCESSORIES SECTION
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3
Wire Feed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3.3
CLASSIC® 300D & 300G
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C3.2
C3.2
ACCESSORIES
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
above.)
OPTIONAL FEATURES (Field Installed)
GENERAL OPTIONS
Remote Control Kit (K2464-1) - Contains remote
control rheostat (for adjusting the CC “STICK” OCV),
and 100ft.(30.5m) cable. (See Wiring/Connection
WARNING
Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly. The use of an arc welder
for pipe thawing is not approved by the CSA, nor is
it recommended or supported by Lincoln Electric.
------------------------------------------------------------------------
TIG OPTIONS
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
carrying, complete with a handle. High frequency
bypass is built in. The K936-4 control cable is
required.
Power Plug Kit (K802D) - A power plug kit for the aux-
iliary power receptacles is available. (Provides a plug
for each receptacle.)
GFCI Receptacle Kit (K1690-1) - Includes one UL
approved 115V ground fault circuit interrupter duplex
type receptacle with cover and installation instructions.
Replaces the factory installed 115V duplex receptacle.
Each receptacle of the GFCI duplex is rated at 20
amps. Maximum total current from the GFCI duplex is
limited to 20 amps. (For Codes 11112, 11113). See
MAINTENANCE 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.
length.
Magnum Parts Kit For PTA-26V TIG TorchKP509
Control Cable (K936-4) (required for TIG Module) -
Control Cable for connecting the K930-2 Tig Module.
Arc Start Switch (K814) (required for TIG Module) -
Comes with a 25ft.(7.6m) cable. Attaches to the TIG
torch for convenient finger control.
Spark Arrestor Kit (K903-1) - Includes a heavy gage
steel, approved spark arrestor, clamp and adapter for
mounting to the muffler exhaust pipe.
Contactor Kit (K938-1) (required for TIG Module) -
Provide “Cold” tungsten Tip when welding with the TIG
Module.
TRAILER (K953-1) - Two-wheeled trailer with optional fender
and light package. For highway use, consult applicable feder-
al, state, and local laws regarding possible additional require-
ments. There is a choice of 2 hitches, a fender & a light pack-
age.
Control Cable Extension (K937-45) - Allows the TIG
Module to be operated at distances up to 200 ft. from
the power source.Available in 45 ft. (13.7m).
K953-1 Trailer
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.
CLASSIC® 300D & 300G
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C3.3
C3.3
ACCESSORIES
WIRE FEED OPTIONS
Magnum Spool Gun (K487-25)-Hand held semiauto-
matic wire feeder requires SG Control Module. 25 ft.
(7.6m)length.
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.
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.
Wire Feed Module (K623-1) - Provides constant volt-
age (CV) output with improved arc stability for
Innershield welding. Excellent for MIG welding.
Recommended wire feeders are the LN-7, LN-23P and
LN-25. (Factory installed on the K1643-6).
LN-25 Wire Feeder (K449)-Portable CC/CV unit for
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.
Magnum® 350 Innershield Gun (for LN-25)(K126-2)-
For self-shielded wire with 15 ft. (4.5m) cable. For
.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)-
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 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.
CLASSIC® 300D & 300G
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C3.4
C3.4
NOTES
CLASSIC® 300D & 300G
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D3.1
D3.1
TABLE OF CONTENTS - MAINTENANCE SECTION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3
GFCI Receptacle Testing & Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.5
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.6
CLASSIC® 300D & 300G
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D3.2
D3.2
MAINTENANCE
MAINTENANCE
4
. Follow the engine service schedule in this manual
and the detailed maintenance and troubleshooting in
the engine manufacturerʼs manual.
WARNING
Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. In some cases, it may be necessary
to remove safety guards to perform required
maintenance. Remove guards only when neces-
sary and replace them when the maintenance
requiring their removal is complete. Always use
the greatest care when working near moving
parts.
COOLING SYSTEM
The CLASSIC® 300D KUBOTA is equipped with a
pressure radiator. Keep the radiator cap tight to pre-
vent loss of coolant. Clean and flush the cooling sys-
tem periodically to prevent clogging the passage and
overheating the engine. When antifreeze is needed,
always 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
the nearest Lincoln Field Service Shop.
-----------------------------------------------------------------------
ELECTRIC SHOCK can kill.
This welder is equipped with a double-shielded ball
bearing having sufficient grease to last indefinitely
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
of grease one inch wide, one inch long, and one inch
high weighs approximately one half ounce. Over-
greasing is far worse than insufficient greasing.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
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
grease.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
COMMUTATOR AND BRUSHES
------------------------------------------------------------------------
MOVING PARTS can injure.
WARNING
• Do not operate with doors open or
guards off.
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-
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
ing armature when stoning the commutator.
front of this operatorʼs manual.
------------------------------------------------------------------------
-----------------------------------------------------------
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
least once every two months. In particularly dirty
locations, this cleaning may be necessary once a
week. Use low pressure air to avoid driving dirt into
the insulation.
Periodically inspect the commutator, slip rings, and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
2. “Current Range Selector” contacts should not be
greased. To keep the contacts clean, rotate the cur-
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.
3. Put a drop of oil on the “Current Range Selector”
shaft at least once every month.
CLASSIC® 300D & 300G
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D3.3
D3.3
MAINTENANCE
Replace brushes when they wear within 1/4”(3.5mm)
of the pigtail. A complete set of replacement brushes
should be kept on hand. Lincoln brushes have a
curved face to fit the commutator. Have an experi-
enced maintenance man seat these brushes by lightly
stoning the commutator as the armature rotates at full
speed until contact is made across the full face of the
brushes. After stoning, blow out the dust with low pres-
sure air.
PURGING AIR FROM FUEL SYSTEM
(KUBOTA V2203M ENGINE)
WARNING
Keep fuel clear of open flames or arcs, allow
engine to cool before working on the fuel system.
Wipe up any spilled fuel and do not start engine
until fumes clear.
------------------------------------------------------------------------
If the engine is running rough and you suspect air has
been trapped in the fuel system, (e.g. the engine was
allowed to run out of fuel) perform the following steps
using qualified personnel:
To seat slip ring brushes, position the brushes in place.
Then slide one end of a piece of fine sandpaper
between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres-
sure on top of the brushes, pull the sandpaper around
the circumference of the rings - in direction of rotation
only - until brushes seat properly. In addition, stone slip
ring with a fine stone. Brushes must be seated 100%.
1. Fully open the air bleeding valve by turning it
counter clockwise, it is located on top of the fuel
injection pump next to the oil filler. (see figure D3.3)
Arcing or excessive exciter brush wear indicates a pos-
sible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.
Air Bleeding
Valve
IDLER MAINTENANCE
CAUTION
Before doing electrical work, disconnect the bat-
tery.
------------------------------------------------------------------------
When installing a new battery or using a jumper battery
to start the engine, be sure the battery polarity is con-
nected properly. The correct polarity is negative
ground. Damage to the engine alternator and the
Engine Control Unit can result from incorrect connec-
tion.
FIGURE D3.3
2. Turn the engine by pressing the start button until
the engine runs smoothly (this should take approx-
imately 10 seconds).
3. Fully close the air bleeding valve by turning it clock-
wise.
1. Proper operation of the idler requires good ground-
ing of the Engine Control Unit, current sensing
printed circuit board and battery.
Contact your Kubota Engine repair facility if problems
persist.
2. 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.
CLASSIC® 300D & 300G
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D3.4
D3.4
MAINTENANCE
ENGINE SERVICE
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE (50 HOURS)
EVERY 100 HOURS OR 3 MONTHS
EVERY 150 HOURS OR 4 MONTHS
EVERY 30O HOURS OR 9 MONTHS
EVERY 400 HOURS OR 12 MONTHS
EVERY 500 HOURS OR 15 MONTHS
EVERY 600 HOURS OR 18 MONTHS
ENGINE SERVICE (NOTE 2)
MAINTENANCE ITEM
Coolant level
TYPE OR QUANTITY
I
I
I
Concentration of antifreeze
R Coolant (NOTE 3)
50/50 Water/Ethylene Glycol
9.5 qrts., 9.0L
Engine oil level (NOTE 1)
Engine oil (NOTE 1 & 3)
Engine oil filter
R
R
R
8.0 qrts., 7.6L (including filter)
Kubota #16414-32430
R
C
Drain water separator & fuel strainer
Fuel filter canister
R
R
Kubota #16631-43560
Kubota #15831-43380
C
I
Fuel pre-filter element
Tension of alternator drive belt
Alternator drive belt wear
Alternator drive belt
I
R
Kubota # 17480-97010
Donaldson # P821575
C
I
Air filter (earlier check may be req'd)
Air filter element
I
I
I
Valve clearances
Intake .0071"-.0086", Exhaust .0071"-.0086"
Electrical systems
All nuts and bolts for tightness
Leaks or engine damage
Battery
I
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.
If necessary use shorter periods.
S25833
CLASSIC® 300D & 300G
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D3.5
D3.5
MAINTENANCE
GFCI RECEPTACLE TESTING AND RESET-
TING 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.
CLASSIC® 300D & 300G
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D3.6
D3.6
MAINTENANCE
1. Case Front Assembly
2. Engine Assembly
3. Radiator Assembly
4. Fuel Tank & Mounting
5. Base & Lift Bale Assembly
6. Exciter and Stator
7. Welding Generator & Coupling (2 of 2)
8. Roof & Doors
9. Generator Brush Holder
FIGURE D3.6 - MAJOR COMPONENT LOCATION
3
8
2
1
4
5
7
9
6
CLASSIC® 300D & 300G
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A4.1
A4.1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4.2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4.3
Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4.5
CLASSIC® 300D & 300G
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A4.2
A4.2
INSTALLATION
TECHNICAL SPECIFICATIONS - CLASSIC® 300D PERKINS
INPUT - DIESEL ENGINE
Make/Model
Description
Speed (RPM)
Displacement
Starting
System
Capacities
4 Cylinder
4 Cycle
135 cu. in
(2.2 ltrs)
12VDC battery
Fuel: 15 gal.
57 L.
(Group 24, 650
cold crank amps)
2.0 KW Starter
Perkins
404D-22
EPA
Naturally Aspirated High Idle 1800
Water-Cooled
Diesel Engine
Low Idle 1400
Full Load 1725
Bore x Stroke
Oil: 10.30 Qts.
9.75 L.
Tier 4 interim
Compliant
Cast Iron Cylinder,
Block/Crankcase
3.3” x 3.9”
(84mm x 100mm)
32.7HP @1800 RPM
Coolant: 9.5 Qts.
9.0 L.
65 A. Alternator
w/ built in reg.
RATED OUTPUT @ 104°F(40°C) - WELDER
DESCRIPTION
RATED DC OUTPUT *
Duty
DC CURRENT RANGE
Fine Adjustments in each Range
40-350 Amps
220-Max.
VOLTS @ RATED AMPS
CYCLE
300 Amp DC Welder
All Copper Windings
30V @ 250A
32V @ 300A
100%
60%
160-240
120-190
Pure DC Power Generator
99V DC Max. OCV @ 1800RPM
80-130
Min.-90
RATED OUTPUT @ 104°F(40°C) - GENERATOR
(1)
Auxiliary Power
3,000 Watts Continuous, 60 Hz AC
26 Amps @ 115V
13 Amps @ 230V
(2)
PHYSICAL DIMENSIONS
MODEL
HEIGHT
WIDTH
DEPTH
WEIGHT
K1643-7 CSA
w/o Wire Feed Module
(Code 11472)
1354 lbs.
(616 kg)
45.5 in.
24.00 in.
65.0 in.
(1156 mm)
(610 mm)
(1651 mm
K1643-8 CSA
w/ Wire Feed Module
(Codes 11473)
1389lbs.
(630 kg)
* Based on a 10 min. period.
(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.
(2)
Height to top of exhaust elbow.
CLASSIC® 300D & 300G
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A4.3
A4.3
INSTALLATION
All Copper Windings - For long life and dependable
GENERAL DESCRIPTION
operation.
The Classic® 300D Perkins is a heavy duty, engine dri-
ven, DC arc welding power source, capable of provid-
ing constant current output for stick welding or DC TIG
welding. This welder is wound with all copper coils,
rated at 300 amps/32 Volts, and provides other
Classic® features such as improved door latches and
stainless hinges. With the addition of the optional
Engine Idler - The Classic® 300D Perkins is
equipped with an electronic automatic engine idler. It
automatically increases and decreases engine speed
when starting and stopping welding or using auxil-
iary power. A built-in time delay permits changing
electrodes before the engine slows to its low idle
speed. The “Idler” control switch on the panel locks the
idler in high idle position when desired.
™
K623-1 Wire Feed Module , the Classic® 300D
Perkins will provide constant voltage output for running
the LN-7, LN-23P, or LN-25 wire feeders. (The Wire
Feed Module is factory installed on the K1643-8). The
optional K924-5 Remote Control Kit, provides a remote
control rheostat for remote fine current and open circuit
Auxiliary Power - 3.0 KVA of nominal 115/230V, 60Hz,
AC. Output voltage is maintained within 10% at all
Section C for Power Plug Kit.)
GFCI Receptacle - One UL approved 115V ground
fault circuit interrupter duplex type receptacle is stan-
information on testing and resetting the GFCI recepta-
cle.
The Classic® 300D Perkins has an Electronic Engine
Protection System. In the event of sudden low oil pres-
sure or high coolant temperature, the engine immedi-
ately shuts down. The Classic® 300D Perkins has a
current range of 40-350 DC amps with output ratings
as follows:
Welder Enclosure - The complete welder is rubber
mounted on a rugged steel “C” channel base.
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 (-).
These units are also capable of providing 3 KVA of
RATED OUTPUT
DUTY CYCLE
Cranking System - A 12 volt electric starter is stan-
250A @ 30V
300A @ 32V
100%
60%
dard.
Air Cleaner - Heavy duty two stage dry type.
Muffler - A muffler and stainless steel exhaust outlet
115/230 volts of 60 cycle AC auxiliary power.
elbow are standard.
The Classic® 300D Perkins uses the Perkins 404D-22
industrial water-cooled diesel engine.
Engine Hour Meter - A meter to record hours of oper-
ation.
DESIGN FEATURES
Control Panel
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.
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.
Adjustment” rheostat. The welder is equipped with a
“Start” button, an “Ignition” switch, an “Idler” control
switch, and a “Glow Plug” button for easier cold weath-
er starting.
Remote Control - The Remote / Local Switch and
Receptacle are standard.
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.
CLASSIC® 300D & 300G
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A4.4
A4.4
INSTALLATION
PRE-OPERATION INSTALLATION
WARNING
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under sta-
tionary or fixed electrical equipment, the surface shall be
covered with a steel plate at least .06”(1.6mm) thick,
which shall extend not more than 5.90”(150mm) beyond
the equipment on all sides.
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
--------------------------------------------------------------------------------
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
MACHINE GROUNDING
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
According to the United States National Electrical
Code, the frame of this portable generator is not
required to be grounded and is permitted to serve as
the grounding means for cord connected equipment
plugged into its receptacle.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• 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
extent to which such requirements may apply to your
particular situation and follow them explicitly. A
------------------------------------------------------------------------
MOVING PARTS can injure.
machine grounding stud marked with the symbol
is
• Do not operate with doors open or
guards off.
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
ground such as a metal water pipe going into the
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
electrical equipment.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at the
front of this operatorʼs manual.
-----------------------------------------------------------
EXHAUST SPARK ARRESTER
Some federal, state or local laws may require that
engines be equipped with exhaust spark arresters
when they are operated in certain locations where
unarrested sparks may present a fire hazard. The
standard muffler included with this welder does not
qualify as a spark arrester. When required by local
regulations, a suitable spark arrester must be installed
and properly maintained.
LIFT BAIL
A lift bail is provided for lifting with a hoist.
WARNING
• Lift only with equipment of adequate
lifting capacity.
• Be sure machine is stable when lifting.
• Do not lift this machine using lift bail if
it is equipped with a heavy accessory
such as trailer or gas cylinder.
CAUTION
FALLING
EQUIPMENT can
cause injury.
• Do not lift machine if lift bail is
damaged.
• Do not operate machine while
suspended from lift bail.
----------------------------------------------------------------------------
Use of an incorrect arrester may lead to engine damage
or performance loss. Contact the engine manufacturer for
specific recommendations.
------------------------------------------------------------------------
LOCATION / VENTILATION
TRAILER (SEE OPTIONAL FEATURES)
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:
Always operate the welder with the doors closed.
Leaving the doors open changes the designed air flow
and may cause overheating.
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.
1. Design capacity of trailer vs. weight of Lincoln equip-
ment and likely additional attachments.
CLASSIC® 300D & 300G
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A4.5
A4.5
INSTALLATION
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
PRE-OPERATION SERVICE
CAUTION
3. Proper placement of the equipment on the trailer to
ensure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.
READ the engine operating and maintenance
instructions supplied with this machine.
------------------------------------------------------------------------
WARNING
4. Typical conditions of use, i.e., travel speed, rough-
ness of surface on which the trailer will be operat-
ed; environmental conditions, likely maintenance.
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
(1)
5. Conformance with federal, state and local laws.
(1)
• Do not leave unattended while
fueling.
Consult your federal, state and local laws regarding specific
requirements for use on public highways.
• Wipe up spilled fuel and allow
fumes to clear before starting
engine.
VEHICLE MOUNTING
DIESEL FUEL
WARNING
can
cause fire
• Do not overfill tank, fuel expan-
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
sion may cause overflow.
DIESEL FUEL ONLY-Low sulphur
fuel or ultra low sulphur fuel in U.S.A. and Canada.
• Only transport this Equipment on serviceable
vehicles 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
crankcase filled with a high quality SAE 10W/30 oil.
This oil should be acceptable for most typical ambient
temperatures. Consult the engine operation manual
for specific engine manufacturerʼs recommendations.
Upon receipt of the welder, check the engine dipstick to
be sure the oil is at the “full” mark. DO NOT overfill.
• Do not exceed maximum rated loads for compo-
nents such as suspension, axles and tires.
• Use appropriate nuts bolts and lockwashers to
attach the equipment base to the metal bed or
frame of vehicle.
• 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
valve on the water separator is in the open position.
With the engine off, route the electrode and work
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-
itive polarity, connect the electrode cable to the termi-
nal marked “+”. For Negative polarity, connect the
electrode cable to the “-” stud. These connections
should be checked periodically and tightened if neces-
sary.
COOLING SYSTEM
The radiator has been filled at the factory with a 50-50
mixture of ethylene glycol antifreeze and water. Check
the radiator level and add a 50-50 solution as needed
(see engine manual or antifreeze container for alter-
nate antifreeze recommendations).
When welding at a considerable distance from the
welder, be sure you use ample sized welding cables.
RECOMMENDED COPPER CABLE SIZES
Cables Sizes for Combined Length
of Electrode Plus Work Cable
Amps
250
Duty Cycle
100%
Up to 200ft.(61m) 200 to 250ft.
(61 to 76m)
1
1/0
2/0
300
60%
1/0
CLASSIC® 300D & 300G
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A4.6
A4.6
INSTALLATION
BATTERY CHARGING
WARNING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes
away.
BATTERY ACID can burn eyes and
skin.
• Wear gloves and eye protection and
be careful when boosting, charging
or working near battery.
To prevent EXPLOSION when:
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.
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.
Use correct polarity - Negative Ground.
To prevent BATTERY DISCHARGE, if you have an
ignition switch, turn it off when engine is notr u n -
ning.
• To prevent BATTERY BUCKLING, tighten nuts on
battery clamp until snug.
------------------------------------------------------------------------
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.
When replacing, jumping or otherwise connecting the
battery to the battery cables, the proper polarity must
be observed. This system is NEGATIVE GROUND.
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B4.1
B4.1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4.2
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4.3
Idler Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4.4
CLASSIC® 300D & 300G
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B4.2
B4.2
OPERATION
7. Allow the engine to run at high idle speed for sev-
eral minutes to warm the engine. Stop the engine
and recheck the oil level, after allowing sufficient
time for the oil to drain into the pan. If the level is
down, fill it to the full mark again. The engine con-
trols were properly set at the factory and should
require no adjusting when received.
ENGINE OPERATION
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
COLD WEATHER STARTING:
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
about -15°F (-26°C), it maybe desirable to install cold-
starting aides.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
Note: Extreme cold weather starting may require
longer glow plug operation.
• Use in open, well ventilated areas or
vent exhaust outside.
WARNING
------------------------------------------------------------------------
MOVING PARTS can injure.
Under NO conditions should ether or other starting
fluids be used!
• Do not operate with doors open or
guards off.
------------------------------------------------------------------------
HIGH ALTITUDE OPERATION:
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
The engine will run correctly up to an altitude of 600m
(2000ft.). If the engine is to be operated permanently at
an altitude above this, the fuel consumption and
exhaust emissions may be excessive.
See additional warning information at the
front of this operatorʼs manual.
-----------------------------------------------------------
Contact the Perkins Application Department for any
engine adjustments that may be required.
Operate the welder with the doors closed. Leaving the
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
oil level, drain accumulated dirt and water from the
water separator located on the fuel rail. Refill the fuel
tank to minimize moisture condensation in the tank.
Also, running out of fuel tends to draw dirt into the fuel
system.
1. Turn the “IDLER” switch to “HIGH”.
2. Turn the “IGNITION” switch to “ON”.
3. Press the Glow Plug button for 20 to 30 seconds.
(maximum 60 seconds).
4. Press the Start button. When the engine starts
running, release both buttons. If the engine fails to
start in 20 seconds, wait 30 seconds and repeat
the above procedure.
When hauling the welder between job sites, close the
fuel feed valve on the separator located on the fuel rail.
If the fuel supply is cut off or runs out while the fuel
pump is operating, air may be entrapped in the fuel dis-
tribution system. If this happens, bleeding of the fuel
system may be necessary. Use qualified personnel to
tion of this manual.
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.
CLASSIC® 300D & 300G
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B4.3
B4.3
OPERATION
DUTY CYCLE
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
cycle is based on a ten minute period; thus, the welder can
be loaded at rated output for six minutes out of every ten
minute period.
Lincoln Electric selects high quality, heavy-duty industrial
engines for the portable welding machines we offer.
While it is normal to see a small amount of crankcase oil
consumption during initial operation, excessive oil use,
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
higher, which are operated at low or no-load conditions for
extended periods of time are especially susceptible to the
conditions described above. To accomplish successful
engine break-in, most diesel-powered equipment needs
only to be run at a reasonably heavy load within the rating
of the welder for some period of time during the engineʼs
early life. However, if the welder is subjected to extensive
light loading, occasional moderate to heavy loading of the
engine may sometimes be necessary. Caution must be
observed in correctly loading a diesel/generator unit.
CAUTION
DO NOT TURN THE “CURRENT RANGE SELECTOR”
WHILE WELDING because the current may arc between
the contacts and damage the switch.
-------------------------------------------------------------------------------
The “Current Range Selector” provides five overlapping cur-
rent ranges. The “Fine Current Adjustment” adjusts the cur-
rent from minimum to maximum within each range. Open cir-
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
output studs by connecting the welding leads togeth-
er, direct shorting of the output studs, or connecting
the output leads to a length of steel will result in cat-
astrophic damage to the generator and voids the
warranty.
A high open circuit voltage setting provides the soft “butter-
ing” arc with best resistance to pop-outs preferred 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 Current Adjustment” near maxi-
mum.
2. Set the welder controls for an output current and volt-
age within the welder rating and duty cycle. Note that
any attempt to exceed the welder rating or duty cycle
for any period of time will result in catastrophic dam-
age to the generator and voids the warranty.
3. Periodically shut off the engine and check the
crankcase oil level.
For example: to 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.
When a forceful “digging” arc is required, usually for vertical
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
“Fine Current Adjustment” setting to get 175 amps.
WARNING
Some arc instability may be experienced with EXX10 elec-
trodes when trying to operate with long arc techniques at set-
tings at the lower end of the open circuit voltage range.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and ground.
-------------------------------------------------------------------------------
FUMES & GASES can be dangerous.
CAUTION
•
•
Keep your head out of the fumes.
Use ventilation or exhaust to remove
fumes from breathing zone.
DO NOT attempt to set the “Current Range Selector” between
the five points designated on the nameplate.
--------------------------------------------------------------------------------
These switches have a spring loaded cam which almost elim-
inates the possibility of setting this switch between the des-
ignated points.
-------------------------------------------------------------------------------
WELDING SPARKS can cause fire or
explosion.
•
Keep flammable material away.
-------------------------------------------------------------------------------
ARC RAYS can burn.
•
Wear eye, ear, and body protection.
-------------------------------------------------------------------------------
CLASSIC® 300D & 300G
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B4.4
B4.4
OPERATION
IDLER OPERATION
AUXILIARY POWER
Start the engine with the “Idler” switch in the “High”
position. Allow it to run at high idle speed for several
operating speeds.
If a GFCI receptacle is tripped, See the MAINTE-
NANCE section for detailed information on testing and
resetting the GFCI receptacle.
The AC auxiliary power, supplied as a standard, has a
rating of 3.0 KVA of 115/230 VAC (60 hertz).
The idler is controlled by the “Idler” toggle switch on the
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
receptacles are provided. The circuit is protected with
circuit breakers.
1. In the “High”
position, the idler solenoid deac-
tivates, and the engine goes to high idle speed. The
speed is controlled by the governor.
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 20 amps can be drawn
from the 115 volt GFCI receptacle. The total combined
load of all receptacles is not to exceed 3.0 KVA.
2. In the “Auto”
/
position, the idler oper-
ates as follows:
a. When welding or drawing power for lights or tools
(approximately 100 watts minimum) from the
receptacles, the idler solenoid deactivates and the
engine operates at high idle speed.
An optional power plug kit is available. When this kit is
specified, the customer is supplied with a plug for each
receptacle.
b. When welding ceases or the power load is turned
off, a preset time delay of about 15 seconds
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
TYPICAL FUEL CONSUMPTION DATA
Low Idle (1375 RPM)-No Load @ 45 Volts
High Idle (1800 RPM)-No Load @ 96.6 Volts
0.28 gal/hr ( 1.06 ltrs/hr)
0.42 gal/hr ( 1.59 ltrs/hr)
3000 Watts
0.59 gal/hr ( 2.23 ltrs/hr)
1.03 gal/hr ( 3.90 ltrs/hr)
1.37 gal/hr ( 5.19 ltrs/hr)
250 Amps @ 30 Volts
300 Amps @ 32 Volts
CLASSIC® 300D & 300G
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C4.1
C4.1
TABLE OF CONTENTS - ACCESSORIES SECTION
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
Wire Feeder Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C4.3
CLASSIC® 300D & 300G
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C4.2
C4.2
ACCESSORIES
TIG OPTIONS
OPTIONAL FEATURES (Field Installed)
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
a handle. High frequency bypass is built in.
Additionally, the K936-3 control cable is required if
remote control is used. If remote control is not used the
K936-4 control cable is required.
WARNING
Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly. The use of an arc welder
for pipe thawing is not approved by the CSA, nor is
it recommended or supported by Lincoln Electric.
------------------------------------------------------------------------
Power Plug Kit K802D
PTA-26V TIG Torch K1783-9
Air cooled 200 amp torch equipped with valve for gas
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
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
pipe.
Arc Start Switch K814 (required for TIG Module)
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.
For highway use, consult applicable federal, state, and local
laws regarding possible additional requirements. There is a
choice of 2 hitches, a fender & a light package.
Contactor Kit K938-1 (required for TIG Module)
Provide “Cold” tungsten Tip when welding with the TIG
Module.
Control Cable Extension K937-45
Allows the TIG Module to be operated at distances up
to 200 ft. from the power source.Available in 45 ft.
(13.7m).
Ball Hitch K958-1
Lunette Eye Hitch K958-2
Fender & Light Kit K959-1
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.
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C4.3
C4.3
ACCESSORIES
WIRE FEEDER OPTIONS
Magnum Spool Gun K487-25
Hand held semiautomatic wire feeder requires SG
Control Module. 25 ft. length.
Wire Feed Module K623-1
Provides constant voltage (CV) output with improved
arc stability for Innershield welding. Excellent for MIG
welding. Recommended wire feeders are the LN-7,
LN-23P and LN-25. (Factory installed on the K1643-2).
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
Input Cable K691-10 ( For SG Control Module)
Portable CC/CV unit for flux-cored and MIG welding.
Includes Gas Solenoid & Internal Contactor. Requires
Wire Feed Module.
For Lincoln engine drives with 14-pin MS-type connec-
tion, separate 115V NEMA receptacle and output
stud connections. 10 ft. length.
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.
Magnum® 350 Innershield Gun for LN-25 K126-2
For self-shielded wire with 15 ft. (4.5m) cable. For
.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
amps, 60% duty cycle. For .068 through 5/64” (1.7
through 2.0 mm) Innershield wire and includes
reduced speed switch. For pipewelding, an M11476
62° gun tube is recommended.
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.
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C4.4
C4.4
NOTES
CLASSIC® 300D & 300G
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D4.1
D4.1
TABLE OF CONTENTS - MAINTENANCE SECTION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
GFCI Receptacle Testing & Resetting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.5
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D4.2
D4.2
MAINTENANCE
4. Follow the engine service schedule in this manual
and the detailed maintenance and troubleshooting in
the engine manufacturerʼs manual.
SAFETY PRECAUTIONS
WARNING
Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. In some cases, it may be necessary
to remove safety guards to perform required
maintenance. Remove guards only when neces-
sary and replace them when the maintenance
requiring their removal is complete. Always use
the greatest care when working near moving
parts.
COOLING SYSTEM
The Classic® 300D Perkins is equipped with a pres-
sure radiator. Keep the radiator cap tight to prevent
loss of coolant. Clean and flush the cooling system
periodically to prevent clogging the passage and over-
heating the engine. When antifreeze is needed, always
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
the nearest Lincoln Field Service Shop.
-----------------------------------------------------------------------
ELECTRIC SHOCK can kill.
This welder is equipped with a double-shielded ball
bearing having sufficient grease to last indefinitely
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
of grease one inch wide, one inch long, and one inch
high weighs approximately one half ounce. Over-
greasing is far worse than insufficient greasing.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
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
grease.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
COMMUTATOR AND BRUSHES
------------------------------------------------------------------------
MOVING PARTS can injure.
WARNING
• Do not operate with doors open or
guards off.
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-
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
ing armature when stoning the commutator.
front of this operatorʼs manual.
------------------------------------------------------------------------
Shifting of the commutator brushes may result in:
- Change in machine output
-----------------------------------------------------------
- Commutator damage
- Excessive brush wear
GENERAL INSTRUCTIONS
Periodically inspect the commutator, slip rings, and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
1. Blow out the welder and controls with an air hose at
least once every two months. In particularly dirty
locations, this cleaning may be necessary once a
week. Use low pressure air to avoid driving dirt into
the insulation.
2. “Current Range Selector” contacts should not be
greased. To keep the contacts clean, rotate the cur-
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.
3. Put a drop of oil on the “Current Range Selector”
shaft at least once every month.
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D4.3
D4.3
MAINTENANCE
Replace brushes when they wear within 1/4” of the pig-
tail. A complete set of replacement brushes should be
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-
tator as the armature rotates at full speed until contact
is made across the full face of the brushes. After ston-
ing, blow out the dust with low pressure air.
PURGING AIR FROM FUEL SYSTEM
(PERKINS 404D-22 ENGINE)
WARNING
Keep fuel clear of open flames or arcs, allow
engine to cool before working on the fuel system.
Wipe up any spilled fuel and do not start engine
until fumes clear.
To seat slip ring brushes, position the brushes in place.
Then slide one end of a piece of fine sandpaper
between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres-
sure on top of the brushes, pull the sandpaper around
the circumference of the rings - in direction of rotation
only - until brushes seat properly. In addition, stone slip
ring with a fine stone. Brushes must be seated 100%.
------------------------------------------------------------------------
If the engine is running rough and you suspect air has
been trapped in the fuel system, (e.g. the engine was
allowed to run out of fuel) perform the following steps
using qualified personnel:
1. Loosen by two or three turns, the vent screw
(Figure D4.3) 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
Lever
circuit board, disconnect the battery.
------------------------------------------------------------------------
When installing a new battery or using a jumper battery
to start the engine, be sure the battery polarity is con-
nected properly. The correct polarity is negative
ground. Damage to the engine alternator and the print-
ed circuit board can result from incorrect connection.
FIGURE D4.3
2. Operate the electric fuel pump by turning the
“Ignition” switch “ON” until fuel, free of air, flows
from the vent point. Tighten the vent screw.
3. Contact your Perkins Engine repair facility if prob-
lems persist.
1. Proper operation of the idler requires good ground-
ing of the printed circuit board, reed switch, and bat-
tery.
2. Idler solenoid is activated for low idle.
3. 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.
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D4.5
D4.5
MAINTENANCE
GFCI RECEPTACLE TESTING AND RESET-
TING 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.
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D4.6
D4.6
MAINTENANCE
1. Case Front Assembly
2. Engine Assembly
3. Radiator Assembly
4. Fuel Tank & Mounting
5. Base & Lift Bale Assembly
6. Exciter & Stator
7. Welding Generator & Coupling
8. Roof & Doors
9. Generator Brush Holder
FIGURE D4.6 - MAJOR COMPONENT LOCATION
3
8
1
4
2
5
7
9
6
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A5.1
A5.1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.3
Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.4
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A5.2
A5.2
INSTALLATION
TECHNICAL SPECIFICATIONS – CLASSIC® 300G (K1754-1)
INPUT - GASOLINE ENGINE
Make/Model
Description
Speed (RPM)
High Idle 1800
Full Load 1800
Displacement
cu. in. (Ltrs.)
Ignition
System
Capacities
Delco Voyager
High Energy
Fuel: 15 gal.
57 Ltrs.
4 Cylinder
4 Cycle
GM
3.0 Liter
Water-Cooled
Gasoline Engine
Cast Iron Cylinder
Block/Crankcase
53.0 HP @
1800 RPM
Distributor Type
Electronic
Oil: 4.5 Qts.
4.3 Ltrs.
Classic® 300G
(K1754-1)
183.0(3.0)
Low Idle 1360
Cooling 9.9 Qts.
9.4 Ltrs.
RATED OUTPUT - WELDER
DESCRIPTION
RATED DC OUTPUT*
DUTY CYCLE
DC CURRENT RANGE
VOLTS @ RATED AMPS
Fine Adjustment in each Range
300 Amp DC Welder
All Copper Windings
Pure DC Power
Generator
30V @ 250A
100%
40-350 Amps
NEMA Rating
32V @ 300A
60%
OUTPUT - GENERATOR
1
Auxiliary Power
3000 Watts, 60 Hz. AC
(26 Amps @ 115V), (13 Amps @ 230V)
ENGINE OPERATING LOAD
FUEL CONSUMPTION
.89 gal/hr (3.37 ltrs/hr)
1.32 gal/hr (5.00 ltrs/hr)
1.42 gal/hr (5.32 ltrs/hr)
1.24 gal/hr (4.70 ltrs/hr)
1.27 gal/hr (4.82 ltrs/hr)
1.33 gal/hr (5.04 ltrs/hr)
1.47 gal/hr (5.57 ltrs/hr)
1.66 gal/hr (6.27 ltrs/hr)
1.83 gal/hr (6.91 ltrs/hr)
2.15 gal/hr (8.12 ltrs/hr)
Low Idle (1360 RPM)-No Load
High Idle (1800 RPM)-No Load
AC Auxiliary-115 Volts-26 Amps
50 Amps @ 22 Volts @ 60% Duty Cycle
100 Amps @ 24 Volts @ 60 % Duty Cycle
150 Amps @ 26 Volts @ 60% Duty Cycle
200 Amps @ 28 Volts @ 60 % Duty Cycle
250 Amps @ 30 Volts @ 60 % Duty Cycle
300 Amps @ 32 Volts @ 60 % Duty Cycle
250 Amps @ 30 Volts @ 100 % Duty Cycle
PHYSICAL DIMENSIONS
HEIGHT
WIDTH
DEPTH
WEIGHT
40.94** in.
1039.9 mm
24.00 in.
66.91in.
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.
* Based on a 10 min. period.
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A5.3
A5.3
INSTALLATION
SAFETY PRECAUTIONS
WARNING
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SUR-
FACES.
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, the surface
shall be covered with a steel plate at least .06”(1.6mm)
thick, which shall extend not more than 5.90”(150mm)
beyond the equipment on all sides.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
------------------------------------------------------------------------
MACHINE GROUNDING
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
According to the United States National Electrical Code,
the frame of this portable generator is not required to be
grounded and is permitted to serve as the grounding
means for cord connected equipment plugged into its
receptacle.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• 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
extent to which such requirements may apply to your
particular situation and follow them explicitly. A machine
-----------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
grounding stud marked with the symbol
is provided
• Stop engine before servicing.
on the welding generator frame foot. In general, if the
machine is to be grounded, it should be connected with
a #8 or larger copper wire to a solid earth ground such
as a metal water pipe going into the 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 electrical equipment.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at the
front of this operatorʼs manual.
-----------------------------------------------------------
PRE-OPERATION INSTALLATION
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
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-
tions, a suitable spark arrester must be installed and
properly maintained.
WARNING
• Lift only with equipment of
adequate lifting capacity.
• Be sure machine is stable
when lifting.
• Do not lift this machine using
lift bail if it is equipped with a
heavy accessory such as trail-
er or gas cylinder.
CAUTION
Use of an incorrect arrester may lead to engine dam-
age or performance loss. Contact the engine manu-
facturer for specific recommendations.
FALLING
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bail.
------------------------------------------------------------------------
• Do not lift machine if lift bail is
------------------------------------------------------------------------
LOCATION / VENTILATION
Always operate the welder with the doors closed.
Leaving the doors open changes the designed air flow
and may cause overheating.
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 out-
side area.
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A5.4
A5.4
INSTALLATION
When welding at a considerable distance from the
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 dam-
age the welding equipment. Some of the factors to be
considered are as follows:
welder, be sure you use ample size welding cables.
RECOMMENDED COPPER CABLE SIZES
Cables Sizes for Combined Length
of Electrode Plus Work Cable
Up to 200 ft.
60.96 m
200 to 250 ft.
200 to76.2 m
Amps
250
Duty Cycle
100%
1. Design capacity of trailer vs. weight of Lincoln equip-
ment and likely additional attachments.
1
1/0
2/0
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
300
60%
1/0
PRE-OPERATION SERVICE
CAUTION
3. Proper placement of the equipment on the trailer to
ensure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.
READ the engine operating and maintenance instruc-
tions supplied with this machine.
4. Typical conditions of use, i.e., travel speed, rough-
ness of surface on which the trailer will be operated;
environmental conditions, likely maintenance.
WARNING
(1)
5. Conformance with federal, state and local laws.
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
(1)
Consult applicable federal, state and local laws regarding specific
requirements for use on public highways.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
WARNING
VEHICLE MOUNTING
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
GASOLINE
fumes to clear before starting
engine.
• Do not overfill tank, fuel expan-
sion may cause overflow.
can cause fire
or explosion.
-------------------------G----A---S--O----L--I-N----E----F--U----E--L-----O---N---L--Y--
• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.
OIL
This unit is supplied from the factory with the engine
crankcase filled with a high quality SAE 10W/30 oil.
This oil should be acceptable for most typical ambient
temperatures.
• Distribute, balance and secure loads so vehicle
is stable under conditions of use.
• Do not exceed maximum rated loads for compo-
nents such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of
vehicle.
Consult the engine operation manual for specific
engine manufacturerʼs recommendations. Upon
receipt of the welder, check the engine dipstick to be
sure the oil is at the “full” mark. DO NOT overfill.
• Follow vehicle manufacturerʼs instructions.
------------------------------------------------------------------------
POLARITY CONTROL AND CABLE SIZES
With the engine off, route the electrode and work
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
Positive polarity, connect the electrode cable to the
terminal marked “+”. For Negative polarity, connect
the electrode cable to the “-” stud. These connections
should be checked periodically and tightened if neces-
sary.
FUEL
Fill the fuel tank with the grade of fuel recommended
in the Engine Operatorʼs manual. Make sure the fuel
valves on the sediment bowl and the water separator
are in the open positions.
COOLING SYSTEM
The radiator has been filled at the factory with a 50-50
mixture of ethylene glycol antifreeze and water.
Check the radiator level and add a 50-50 solution as
needed (see engine manual or antifreeze container for
alternate antifreeze recommendations)
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A5.5
A5.5
INSTALLATION
BATTERY CHARGING
WARNING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes
away.
BATTERY ACID can burn eyes and
skin.
• Wear gloves and eye protection and
be careful when boosting, charging
or working near battery.
To prevent EXPLOSION when:
• 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
the ground lead on the base.
To prevent ELECTRICAL DAMAGE when:
•
•
Installing a new battery.
Using a booster.
Use correct polarity - Negative Ground.
• To prevent BATTERY DISCHARGE, if you have an
ignition switch, turn it off when engine is not run-
ning.
• To prevent BATTERY BUCKLING, tighten nuts on
battery clamp until snug.
------------------------------------------------------------------------
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.
When replacing, jumping or otherwise connecting the
battery to the battery cables, the proper polarity must
be observed. This system is NEGATIVE GROUND.
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A5.6
A5.6
NOTES
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B5.1
B5.1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5.2
Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5.3
CLASSIC® 300D & 300G
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B5.2
B5.2
OPERATION
SAFETY PRECAUTIONS
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, the surface
shall be covered with a steel plate at least .06”(1.6mm)
thick, which shall extend not more than 5.90”(150mm)
beyond the equipment on all sides.
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
The Classic® 300G uses the GM 3.0L industrial water-
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
cooled gasoline engine.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
RATED OUTPUT
250A @ 30V
300A @ 32V
DUTY CYCLE
100%
60%
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
DESIGN FEATURES
Control Panel
----------------------------------------------------
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 Range
Selector” switch and a “Fine Current Adjustment” rheo-
stat. The welder is equipped with a “Start” button, an
“Ignition” switch, an “Idler” control switch, and a “Glow
Plug” button for easier cold weather starting.
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at the
front of this operatorʼs manual.
The control panel also contains an engine temperature
gauge, a battery charging ammeter, an oil pressure
gauge, two three prong grounding type receptacles and
four circuit breakers for auxiliary power.
Operate the welder with the doors closed. Leaving the
doors open changes the designed air flow and can cause
overheating.
All Copper Windings - For long life and dependable
GENERAL DESCRIPTION
operation.
®
The Classic 300G is a heavy duty, engine driven, DC arc
Engine Idler Control - The Classic® 300G is equipped
with an electronic automatic engine idle control. It auto-
matically 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”
control switch on the panel locks the idler in high idle posi-
tion when desired.
welding power source, capable of providing constant cur-
rent output for stick welding or DC TIG welding. This
welder is wound with all copper coils, rated at 300
amps/32 Volts, and provides other Classic® features such
as improved door latches and stainless hinges. With the
™
addition of the optional K623-1 Wire Feed Module the
Classic® 300G will provide constant voltage output for
running the LN-7, LN-23P, or LN-25 wire feeders. The
optional K924-4 Remote Control Kit (field installed) pro-
vides a switch, or K924-5 Remote Control Kits provide a
receptacle and a remote control rheostat for remote fine
current and open circuit voltage adjustment.
Auxiliary Power - 3.0 kVA of nominal 115/230V, 60Hz,
AC. Output voltage is maintained within
10% at all
loads up to rated capacity. (See Optional Features in
Section C for Power Plug Kit.)
Welder Enclosure - The complete welder is rubber
The Classic® 300G has an electronic Engine Protection
system. In the event of sudden low oil pressure or high
coolant temperature, the engine immediately shuts down.
The Classic® 300G has a current range of 40-350 DC
amps with output ratings as follows:
mounted on a rugged steel “C” channel base.
The output terminals are placed at the side of the
machines so that they are protected by the door. The out-
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.
CLASSIC® 300D & 300G
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B5.3
B5.3
OPERATION
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
distribution system. If this happens, bleeding of the
fuel system may be necessary. Refer to the instruc-
Engine Hour Meter - A meter to record hours of opera-
tion.
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.
REFER TO THE ENGINE
Operation and maintenance manual for additional
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-
ther adjustment of the OCV. Total OCV adjustment
range is about 10 Volts.
DUTY CYCLE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and ground.
STARTING THE CLASSIC® 300G GM 3.0L
GASOLINE ENGINE
1. Turn the “IDLER” switch to “HIGH”.(Optional )
2. Turn the “IGNITION” switch to “ON”.
FUMES & GASES can be dangerous.
•
•
Keep your head out of the fumes.
Use ventilation or exhaust to remove
fumes from breathing zone.
3. Press the Start button. When the engine starts run-
ning, release button. If the engine fails to start in 20
seconds, wait 30 seconds and repeat the above pro-
cedure.
WELDING SPARKS can cause fire or
explosion.
4. Observe the oil pressure. If no pressure shows with-
in 30 seconds, stop the engine and consult the
engine operating manual. To stop the engine, turn
the “IGNITION” switch to “OFF”.
•
Keep flammable material away.
5. Allow the engine to run at high idle speed for sev-
eral minutes to warm up. If idle control switch is left
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!
ARC RAYS can burn.
Wear eye, ear, and body protection.
•
-------------------------------------------------------------------------
The NEMA output rating of the Classic® 300G is 300
amperes at 32 arc volts on a 60% duty cycle (consult
Specifications in this manual for alternate ratings).
Duty cycle is based on a ten minute period; thus, the
welder can be loaded at rated output for six minutes
out of every ten minute period.
STOPPING THE ENGINE
• Turn the “IGNITION” switch to “OFF”
• 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
tank to minimize moisture condensation in the tank.
Also, running out of fuel tends to draw dirt into the fuel
system.
CLASSIC® 300D & 300G
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B5.4
B5.4
OPERATION
• When welding or drawing power for lights or tools
(approximately 100-150 watts minimum) from the
receptacles, the engine operates at high idle speed.
CONTROL OF WELDING CURRENT
CAUTION
• When welding ceases or the power load is turned off,
a preset time delay of about 10 seconds starts. This
time delay cannot be adjusted.
DO NOT TURN THE “CURRENT RANGE SELEC-
TOR” WHILE WELDING because the current may
arc between the contacts and damage the switch.
------------------------------------------------------------------------
The “Current Range Selector” provides five overlap-
ping current ranges. The “Fine Current Adjustment”
adjusts the current from minimum to maximum within
each range. Open circuit voltage is also controlled by
the “Fine Current Adjustment” permitting control of the
arc characteristics.
• If the welding or power load is not re-started before
the end of the time delay the throttle body controller
reduces the engine to low idle speed.
AUXILIARY POWER
The AC auxiliary power, supplied as a standard, has a
rating of 3.0 kVA of 115/230 VAC (60 hertz).
A high open circuit voltage setting provides the soft
“buttering” arc with best resistance to pop-outs pre-
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
Current Adjustment” near maximum. For example: to
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.
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.
When a forceful “digging” arc is required, usually for
vertical and overhead welding, use a higher “Current
Range Selector” setting and lower open circuit voltage.
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.
An optional power plug kit is available. When this kit is
specified, the customer is supplied with a plug for each
receptacle.
Some arc instability may be experienced with EXX10
electrodes when trying to operate with long arc tech-
niques at settings at the lower end of the open circuit
voltage range.
THROTTLE BODY DEICING SYSTEM
The welder has been designed to allow continuous
year-round operation. Engine coolant is channeled
through the Throttle Bottle Injector (TBI) housing to
prevent the build up of ice on the TBI throat around the
throttle plate. The electronic controller is programmed
to automatically compensate for the build up of ice on
the throttle plate. There will be no noticeable change in
the operation of the welder should icing develop. On
start-up, there is a possibility for the engine to over-
speed ( to a maximum of 2000 RPM ) for up to 10 sec-
onds after throttle body icing conditions have occurred.
The electronic governor will correct itself for the new
operating conditions and normal operation will resume.
CAUTION
DO NOT attempt to set the “Current Range Selector”
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.
IDLER CONTROL OPERATION
The idle is controlled by the “Idler” toggle switch on the
welder control panel. The switch has two positions as
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:
CLASSIC® 300D & 300G
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C5.1
C5.1
TABLE OF CONTENTS - ACCESSORIES SECTION
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C5
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C5.2
CLASSIC® 300D & 300G
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C5.2
C5.2
ACCESSORIES
OPTIONAL EQUIPMENT (Field Installed)
Wire Feed Module (K623-1) - Provides constant volt-
age (CV) output with improved arc stability for
Innershield welding. Excellent for MIG welding.
Recommended wire feeders are the LN-7, LN-23P and
LN-25.
Accessory Set (K704) - Includes 35 ft. (10.7m) elec-
trode and 30 ft. (9.1m) work cables, headshield, work
clamp and electrode holder.
WARNING
GFCI Receptacle Kit (K1690-1) - Includes one UL
approved 115V ground fault circuit interrupter duplex
type receptacle and installation instructions. Replaces
the factory installed 115V duplex receptacle. Each
receptacle of the GFCI duplex is rated at 20 amps.
Maximum total current from the GFCI duplex is limited
to 20 amps.
Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly. The use of an arc welder
for pipe thawing is not approved by the CSA, nor is
it recommended or supported by Lincoln Electric.
------------------------------------------------------------------------
Power Plug Kit (K802D) - A 20 amp power plug kit for
the auxiliary power receptacles is available. (Provides
a plug for each receptacle.)
TIG Module - Portable, high frequency unit with gas
valve for TIG welding. Rated at 300 amps / 60% duty
cycle. (Request Publication E3.205).
Order K930-2
Remote Control Kit (K924-4) - Contains switch,
receptacle, remote control rheostat, and 100 ft (30.5m)
cable for adjusting the OCV at the welding site.
Control Cable - Connects TIG Module to the Classic®
300G.
Order K936-4
Trailer (K953-1) - Two-wheeled trailer with optional
fender and light package. For highway use, consult
applicable federal, state, and local laws regarding pos-
sible additional requirements. Their is a choice of 2
hitches, a fender & a light package. Order:
K953-1 Trailer
Arc Start Switch - Provides on/off control at the TIG
Module.
Order K814
Contactor Kit - For use with TIG Module.
Order K938-1
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
Control Cable Extension - Allows the TIG Module to
be operated at distances up to 200 ft. from the power
source. Available length: 45 ft. (13.7m).
Order K937-45
K959-1 Fender & Light Kit.
K965-1 Cable Storage Rack
Remote Control Kit (K924-5) - Contains a remote
control rheostat, and 100 ft. (30.5m) cable for adjust-
ing the OCV at the welding site.
Water Valve Kit - For use with a water-cooled TIG
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),
remote control potentiometer (for adjusting the CV
“WIRE” OCV), and 100ft.(30.5m) cable.
K2261-1 OIL DRAIN KIT - Includes ball valve, hose
and clamp.
CLASSIC® 300D & 300G
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D5.1
D5.1
TABLE OF CONTENTS - MAINTENANCE SECTION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5
Idler Control Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.3
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.5
CLASSIC® 300D & 300G
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D5.2
D5.2
MAINTENANCE
• When necessary, remove the sediment bowl, if so
equipped, from beneath the fuel tank and clean out
any accumulated dirt and water.
SAFETY PRECAUTIONS
WARNING
Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. In some cases, it may be necessary
to remove safety guards to perform required
maintenance. Remove guards only when neces-
sary and replace them when the maintenance
requiring their removal is complete. Always use
the greatest care when working near moving
parts.
• Follow the engine service schedule in this manual
and the detailed maintenance and troubleshooting in
the engine manufacturerʼs manual.
COOLING SYSTEM
The Classic® 300G is equipped with a pressure radia-
tor. Keep the radiator cap tight to prevent loss of
coolant. Clean and flush the cooling system periodical-
ly to prevent clogging the passage and overheating the
engine. When antifreeze is needed, always use the
permanent type. Capacity = 9.9 qts (9.4 Ltrs.).
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
the nearest Lincoln Field Service Shop.
-----------------------------------------------------------------------
ELECTRIC SHOCK can kill.
BEARINGS
This welder is equipped with a double-shielded ball
bearing having sufficient grease to last indefinitely
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
of grease one inch wide, one inch long, and one inch
high weighs approximately one half ounce. Over-
greasing is far worse than insufficient greasing.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• 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
grease.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
COMMUTATOR AND BRUSHES
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
WARNING
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-
front of this operatorʼs manual.
-----------------------------------------------------------
ing armature when stoning the commutator.
------------------------------------------------------------------------
GENERAL INSTRUCTIONS
Shifting of the commutator brushes may result in:
- Change in machine output
• Blow out the welder and controls with an air hose at
least once every two months. In particularly dirty
locations, this cleaning may be necessary once a
week. Use low pressure air to avoid driving dirt into
the insulation.
- Commutator damage
- Excessive brush wear
Periodically inspect the commutator, slip rings, and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
• “Current Range Selector” contacts should not be
greased. To keep the contacts clean, rotate the cur-
rent control through its entire range frequently. Good
practice is to turn the handle from maximum to mini-
mum setting twice each morning before starting to
weld.
• Put a drop of oil on the “Current Range Selector”
shaft at least once every month.
CLASSIC® 300D & 300G
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D5.3
D5.3
MAINTENANCE
Replace brushes when they wear within 1/4” of the pig-
tail. A complete set of replacement brushes should be
kept on hand. Lincoln brushes have a curved face
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
contact is made across the full face of the brushes.
After stoning, blow out the dust with low pressure air.
PURGING AIR FROM FUEL SYSTEM (GM
3.0L ENGINE)
WARNING
Keep fuel clear of open flames or arcs, allow
engine to cool before working on the fuel system.
Wipe up any spilled fuel and do not start engine
until fumes clear.
To seat slip ring brushes, position the brushes in place.
Then slide one end of a piece of fine sandpaper
between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres-
sure on top of the brushes, pull the sandpaper around
the circumference of the rings - in direction of rotation
only - until brushes seat properly. In addition, stone slip
ring with a fine stone. Brushes must be seated 100%.
------------------------------------------------------------------------
The fuel system operates as follows, The fuel pump
will operate for a maximum of 3 seconds when the igni-
tion switch is turned “ON”. The pump will restart once
the start button is pushed and continue when the
engine starts. To purge the system of air if fuel lines
have been removed, the ignition switch can be toggled
“ON” and “OFF” (at 3 second intervals) until fuel flows
through the fuel return line in the neck of the tank.
Arcing or excessive exciter brush wear indicates a pos-
sible misaligned shaft. Have an authorized Field
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
the engine is properly tuned.
IDLER CONTROL MAINTENANCE
ENGINE MAINTENANCE
CAUTION
Before doing electrical work, disconnect the bat-
Refer to the engine operation and maintenance manu-
al for additional information on the engine.
tery.
------------------------------------------------------------------------
When installing a new battery or using a jumper battery
to start the engine, be sure the battery polarity is con-
nected properly. The correct polarity is negative
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
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.
CLASSIC® 300D & 300G
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D5.4
D5.4
MAINTENANCE
ENGINE SERVICE
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE - (50 HOURS)
EVERY 100 HOURS OR 3 MONTHS
EVERY 200 HOURS OR 6 MONTHS
EVERY 600 HOURS OR 12 MONTHS
ENGINE SERVICE (NOTE 2)
MAINTENANCE ITEM
TYPE OR QUANTITY
50/50 Water/Ethylene Glycol
9.9 qrts, 9.4L
I
I
Coolant level
I
Concentration of antifreeze
Radiator for contamination or blockage
Coolant (NOTE 3)
I
R
Engine oil level ( NOTE 1 )
Engine oil ( NOTE 1 & 3 )
Engine oil filter
R
R
C
R
R
4.5 qr
ts, 4.3L ( i
ncluding filter )
AC PF25
C
Drain fuel bowl
R
Fuel filter canister
PSI# 32500292
I
Tension of Alternator/ Fan belt
Alternator/ Fan belt wear
Alternator Belt
I
R
R
I
Good Year 11AV0955
Good Year 11AV1220
Fan Belt
Tighten cylinder head
Spark Plugs (Gap = 0.040)
Electrical systems
R
I
4 - AC R46TS
I
All nuts and bolts for tightness
Air filter (earlier check may be req'd)
Air filter element
4
I
C
C
R
Donaldson#P181050 Nelson #70206N
BCI GROUP 45
Leaks or engine damage
Battery
I
I = Inspect
Notes (1) Consult Engine Operators Manual for oil Recommendations.
C = Clean
R = Replace
(2) Consult engine operators manual for additional maintenance schedule information.
(3) Fill slowly! Ensure correct quantity is used.
2/01
(4) Clean the air filter if the engine is operating in very dusty conditions.
Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.
These preventative maintenance periods apply to average conditions of operation.
If necessary, use shorter periods.
S20919-3
CLASSIC® 300D & 300G
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D5.5
D5.5
MAINTENANCE
1. Case Front Assembly
2. Engine Assembly
3. Radiator Assembly
4. Fuel Tank & Mounting
5. Base & Lift Bale Assembly
6. Exciter and Stator
7. Welding Generator & Coupling (2 of 2)
8. Roof & Doors
9. Alternator Brush Holder
10. Generator Brush Holder
FIGURE D5.5 - MAJOR COMPONENT LOCATION
3
8
1
2
4
5
7
10
6
9
CLASSIC® 300D & 300G
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D5.6
D5.6
NOTES
CLASSIC® 300D & 300G
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E-1
E-1
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
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
CLASSIC® 300D & 300G
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E-2
E-2
THEORY OF OPERATION
FIGURE E.1 - GENERAL DESCRIPTION (Classic® 300G, Zenith Fuel System/GM Engine)
SELECTOR
SWITCH
NEGATIVE
OUTPUT
TERMINAL
CURRENT
SENSOR
P.C. BOARD
IDLE
SWITCH
115 & 230VAC
RECEPTACLES
ENGINE
RPM CONTROL
ENGINE
GENERATOR
FRAME
CONTROL
COMPONENTS
AND
FUEL PUMP
SERIES
COILS
SENSORS
HOUR METER
ZENITH
E.C.U.
ENGINE FAILURE LAMP
ALTERNATOR STATOR
GASOLINE
ENGINE
ARMATURE
MECHANICAL
COUPLING
GENERATOR
ROTATOR
SHAFT
IGNITION
SWITCH
ARMATURE
SLIP
RINGS
ENGINE
ALTERNATOR
+
-
INTERPOLE
RESIDUAL
MAGNETISM
COILS
FLASHING
FIELD
SHUNT
WINDINGS
START
AMMETER
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
CLASSIC® 300D & 300G
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E-3
E-3
THEORY OF OPERATION
FIGURE E.2 - GENERAL DESCRIPTION (Classic® 300D, Perkins Engine)
TEMP.
SWITCH
ENGINE
FAILURE
LAMP
SELECTOR
SWITCH
IDLE SWITCH
AUTO POSITION
REED
RELAY
CR2
NEGATIVE
OUTPUT
TERMINAL
HOUR
METER
IDLER / ENGINE
PROTECTION
P.C. BOARD
OIL
PRESSURE
115 & 230VAC
RECEPTACLES
IGNITION
SWITCH
GENERATOR
FRAME
TOROIDAL
CURRENT
TRANSFORMER
FUEL
PUMP
SERIES
COILS
GLOW
PLUGS
IDLER
SOLENOID
FUEL
PUMP
SOLENOID
GLOW
PLUG
BUTTON
ALTERNATOR STATOR
ROTATOR
(PERKINS)
DIESEL
ENGINE
ENGINE
ALTERNATOR
GENERATOR
ARMATURE
MECHANICAL
COUPLING
ARMATURE
SHAFT
EXCITER WINDING
SLIP
RINGS
AMMETER
START
+
-
BUTTON
INTERPOLE
COILS
RESIDUAL
MAGNETISM
FLASHING
STARTER
MOTOR
FIELD
SHUNT
WINDINGS
FIELD
RECTIFIER
GENERATOR
FIELD CONTROL
RHEOSTAT
POSITIVE
OUTPUT
BATTERY
TERMINAL
FIGURE E.3 - GENERAL DESCRIPTION (Classic® 300D, Kubota Engine)
SELECTOR
SWITCH
NEGATIVE
OUTPUT
TERMINAL
CURRENT
SENSOR
P.C. BOARD
IDLE SWITCH
ENGINE
ENGINE
CONTROL
UNIT
ENGINE FAILURE LAMP
OIL PRESSURE SWITCH
WATER
TEMP.
ENGINE
SPEED
HOUR
ACTUATOR
METER
SENSOR
115 & 230VAC
SENSOR
RECEPTACLES
(ECU)
GENERATOR
FRAME
SERIES
COILS
TEMPERATURE SWITCH
IGNITION
SWITCH
(KUBOTA)
DIESEL
ALTERNATOR STATOR
ROTATOR
GLOW
PLUG
MECHANICAL
COUPLING
GENERATOR
ARMATURE
SHAFT
ENGINE
ENGINE
ARMATURE
SLIP
ALTERNATOR
BUTTON
RINGS
GLOW
PLUGS
+
-
INTERPOLE
COILS
RESIDUAL
FLASHING
MAGNETISM
AMMETER
FIELD
SHUNT
WINDINGS
START
ENGINE
STARTER
RELAY
BUTTON
RPM CONTROL
(CUSTOM ARC)
FIELD
RECTIFIER
STARTER
MOTOR
GENERATOR
FIELD CONTROL
RHEOSTAT
POSITIVE
OUTPUT
BATTERY
TERMINAL
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
CLASSIC® 300D & 300G
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 - BATTERY, STARTER, ENGINE, ALTERNATOR & PROTECTION CIRCUITS
(Classic® 300G, Zenith Fuel System/GM Engine)
SELECTOR
SWITCH
NEGATIVE
OUTPUT
TERMINAL
CURRENT
SENSOR
P.C. BOARD
IDLE
SWITCH
115 & 230VAC
RECEPTACLES
ENGINE
RPM CONTROL
ENGINE
GENERATOR
FRAME
CONTROL
COMPONENTS
AND
FUEL PUMP
SERIES
COILS
SENSORS
HOUR METER
ZENITH
E.C.U.
ENGINE FAILURE LAMP
ALTERNATOR STATOR
GASOLINE
ENGINE
ARMATURE
MECHANICAL
COUPLING
GENERATOR
ROTATOR
SHAFT
IGNITION
SWITCH
ARMATURE
SLIP
RINGS
ENGINE
ALTERNATOR
+
-
INTERPOLE
RESIDUAL
MAGNETISM
COILS
FLASHING
FIELD
SHUNT
WINDINGS
START
AMMETER
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.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
E-5
E-5
THEORY OF OPERATION
FIGURE E.5 - BATTERY, STARTER, ENGINE, ALTERNATOR & PROTECTION CIRCUITS
(Classic® 300D, Perkins Engine)
TEMP.
SWITCH
ENGINE
SELECTOR
SWITCH
FAILURE
LAMP
IDLE SWITCH
AUTO POSITION
REED
RELAY
CR2
NEGATIVE
OUTPUT
TERMINAL
HOUR
METER
IDLER / ENGINE
PROTECTION
P.C. BOARD
OIL
PRESSURE
115 & 230VAC
RECEPTACLES
IGNITION
SWITCH
GENERATOR
FRAME
TOROIDAL
CURRENT
TRANSFORMER
FUEL
PUMP
SERIES
COILS
GLOW
PLUGS
IDLER
SOLENOID
FUEL
PUMP
SOLENOID
GLOW
PLUG
BUTTON
ALTERNATOR STATOR
ROTATOR
(PERKINS)
DIESEL
ENGINE
ENGINE
ALTERNATOR
GENERATOR
ARMATURE
MECHANICAL
COUPLING
ARMATURE
SHAFT
EXCITER WINDING
SLIP
RINGS
AMMETER
START
+
-
BUTTON
INTERPOLE
COILS
RESIDUAL
MAGNETISM
FLASHING
STARTER
MOTOR
FIELD
SHUNT
WINDINGS
FIELD
RECTIFIER
GENERATOR
FIELD CONTROL
RHEOSTAT
POSITIVE
OUTPUT
BATTERY
TERMINAL
FIGURE E.6 - BATTERY, STARTER, ENGINE, ALTERNATOR & PROTECTION CIRCUITS
(Classic® 300D, Kubota Engine)
SELECTOR
SWITCH
NEGATIVE
OUTPUT
TERMINAL
CURRENT
SENSOR
P.C. BOARD
IDLE SWITCH
ENGINE
ENGINE
CONTROL
UNIT
ENGINE FAILURE LAMP
OIL PRESSURE SWITCH
WATER
TEMP.
ENGINE
SPEED
HOUR
ACTUATOR
METER
SENSOR
115 & 230VAC
SENSOR
RECEPTACLES
(ECU)
GENERATOR
FRAME
SERIES
COILS
TEMPERATURE SWITCH
IGNITION
SWITCH
(KUBOTA)
DIESEL
ALTERNATOR STATOR
ROTATOR
GLOW
PLUG
MECHANICAL
COUPLING
GENERATOR
ARMATURE
SHAFT
ENGINE
ENGINE
ARMATURE
SLIP
ALTERNATOR
BUTTON
RINGS
GLOW
PLUGS
+
-
INTERPOLE
COILS
RESIDUAL
FLASHING
MAGNETISM
AMMETER
FIELD
SHUNT
WINDINGS
START
ENGINE
STARTER
RELAY
BUTTON
RPM CONTROL
(CUSTOM ARC)
FIELD
RECTIFIER
STARTER
MOTOR
GENERATOR
FIELD CONTROL
RHEOSTAT
POSITIVE
OUTPUT
BATTERY
TERMINAL
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
CLASSIC® 300D & 300G
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E-6
E-6
THEORY OF OPERATION
ENGINE, GENERATOR ARMATURE
AND FRAME, ALTERNATOR STA-
TOR AND ROTOR
CURRENT RANGE SELECTOR
The selector switch acts as a coarse current
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
connected in series with the negative output ter-
minal.
EXCITATION (FLASHING)
When the engine is started and running, voltage
produced by residual magnetism in the DC weld-
ing generator passes through a “flashing” diode,
and is applied to the alternator rotor via a brush
and slip ring configuration. This excitation (“flash-
ing”) voltage magnetizes the rotor lamination. The
alternator rotor is connected to the armature shaft,
which is mechanically coupled to the engine. The
rotating magnet (rotor) induces a voltage in the
stationary windings of the alternator stator.
FINE CURRENT ADJUSTMENT
The field rheostat control functions as a fine out-
put current adjustment by controlling the current
through the shunt windings. This controls the
amount of magnetism created in the shunt field
windings. Open circuit weld voltage can also be
controlled by the field rheostat control.
ENGINE HIGH IDLE RPM (OCV)
AUXILIARY AND FIELD FEEDBACK
ADJUSTMENT
COILS
Classic® 300G (Codes 10659, 10912, and 11135)
The Classic® 300G utilizes an electronic engine
control system manufactured by Zenith fuel sys-
tems LLC. This system maintains a steady RPM
by constantly sensing engine speed and making
adjustments as needed.
There are two isolated windings incorporated in
the stator lamination assembly. One of these
windings is tapped and provides 115VAC and
230VAC of auxiliary power to the appropriate
receptacles. The other 115VAC isolated winding is
rectified to a DC voltage and is used to supply
field feedback voltage to the rotor. It also supplies
voltage, through the generator field rheostat con-
trol, to the field shunt windings in the main gener-
ator frame.
A potentiometer mounted on the output rail allows
the operator to adjust the high idle engine speed
between 1700 and 1800 RPMʼs in 20 RPM incre-
ments. This is to allow further adjustment of the
welding generator open circuit voltage (OCV).
Total OCV adjustment range is about 10 Volts.
INTERPOLE AND SERIES COILS
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.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
CLASSIC® 300D & 300G
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E-7
E-7
THEORY OF OPERATION
FIGURE E.8 - CLASSIC® 300D, PERKINS ENGINE
TEMP.
SWITCH
ENGINE
FAILURE
LAMP
SELECTOR
SWITCH
IDLE SWITCH
AUTO POSITION
REED
RELAY
CR2
NEGATIVE
OUTPUT
TERMINAL
HOUR
METER
IDLER / ENGINE
PROTECTION
P.C. BOARD
OIL
PRESSURE
115 & 230VAC
RECEPTACLES
IGNITION
SWITCH
GENERATOR
FRAME
TOROIDAL
CURRENT
TRANSFORMER
FUEL
PUMP
SERIES
COILS
GLOW
PLUGS
IDLER
SOLENOID
FUEL
PUMP
SOLENOID
GLOW
PLUG
BUTTON
ALTERNATOR STATOR
ROTATOR
(PERKINS)
DIESEL
ENGINE
ENGINE
ALTERNATOR
GENERATOR
ARMATURE
MECHANICAL
COUPLING
ARMATURE
SHAFT
EXCITER WINDING
SLIP
RINGS
AMMETER
START
+
-
BUTTON
INTERPOLE
COILS
RESIDUAL
MAGNETISM
FLASHING
STARTER
MOTOR
FIELD
SHUNT
WINDINGS
FIELD
RECTIFIER
GENERATOR
FIELD CONTROL
RHEOSTAT
POSITIVE
OUTPUT
BATTERY
TERMINAL
FIGURE E.9 - CLASSIC® 300D, KUBOTA ENGINE
SELECTOR
SWITCH
NEGATIVE
OUTPUT
TERMINAL
CURRENT
SENSOR
P.C. BOARD
IDLE SWITCH
ENGINE
HOUR
ENGINE
CONTROL
UNIT
ENGINE FAILURE LAMP
OIL PRESSURE SWITCH
WATER
TEMP.
ENGINE
SPEED
ACTUATOR
METER
SENSOR
115 & 230VAC
RECEPTACLES
SENSOR
(ECU)
GENERATOR
FRAME
SERIES
COILS
TEMPERATURE SWITCH
IGNITION
SWITCH
(KUBOTA)
DIESEL
ALTERNATOR STATOR
ROTATOR
GLOW
PLUG
MECHANICAL
COUPLING
GENERATOR
ARMATURE
SHAFT
ENGINE
ENGINE
ARMATURE
SLIP
ALTERNATOR
BUTTON
RINGS
GLOW
PLUGS
+
-
INTERPOLE
COILS
RESIDUAL
FLASHING
MAGNETISM
AMMETER
FIELD
SHUNT
WINDINGS
START
ENGINE
STARTER
RELAY
BUTTON
RPM CONTROL
(CUSTOM ARC)
FIELD
RECTIFIER
STARTER
MOTOR
GENERATOR
FIELD CONTROL
RHEOSTAT
POSITIVE
OUTPUT
BATTERY
TERMINAL
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
E-8
E-8
THEORY OF OPERATION
Classic® 300D Kubota (Codes: 11112, 11113,
Classic® 300D Perkins (Codes 10545, 10546,
10657, 10658, 10911, 10927, 11110, 11111,
11248, 11249, 11280, 11281, 11411, 11412,
11472, and 11473)
11243, 11244, 11413, 11414, 11474, and 11475)
The Kubota powered Classic® 300D machines
utilize an electronic engine control system which
is a part of the Kubota engine. This system main-
tains a steady RPM by constantly sensing engine
speed and making adjustments as needed.
The Perkins powered Classic® 300D machines
have a mechanical governor that maintains the
engine RPM when the engine is running at high
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
TERMINAL
CURRENT
SENSOR
P.C. BOARD
IDLE
SWITCH
115 & 230VAC
RECEPTACLES
ENGINE
ENGINE
RPM CONTROL
GENERATOR
FRAME
CONTROL
COMPONENTS
AND
FUEL PUMP
SERIES
COILS
SENSORS
HOUR METER
ZENITH
E.C.U.
ENGINE FAILURE LAMP
ALTERNATOR STATOR
GASOLINE
ENGINE
ARMATURE
MECHANICAL
COUPLING
GENERATOR
ROTATOR
SHAFT
IGNITION
SWITCH
ARMATURE
SLIP
RINGS
ENGINE
ALTERNATOR
+
-
INTERPOLE
RESIDUAL
MAGNETISM
COILS
FLASHING
FIELD
SHUNT
WINDINGS
START
AMMETER
FIELD
RECTIFIER
STARTER
MOTOR
GENERATOR
FIELD CONTROL
RHEOSTAT
POSITIVE
OUTPUT
TERMINAL
BATTERY
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
CLASSIC® 300D & 300G
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E-9
E-9
THEORY OF OPERATION
ENGINE IDLER CIRCUIT
Classic® 300D Perkins (Codes 10545, 10546,
10657, 10658, 10911, and 10927)
Classic® 300G (Codes 10659, 10912, and
11135)
The above models use a high speed solenoid,
connected to the governor linkage, and operated
by the idler/engine protection PC board. In these
machines, the solenoid increases the RPM when
activated.
The Zenith ECU used in the Classic® 300G con-
trols whether the engine operates at high idle or
low idle. Closing the circuit between pins #11 and
#13 of the ECU signal that high RPM is required
and the engine immediately accelerates to high
idle RPM. Opening this will cause the engine
RPM to drop to low idle speed, (about 1360 RPM)
after a delay of about 15 seconds. If the pin #11
to pin #13 circuit is re-closed during this delay,
engine RPM will remain high.
When the idle switch is in the auto position, and
welding current is being drawn, the reed switch
CR2 is closed. This signals the idler PC board to
activate the high speed solenoid, which then
increases the engine speed to high idle RPM.
When auxiliary power is being used, the current is
passed through the toroidal current transformer.
This also signals the idler PC board to activate the
high speed solenoid. When welding ceases or
the auxiliary load is removed, a preset time delay
of about 15 seconds starts. When this 15 second
delay has passed, the idler PC board deactivates
the high speed solenoid, and allows the machine
will return to a low speed condition. If welding is
resumed, or an auxiliary load is applied during this
delay, the solenoid will remain active and the
engine RPM remains high.
The current sensor PC board detects current flow
in both the auxiliary and the weld circuits. When
sufficient current is flowing in either of these cir-
cuits, the current sensor PC board closes the #11
- #13 circuit, when current flow ceases, the circuit
is opened.
The idle switch and the current sensing PC board
are wired in parallel across the #11 - #13 circuit
described above. When the idle switch is set to
the high position, the contacts are closed and the
ECU operates the engine continuously at high
RPM. When the idle switch is in the Auto position,
the contacts are open, and the current sensor PC
board has control of the #11 - #13 circuit.
When the idle switch is in the high position, the
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.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
CLASSIC® 300D & 300G
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E-10
E-10
THEORY OF OPERATION
The current sensor PC board detects current flow
in both the auxiliary and the weld circuits. When
sufficient current is flowing in either of these cir-
cuits, the lead connected to pin #31 is grounded,
signaling that high RPM is required. When cur-
rent flow ceases, the lead connected to pin #31 is
disconnected from chassis ground, and the
engine idles down after the delay described
above.
When the idle switch is in the auto position, and
welding current is being drawn, the reed switch
CR2 is closed. This signals the idler PC board to
deactivate the idle solenoid, allowing the governor
to increase the engine speed to high RPM. When
auxiliary power is being used, the current is
passed through the toroidal current transformer.
This also signals the idler PC board to deactivate
the idle solenoid. When welding ceases or the
auxiliary load is removed, a preset time delay of
about 15 seconds begins. When this 15 second
delay has passed, the PC board activates the idle
solenoid, as described above, and pulls the
engine governor linkage to the low idle RPM posi-
tion. If welding is resumed, or an auxiliary load is
applied during this delay, the engine RPM will
remain high.
The idle switch and the current sensing PC board
are wired in parallel between chassis ground and
the pin#31 circuit described above. When the idle
switch is set to the high position, the contacts are
closed and the ECU operates the engine continu-
ously at high RPM. When the idle switch is in the
Auto position, the contacts are open, and the cur-
rent sensor PC board controls whether the pin
#31 circuit is grounded or open.
When the idle switch is in the high position, the
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.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
CLASSIC® 300D & 300G
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E-11
E-11
THEORY OF OPERATION
FIGURE E.10 - DC GENERATOR MACHINES
C
U
R
R
E
N
T
F
I
E
L
D
SHUNT FIELD WINDINGS
MAGNETIC FIELD
GENERATOR
DC CURRENT
BRUSH
BRUSH
ARMATURE
SHAFT
MECHANICAL
COUPLING
ARMATURE
MAGNETIC FIELD
SHUNT FIELD WINDINGS
DC CURRENT
C
U
R
R
E
N
T
F
I
E
L
D
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.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
CLASSIC® 300D & 300G
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E-12
E-12
NOTES
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
F-1
F-1
TROUBLESHOOTING AND REPAIR
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
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
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
CLASSIC® 300D & 300G
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F-2
F-2
TROUBLESHOOTING AND REPAIR
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.
---------------------------------------------------------------------------------------------------------------------------
Step 3. RECOMMENDED
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
COURSE OF ACTION
The last column labeled “Recommended
Course of Action” lists the most likely com-
ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject com-
ponent is either good or bad. If there are a
number of possible components, check the
components in the order listed to eliminate
one possibility at a time until you locate the
cause of your problem.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos-
sible symptoms that the machine may exhib-
it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function prob-
lems and welding problems.
All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
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.
-----------------------------------------------------------------------------------------------------------------------------------
CLASSIC® 300D & 300G
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F-3
F-3
TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Donʼt set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board canʼt be
installed immediately, put it back in the static-shield-
ing bag.
WARNING
ELECTRIC SHOCK
can kill.
•
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
- If the PC board uses protective shorting jumpers,
donʼt remove them until installation is complete.
- 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-
er failure analysis.
CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems when troubleshooting and replacing PC boards,
please use the following procedure:
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
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
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
2. Check for loose connections at the PC board
to assure that the PC board is properly
connected.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:
a. If the original problem does not reappear by
substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal strips.
b. If the original problem is recreated by the
substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.
PC board can be damaged by static electricity.
- Remove your bodyʼs static
charge before opening the static-
shielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
to
a
grounded part of the
ATTENTION
Static-Sensitive
Devices
equipment frame.
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.
- If you donʼt have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
Handle only at
Static-Safe
Workstations
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
CLASSIC® 300D & 300G
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F-4
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
Both the weld and auxiliary
output voltages are low.
Perform the Engine RPM
Make sure the engine is
operating at high idle speed.
Perform the Brush and Slip
Make sure that no load is
connected to either the weld or
auxiliary outputs.
Perform the Flash Voltage
Perform Exciter Rotor
Check that the remote/local
switch (if so equipped) is in
the local control position.
Perform the Brush and Slip
There is no, or very low weld
output, and no auxiliary output.
Perform the Flash Voltage
Check that the auxiliary power
circuit breakers and Ground
Fault Circuit Interrupters
(GFCIs) (if so equipped) are
not tripped.
Perform the Exciter Rotor
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.
CLASSIC® 300D & 300G
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F-5
Observe Safety Guidelines detailed in the beginning of this manual.
F-5
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
There is no, or very low weld
output voltage. The auxiliary
output is normal.
Check that the remote/local
switch (If so equipped) is
positioned correctly.
Perform the Welding
If a remote current control is
being used, try switching to
local control. The remote
current control may be faulty.
Perform the Shunt Field Coil
Check all leads and cables for
damaged or poor connections.
Perform the Shunt Field
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,
weld output is normal.
Check that the auxiliary power
circuit breakers are not tripped.
Check for auxiliary voltage at
the receptacle input terminals,
if normal voltage is present,
replace receptacle.
If the machine is equipped with
a ground fault circuit
interrupter (GFCI), it may be
tripped.
Check for auxiliary voltage at
the connections closest to the
exciter stator windings. See
wiring diagram.
NOTE: GFCIs will not reliably
reset, unless engine is
operating at high idle
RPM.
• If normal voltage is present,
check the wiring and circuit
breakers between the test
points and the receptacle.
Repair or replace any defective
parts or wiring.
Check all leads and cables for
damaged or poor connections.
• 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
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.
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F-6
Observe Safety Guidelines detailed in the beginning of this manual.
F-6
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
The output takes a long time to
build up and the AC auxiliary
voltage varies when the fine
current control is adjusted.
Check the “flashing” diode
located on the DC welding
generator brush holder. The
diode may be “shorted” or
installed incorrectly.
N/A
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.
CLASSIC® 300D & 300G
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F-7
Observe Safety Guidelines detailed in the beginning of this manual.
F-7
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
The weld output is considerably
less than indicated on the dials
or varies abnormally. Auxiliary
output appears normal.
Check welding cables for
Perform the Engine RPM
damaged or poor connections.
Welding cable may be
excessively long, too small, or
coiled. Try using a set of
short test cables of adequate
size.
Check the exciter brushes
and, if necessary, perform the
Check the welding generator
brushes and, if necessary,
perform the Welding
If a remote current control is
being used, try switching to
local control. The remote
current control may be faulty.
The engine may not be
maintaining steady RPM.
Make sure there is an
Check all the large weld
current carrying leads inside
the machine for damaged
conductors, insulation, and
poor connections.
adequate supply of clean,
fresh fuel. Replace fuel filters
if necessary. Have engine
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
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.
CLASSIC® 300D & 300G
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F-8
Observe Safety Guidelines detailed in the beginning of this manual.
F-8
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
The weld output is considerably
less than indicated on the dials
or varies abnormally. Auxiliary
output appears normal.
Perform the Shunt Field Coil
N/A
Check the Generator brush
rocker position; perform the
(Continued)
Procedure if necessary.
The weld output is considerably
higher than indicated on the
dials. Auxiliary voltage appears
normal.
If a remote current control is
being used, try switching to
local control. The remote
current control may be faulty.
The engine RPM may be too
high; perform the Engine RPM
There may be a short circuit in
the series field coils. Perform
Perform the Exciter Rotor
Perform the Shunt Field Coil
Verify that the rocker is
positioned correctly, according
to the factory drill mark.
Perform the Rocker
necessary.
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.
CLASSIC® 300D & 300G
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F-9
Observe Safety Guidelines detailed in the beginning of this manual.
F-9
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
WELDING PROBLEMS
The engine RPM may be
The weld current or voltage
The welding arc is loud and
spatters excessively.
incorrect; perform the Engine
settings may be incorrect.
The polarity may be incorrect
for the process in use.
Check the exciter brushes
and slip rings, and if
necessary, perform the Brush
If a remote current control is
being used, try switching to
local control. The remote
current control may be faulty.
Check the DC welding
generator brushes and
commutator. Perform the
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.)
Perform the Exciter Rotor
Perform the Shunt Field Coil
Verify that the rocker is
positioned correctly, according
to the factory drill mark.
Adjust the rocker position per
the procedure in this manual.
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.
CLASSIC® 300D & 300G
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F-10
Observe Safety Guidelines detailed in the beginning of this manual.
F-10
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
WELDING PROBLEMS
The welding arc frequently “pops
out”. Welding heat seems
normal and auxiliary output
voltage appears normal.
The engine RPM may be
The fine current control
incorrect; perform the Engine
rheostat may be set too low.
Try increasing the fine current
control setting. Drop the range
selector to a lower setting if
arc is too hot.
Check the exciter brushes
and slip rings. If necessary,
perform the Brush and Slip
If a remote control is being
used, try switching to local
control. The remote control
unit may be faulty.
Check the DC welding
generator brushes and
commutator. If necessary,
perform the Welding
Check welding cables for
damaged or poor connections.
Welding cable may be
excessively long, too small, or
coiled. Try using a set of short
test cables of adequate size.
Perform the Flash Voltage
Perform the Shunt Field
Check that the rocker is
aligned to the factory drill
mark, and perform the
Procedure if necessary.
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.
CLASSIC® 300D & 300G
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F-11
Observe Safety Guidelines detailed in the beginning of this manual.
F-11
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
WELDING PROBLEMS
The engine will not crank when
the start button is pressed.
Make sure battery is fully
charged and properly
The battery may be
discharged. Check, and if
necessary, charge or replace
the battery.
connected per the wiring
(Classic® 300G and 300D
Perkins)
diagram. Check for positive
battery voltage where the
lead from the start button
connects to the starter
The battery cables or battery
connections may be loose or
corroded. Service the battery
terminals.
solenoid, while holding in the
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
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.
CLASSIC® 300D & 300G
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F-12
Observe Safety Guidelines detailed in the beginning of this manual.
F-12
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
FUNCTION PROBLEMS
The engine will not crank when
the start button is pressed.
Make sure battery is fully
charged and properly
connected per the wiring
diagram. Turn on the
The battery may be
discharged. Check, and if
necessary, charge or replace
the battery.
(Classic® 300D Kubota)
run/stop switch, and within 30
seconds, press the start
button while checking for
positive battery voltage where
the lead #62 connects to the
starter solenoid.
The battery cables or battery
connections may be loose or
corroded. Service the battery
terminals.
• 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
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.
CLASSIC® 300D & 300G
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F-13
Observe Safety Guidelines detailed in the beginning of this manual.
F-13
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
FUNCTION PROBLEMS
The engine will not crank when
the start button is pressed.
• Check that the Engine Control
Module (ECU) is getting
battery power and has a good
ground connection (See
wiring diagram)
(Classic® 300D Kubota)
(Continued)
• Check lead #52B between the
start button and the ECU.
• Replace the ECU.
The engine cranks when the
start button is pressed, but will
not start.
Make sure the run/stop switch
is in the run position.
Perform the Engine Fuel
The run/stop switch may have
been left in the run position for
more that 30 seconds (60
seconds for some models).
Reset the engine protection
system by moving the run/stop
switch off, then on again.
(Classic® 300G and Classic®
300D Perkins)
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
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.
CLASSIC® 300D & 300G
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F-14
Observe Safety Guidelines detailed in the beginning of this manual.
F-14
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
FUNCTION PROBLEMS
The engine cranks when the
start button is pressed, but will
not start.
Verify that the engine control
unit is getting battery power
at pin #15, Lead 212D and a
good chassis ground
connection at pins #1 and
#19.
Make sure the run/stop switch
is in the run position.
The run/stop switch may have
been left in the run position for
more that 30 seconds (60
seconds for some models).
Reset the engine protection
system by moving the run/stop
switch off, then on again.
(Classic® 300D Kubota)
Check the wiring and
connections between the
engine control unit and the
speed sensor, the water
sensor and the actuator.
Check that there is an
adequate supply of fresh clean
fuel, and that the fuel shut-off
valve is open.
If the control unit has power,
a good chassis ground
connection and the wiring
described above is in good
condition, the engine and
engine control components
should be checked by a
qualified Kubota repair
technician.
Check and if necessary,
replace the fuel filter.
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.
There may be air in the fuel
system. See the engine
manufacturerʼs manual and
bleed all air from the fuel
system.
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.
CLASSIC® 300D & 300G
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F-15
Observe Safety Guidelines detailed in the beginning of this manual.
F-15
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
FUNCTION PROBLEMS
The engine starts normally, but
shuts down after running for
several seconds.
The idle/engine protection PC
board, engine control unit,
alternator, oil pressure switch,
or engine coolant temperature
switch may be faulty.
The oil pressure may be low.
Check the oil level and add oil
as needed. If necessary,
contact the engine
manufacturer, or a qualified
engine specialist to determine
the cause of the low oil
pressure condition, and make
any required adjustments or
repairs.
Perform the Engine
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
power.
Check that there is an
Perform the Engine RPM
adequate supply of fresh clean
fuel, and that the fuel shut-off
valve is fully open.
There may be internal
problems with the engine.
Contact the engine
Check the fuel and air filters,
replace if necessary.
manufacturer or a qualified
engine repair technician.
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.
CLASSIC® 300D & 300G
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F-16
Observe Safety Guidelines detailed in the beginning of this manual.
F-16
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
FUNCTION PROBLEMS
N/A
Check the run/stop switch,
replace if necessary.
The engine will not shut down
when the run/stop switch is
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
charged.
The battery may be faulty.
Recharge and test the battery.
Replace it if necessary.
Perform the Engine Alternator
The engine alternator drive belt
may be loose. Replace and/or
adjust the belt tension.
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.
CLASSIC® 300D & 300G
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F-17
Observe Safety Guidelines detailed in the beginning of this manual.
F-17
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
FUNCTION PROBLEMS
The machine will not idle down
to low RPM when weld and
Check the Idle Switch for
Make sure the idle switch is in
proper operation. See wiring
diagram.
the “AUTO IDLE” position.
auxiliary loads are removed.
The machine has normal weld
and auxiliary output. The engine
starts and shuts down normally.
Make sure there is no external
load on the weld terminals or
the auxiliary power
Perkins powered units:
The idle solenoid linkage, if
so equipped, may be bent or
out of adjustment. Check that
the linkage moves freely and
that the plunger does not bind
in any way.
receptacles. Disconnect the
weld cables and unplug
anything that may be
connected to the auxiliary
receptacles.
Check that the solenoid can
freely pull in and solidly seat
against its internal stop.
For machines equipped with
an idle solenoid, check for
mechanical restrictions in the
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
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
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.
CLASSIC® 300D & 300G
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F-18
Observe Safety Guidelines detailed in the beginning of this manual.
F-18
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
FUNCTION PROBLEMS
The machine will not idle down
to low RPM when weld and
If the machine idles down
after the sensor is unplugged,
check the wiring between the
PC board and toroidal current
sensor for damaged insulation
and electrical contact with
other electrically live
auxiliary loads are removed.
The machine has normal weld
and auxiliary output. The engine
starts and shuts down normally.
(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
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.
CLASSIC® 300D & 300G
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F-19
Observe Safety Guidelines detailed in the beginning of this manual.
F-19
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
FUNCTION PROBLEMS
The engine goes to low idle, but
will not stay at low idle. The
machine has normal weld and
auxiliary output. The engine
starts and shuts down normally.
The low idle RPM may be too
low. Perform the engine idle
adjustment procedure.
Make sure there are no
external loads on the weld
terminals or the auxiliary
power receptacles. Disconnect
the weld cables and unplug
anything that may be
The idle solenoid linkage may
be out of adjustment. Check
that the linkage moves freely
and that the plunger is not
binding in any way. Check
that the solenoid can freely
pull in and solidly seat
connected to the auxiliary
receptacles.
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
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.
CLASSIC® 300D & 300G
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F-20
Observe Safety Guidelines detailed in the beginning of this manual.
F-20
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
FUNCTION PROBLEMS
The engine goes to low idle, but
will not stay at low idle. The
machine has normal weld and
auxiliary output. The engine
starts and shuts down normally.
For Classic® 300G and
N/A
Kubota powered Classic®
300D:
Check all wiring connecting
the current sensor and the
engine control unit.
(Continued)
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
idle when the idle switch is
moved to the “High” position.
The idle system functions
The Idle switch may be
defective.
N/A
Wiring connecting the idle
switch may be faulty.
normally while welding or using
auxiliary power. The engine
starts and shuts down normally.
See Wiring Diagram.
The engine will not go to high
idle when striking an arc or
when using auxiliary power.
The engine goes to high idle,
and the weld and auxiliary
power are normal when the idle
switch is in the “High Idle”
position. The engine starts,
runs, and shuts down normally.
Check that the welding cables
and the auxiliary power lead
connections are tight and in
good condition.
The idle/engine protection PC
board may have failed.
The current sensor PC board
may have failed.
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.
CLASSIC® 300D & 300G
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F-21
Observe Safety Guidelines detailed in the beginning of this manual.
F-21
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
FUNCTION PROBLEMS
The engine will not go to high
idle when striking an arc. The
automatic idle system functions
normally when using auxiliary
power. Weld and auxiliary
Perkins powered models:
Check that the welding cables,
electrode holder, and work
clamp are tight and in good
condition.
The 2 CR Reed Relay, or the
wiring that connect it to the
PC board and chassis ground
may be faulty. The Reed
relay should close when
sufficient current is drawn
from the weld output
This may be normal operation
if the machine has a Wire
Feed Module, and is operating
in CV mode. See the
power are normal when the idle
switch is in the “High Idle”
position. The engine starts,
runs, and shuts down normally.
terminals.
operatorʼs manual for the Wire
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
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.
CLASSIC® 300D & 300G
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F-22
Observe Safety Guidelines detailed in the beginning of this manual.
F-22
TROUBLESHOOTING AND REPAIR
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
FUNCTION PROBLEMS
The engine will not go to high
idle when using auxiliary power.
The automatic idle system
functions normally when welding.
Weld and auxiliary power is
normal when the idle switch is in
the “High Idle” position. The
engine starts, runs, and shuts
down normally.
The Toroidal Current
Transformer or the wiring
connecting it to the
The load applied to the
auxiliary receptacles may be
too low. A load of 150 Watts
minimum is required for the
idle system to operate reliably.
idler/engine protection PC
board may be faulty.
The idler/engine protection
PC board may be faulty.
Check that any power cords
are in good condition and
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
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.
CLASSIC® 300D & 300G
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F-23
F-23
TROUBLESHOOTING AND REPAIR
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.
If for any reason you do not understand the test procedures or are unable to perform the
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)
CLASSIC® 300D & 300G
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F-24
F-24
TROUBLESHOOTING AND REPAIR
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
necessary to re-seat them. This can be done by
placing a strip of 180 grit sandpaper between the
slip rings and the brushes. Make sure the abrasive
side is against the brushes. Pull the strip around
the circumference of the slip rings in the direction
of the rotor rotation only. Repeat this procedure
until the surface of each brush is in full contact with
its matching slip ring.
Use low pressure compressed air to thoroughly
blow the carbon, commutator stone and sandpaper
dust from the machine before operating.
Securely connect the leads to the brush terminals
(see wiring diagram) and replace the alternator
cover if testing and service is complete.
• Brushes should be clean and free of oil and
grease.
• The brushes should be of sufficient length
and have adequate spring tension.
(Generally, the brushes should be replaced if
either brush has less than 1/4” remaining
before it reaches the end of itʼs travel.)
• Brushes should be making good, continuous
contact with the slip rings, and should be rid-
ing near the center of the slip rings. (The
brush holder bracket may need to be slightly
bent to achieve acceptable alignment.)
Note: If slip rings are very dark in color, display
evidence of excessive arcing, or a have
worn prematurely, these may be signs of a
grounded or shorted rotor. Perform the
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.
CLASSIC® 300D & 300G
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F-25
F-25
TROUBLESHOOTING AND REPAIR
ENGINE ALTERNATOR TEST PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the engine alternator is operating normally.
MATERIALS NEEDED
Multimeter
Miscellaneous hand tools
Wiring diagram
CLASSIC® 300D & 300G
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F-26
F-26
TROUBLESHOOTING AND REPAIR
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.
CLASSIC® 300D & 300G
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F-27
F-27
TROUBLESHOOTING AND REPAIR
ENGINE FUEL SYSTEM VOLTAGE TEST PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the fuel system is getting the electrical power needed to function
correctly.
MATERIALS NEEDED
Miscellaneous hand tools
Multimeter
CLASSIC® 300D & 300G
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F-28
F-28
TROUBLESHOOTING AND REPAIR
ENGINE FUEL SYSTEM VOLTAGE TEST PROCEDURE (continued)
PROCEDURE
1. Open and secure the side door.
NOTE: Secure the doors in the open position using
the door restraint system. If the machine
does not have a door restraint system,
remove the doors or securely restrain them
to prevent them from falling closed.
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.
CLASSIC® 300D & 300G
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F-29
F-29
TROUBLESHOOTING AND REPAIR
ENGINE PROTECTION SYSTEM TEST PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
Miscellaneous hand tools
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.
CLASSIC® 300D & 300G
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F-30
F-30
TROUBLESHOOTING AND REPAIR
ENGINE PROTECTION SYSTEM TEST PROCEDURE (continued)
10. Shut off the engine and reconnect any one of
the three leads that had been disconnected in
steps 1 through 3, then start the engine and
allow it to run. If the engine shuts down, the
component that had just been connected is
faulty and should be repaired or replaced.
11. If the engine continues to run after reconnect-
ing one of the wires, repeat step #9, connecting
one of the two remaining wires, then repeat
step #9 again connecting the last wire. Repair
or replace any faulty component.
PROCEDURE
1. Open the side doors on the Classic® 300
machine.
NOTE: Secure the doors in the open position using
the door restraint system. If the machine
does not have a door restraint system,
remove the doors or securely restrain them
to prevent them from falling closed.
Classic® 300D Perkins powered machines:
Be certain to reconnect all lead wires and close the
CAUTION
doors when testing and service is complete.
The following procedure will temporarily disable
the engine protection system. Be absolutely certain
that engine temperature and oil pressure are with-
in the normal range. IF THE ENGINE IS PERMIT-
TED TO RUN WHITE OVERHEATED OR WITH
TOW OIL PRESSURE, SEVERE ENGINE DAM-
AGE WILL LIKELY RESULT, AND THE ENGINE
WARRANTY WILL NOT COVER THE DAMAGE.
Be absolutely certain that all wires are connected
when the test is completed.
Classic® 300D Kubota powered machines:
The Kubota engine control module will flash the
engine protection fault light, indicating where the
fault was detected. See the machine schematic for
a list of codes. Use this code to determine what
sensor or associated wiring is causing the problem
and check the wiring.
The sensors and engine control unit are part of the
Kubota engine. If the wiring and connections are in
good condition, the engine should be serviced by a
qualified Kubota service technician.
2. Disconnect the lead wire connecting the PC
board to the engine coolant temperature gage
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.
CLASSIC® 300D & 300G
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F-31
F-31
TROUBLESHOOTING AND REPAIR
ENGINE RPM ADJUSTMENT TEST PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the engine is operating at the correct RPM, for both high and low
idle positions.
MATERIALS NEEDED
Miscellaneous hand tools
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.
CLASSIC® 300D & 300G
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F-32
F-32
TROUBLESHOOTING AND REPAIR
ENGINE RPM ADJUSTMENT TEST PROCEDURE (continued)
Frequency counter method:
PROCEDURE
NOTE: A dedicated frequency counter can be used
for this test, but many high quality digital
multimeters also have this function, and
can be easily utilized. See the manufactur-
er's instructions for your frequency counter
or multimeter.
1. Turn the engine off.
2. Place the RPM adjustment potentiometer or
"Custom Arc" control to maximum (Classic®
300G and Classic® 300D Kubota models only.)
3. Open the side door.
Set your frequency counter per the meter manu-
facturer's instructions, and plug the probes into one
of the 120VAC auxiliary receptacles.
Start the engine and place the idle switch in the
"HIGH IDLE" position. Make sure that there is no
load on the machine and allow the engine RPM to
stabilize.
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 or securely restrain it to
prevent it from falling closed.
Classic® 300D Perkins only:
Check that the linkage attaching the solenoid to the
engine speed control lever is properly aligned and
in good condition.
The frequency should read between 59.7 and 60.3
Hz.
Move the idle switch to the "AUTO IDLE" position
and wait for the engine RPM to drop and stabilize
at the low idle RPM.
The frequency counter should read as follows:
Strobe-Tach Method:
Place a highly visible mark on the engine crank-
shaft pulley, or another rotating component con-
nected to the engine crankshaft.
• 44.2 to 49.2 Hz. for Classic® 300G and Classic®
Connect the strobe-tach according to the manufac-
300Ds powered by the Perkins 104.22 engines.
turer's instructions.
• 45 to 48.3 Hz. for Classic® 300Ds powered by
other Perkins engines
• 46.3 to 47 Hz. for Classic® 300D Kubota models.
Start the engine and place the idle switch in the
"HIGH IDLE" position. Make sure that there is no
load on the machine and allow the engine RPM to
stabilize.
Direct the strobe-tach light on the highly visible
mark that had been applied earlier and synchro-
nize the light with the rotating mark. See the
strobe-tach manufacturer's instructions.
If either of the readings is incorrect, proceed to the
later in this section.
NOTE: For Lincoln Electric 1800 RPM (4 Pole)
machines, that have 60 Hz AC auxiliary
power; the engine RPM can be determined
by multiplying the frequency of the auxiliary
power output, in Hz. By 30. (Example: 60
Hz. * 30 = 1800 RPM)
The tach should read between 1790 and 1810
RPM
Move the idle switch to the "AUTO IDLE" position
and wait for the engine RPM to drop and stabilize
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
later in this section.
CLASSIC® 300D & 300G
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F-33
F-33
TROUBLESHOOTING AND REPAIR
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.
CLASSIC® 300D & 300G
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F-34
F-34
NOTES
CLASSIC® 300D & 300G
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F-35
F-35
TROUBLESHOOTING AND REPAIR
FLASHING VOLTAGE TEST PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test checks the exciter rotor flashing voltage.
MATERIALS NEEDED
Miscellaneous hand tools
Multimeter
Wiring diagram
CLASSIC® 300D & 300G
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F-36
F-36
TROUBLESHOOTING AND REPAIR
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.
CLASSIC® 300D & 300G
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F-37
F-37
TROUBLESHOOTING AND REPAIR
ROCKER ADJUSTMENT PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
Miscellaneous hand tools
Drill with 1/8" bit Tachometer or frequency meter.
CLASSIC® 300D & 300G
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F-38
F-38
TROUBLESHOOTING AND REPAIR
ROCKER ADJUSTMENT PROCEDURE (continued)
FIGURE F.1 – FACTORY SET POINT DRILL MARK LOCATIONS
EXCITER BRACKET
DRILL MARKS
ROCKER
PROCEDURE
A tachometer will be required for this phase of the
details about measuring engine RPM.
When the rocker is set for the first time at the fac-
tory, a 1/8" drill is used to mark the position of both
the rocker and the exciter bracket. See Figure F.1
Initial rocker placement:
If a machine is not operating within the specified
limits, and nothing else appears to be faulty, the
rocker position should be checked. If the drill marks
are not aligned, the rocker and/or the exciter brack-
et should be reset to the original factory position.
If it has been determined that a rocker adjustment
is necessary on an unaltered machine; the rocker
should only be moved in very small increments,
and the total movement should be no more than
1/2 the diameter of the drill mark.
The rocker should be initially positioned so the cen-
ter of brushes visually lines up with the center of
the main poles. Lining up the four brush holder
studs with the four exciter bracket mounting bolts is
acceptable for initial placement. The rocker should
be tight against the shoulder of the hub and the
clamping screw should be tightened only enough
to assure the rocker cannot move. DO NOT OVER
TIGHTEN.
IMPORTANT: Over tightening the rocker clamp
IMPORTANT! The following procedures should
only be attempted if all the other systems have
been thoroughly checked and are functioning
normally.
screw can destroy the rocker.
Setting the rocker if the factory drill mark is
missing or invalid due to component replace-
ment:
CLASSIC® 300D & 300G
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F-39
F-39
TROUBLESHOOTING AND REPAIR
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.
Generally, moving the rocker opposite the arma-
ture rotation direction will increase output voltage.
When making this adjustment, the rocker should
only be moved in very small increments. The
adjustment may need to be repeated several times
to achieve the desired result.
Start the engine, place the idle switch in the high
idle position, and seat the brushes using a com-
Check the OCV, (Open Circuit Voltage)
Place the range selector switch in the maximum
position. Use a load bank to apply a 100% duty
cycle load (250 amps @ 30 volts). Look at the
brushes while the load is applied. If excessive
sparking is observed, adjust the rocker position to
minimize sparking. Generally, moving the rocker
slightly in the direction of the armature rotation will
reduce sparking.
Continue running the machine under load for at
least 30 minutes to bring the machine up to normal
operating temperature and to fully seat the brush-
es.
Remove the load and check the voltage at the out-
put studs. The voltage should measure from 93 to
99 Volts DC.
After the rocker has been adjusted and the
machine is operating normally, the rocker locking
screw should be tightened to 70-75 Inch-Lbs.
If new parts had been installed, the new rocker
and/or exciter bracket location should be marked
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,
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.
CLASSIC® 300D & 300G
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F-40
F-40
NOTES
CLASSIC® 300D & 300G
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F-41
F-41
TROUBLESHOOTING AND REPAIR
EXCITER ROTOR RESISTANCE AND GROUND TESTS 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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the exciter / auxiliary power alternator rotor winding is open,
shorted, or grounded.
MATERIALS NEEDED
Miscellaneous hand tools
Ohmmeter (Analog type meter required for dynamic resistance test.)
Wiring diagram
CLASSIC® 300D & 300G
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F-42
F-42
TROUBLESHOOTING AND REPAIR
EXCITER ROTOR RESISTANCE AND GROUND TESTS PROCEDURE
(Exciter / Auxiliary Power Alternator) (continued)
FIGURE F.2 – LEAD LOCATION
If these resistance values are normal, continue
testing, using the dynamic rotor resistance and
ground test.
PROCEDURE
"Static" Tests:
1. Turn the engine off.
"Dynamic" Tests:
(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
mechanical forces encountered during normal
operation.
NOTE: This test is best performed with a good
quality analog type ohmmeter. Many digital
meters will not provide stable or accurate
resistance readings while the rotor is spin-
ning.
3. Locate and label the leads connected to the
rotor brush holder assembly. Remove the
leads. This will electrically isolate the rotor
windings.
4. Using the ohmmeter, check the rotor winding
resistance across the slip rings. Normal resis-
tance is approximately 41.5* ohms, at 77°F.
(25° C.) See Figure F.2
5. Measure the resistance to ground. Place one
meter probe on either of the slip rings. Place the
other probe on any good unpainted chassis
ground. The resistance should be very high, at
least 500,000 (500k) ohms.
This test requires that the brushes and slip rings
are clean, in good condition, and are properly seat-
ed.
Perform the Brush and Slip RIng Service
Procedure if necessary.
6. If the resistance measurements are not as
specified the rotor may be faulty and should be
replaced.
CLASSIC® 300D & 300G
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F-43
F-43
TROUBLESHOOTING AND REPAIR
EXCITER ROTOR RESISTANCE AND GROUND TESTS PROCEDURE
(Exciter / Auxiliary Power Alternator) (continued)
7. Insulate the lead wires that had been discon-
nected from the brushes during the static rotor
resistance test. Position and secure them so
they cannot become damaged by the spinning
rotor. 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
0
0
approximately 42* ohms at 77 F (25 C).
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.
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F-44
F-44
NOTES
CLASSIC® 300D & 300G
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F-45
F-45
TROUBLESHOOTING AND REPAIR
SHUNT FIELD COIL RESISTANCE AND GROUND TEST PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
Miscellaneous hand tools
Multimeter
Wiring diagram
CLASSIC® 300D & 300G
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F-46
F-46
TROUBLESHOOTING AND REPAIR
SHUNT FIELD COIL RESISTANCE AND GROUND TEST
PROCEDURE (continued)
PROCEDURE
1. Turn the engine off.
Shunt coil ground test:
7. With the jumper plug or wire feed module
unplugged from J5, measure the resistance
between either the brown or blue wires and a
good clean chassis ground. The resistance
should be very high, 500,000 (500k) Ohms min-
imum.
8. If the resistance is still lower than 500,000
(500k) Ohms, check the shunt coil lead wires
between the test points and the coils. Also
check the lead wire connecting the two shunt
coils together inside of the generator. Look for
pinched wires and damaged insulation. If the
low resistance is determined to be between
chassis wound and one of the shunt coils,
replace the coil set.
2. Open either or both of the doors on the
machine.
NOTE: Secure the doors in the open position using
the door restraint system. If the machine does not
have a door restraint system, remove the doors or
securely restrain them to prevent them from falling
closed.
Test the shunt coil resistance:
3. Remove the jumper plug or wire feed module
harness plug from J5. Locate the brown and
blue wires in J5, (pin numbers 3 and 5). Check
the resistance between these two leads.
Resistance should measure about 59 ohms at
77°F. (25° C.)
9. Reconnect the wires and replace any covers
NOTE: It is always best to place probes in the lead
end of Molex connectors. Molex pins can
be easily damaged if probes are inserted in
the connection pin end.
4. If the resistance reading is correct, proceed to
that have been removed.
*NOTE: The resistance in the copper windings will
change with temperature. Higher temperatures will
produce slightly higher resistance, and lower tem-
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.
CLASSIC® 300D & 300G
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F-47
F-47
TROUBLESHOOTING AND REPAIR
SHUNT FIELD CIRCUIT VOLTAGE TEST PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
Miscellaneous hand tools
Multimeter
Wiring diagram
CLASSIC® 300D & 300G
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F-48
F-48
TROUBLESHOOTING AND REPAIR
SHUNT FIELD CIRCUIT VOLTAGE TEST PROCEDURE (continued)
PROCEDURE
1. Turn the engine off.
2. Open either or both of the side doors.
NOTE: Secure the doors in the open position
using the door restraint system. If the
machine does not have a door restraint
system, remove the doors or securely
restrain them to prevent them from falling
closed.
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-
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.
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F-49
F-49
TROUBLESHOOTING AND REPAIR
EXCITER STATOR SHORT CIRCUIT & GROUND TEST PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
Miscellaneous hand tools
Multimeter
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F-50
F-50
TROUBLESHOOTING AND REPAIR
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
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.
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.
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F-51
F-51
TROUBLESHOOTING AND REPAIR
WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
Miscellaneous hand tools
Multimeter
Wiring diagram
CLASSIC® 300D & 300G
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F-52
F-52
TROUBLESHOOTING AND REPAIR
WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST PROCEDURE
(continued)
PROCEDURE
1. Turn the engine off.
Weld circuit ground test:
2. Measure the resistance between either of the
two weld output terminals and a clean chassis
ground connection.
9. If the resistance measurement is too low, check
the heavy weld current carrying leads and con-
nections for damaged insulation or dirt buildup
between the negative (Series Coils) and posi-
tive (Interpole Coils) circuits. If the low resis-
tance point is between the stator coils, the coils
will require replacement or repair. Check for
insulation damage between the yellow and
white leads connecting to J5.
The resistance measurement should be very
high 500,000 (500k) Ohms minimum.
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.
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F-53
F-53
TROUBLESHOOTING AND REPAIR
WELDING GENERATOR BRUSH AND COMMUTATOR
INSPECTION AND SERVICE PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure provides guidelines for checking and servicing the welding generator com-
mutator and brushes.
MATERIALS NEEDED
Miscellaneous hand tools
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.
CLASSIC® 300D & 300G
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F-54
F-54
TROUBLESHOOTING AND REPAIR
WELDING GENERATOR BRUSH AND COMMUTATOR
INSPECTION AND SERVICE PROCEDURE (continued)
FIGURE F.3 - DRILL MARK LOCATIONS
EXCITER BRACKET
DRILL MARKS
ROCKER
Blackened Commutator:
PROCEDURE
A commutator that appears an even black color all
around may indicate a grounded armature, shorted
weld circuit, a serious overload condition, or out-of-
adjustment rocker. It could also indicate the use of
poor quality brushes, or brushes that have been
contaminated with oil or some other foreign sub-
stance.
• Check the rocker position. Be certain that it is
aligned with or very close to the factory drill
mark. See Figure F.3. IMPORTANT: If the rocker
position requires adjustment, do not over tighten
the rocker clamping screw. This screw should be
tightened to a torque of 70 to 75 Inch-Lbs. Over
tightening can destroy the rocker.
1. Shut off the engine.
2. Open either, or both of the side doors of the
Classic® 300 machine.
NOTE: Secure the doors in the open position using
the door restraint system. If the machine
does not have a door restraint system,
remove the doors or securely restrain them
to prevent them from falling closed.
3. Disconnect the negative battery cable.
4. Remove the cover protecting the welder gener-
ator brushes.
Examine the Commutator:
Normal appearance:
• Perform the Weld Circuit Ground and Short
The commutator should appear smooth, and have
• 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.
an even brown color where the brushes ride.
• If brush quality or contamination is not suspect-
ed, clean the commutator by lightly stoning the
surface. See caution note on commutator stone
use.
CLASSIC® 300D & 300G
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F-55
F-55
TROUBLESHOOTING AND REPAIR
WELDING GENERATOR BRUSH AND COMMUTATOR
INSPECTION AND SERVICE PROCEDURE (continued)
Pitted and Are Damaged Commutator:
Examine the brushes:
If pitting and arc damage to the commutator is evi-
dent, the machine may have been used with badly
worn brushes. The brush spring tension may have
been too low, or the brushes may have been stick-
ing in the holders. An out-of-adjustment rocker or a
serious overload may also cause this condition.
The brushes and springs should all be in place and
not be excessively worn. Brushes should be
replaced if they are worn to within 1/4" of the pigtail
lead.
The pigtail lead of each brush should be positioned
so it allows free movement of the brush while it
wears.
The brushes should be seated so that the face of
each brush makes 95% minimum contact with the
commutator. Lightly stone the commutator to seat
the brushes. See caution note on commutator
stone usage.
•
Examine the inside of the brush clovers and
other parts that are close to the commutator. If
there is a significant amount of solder and
debris that has been thrown from the commu-
tator, the armature will need to be replaced and
the stator coils must be carefully examined and
tested for damage.
Examine the brush holders:
•
•
Perform the Weld Circuit Ground and Short
The brush holder insulators must be clean and in
good condition and all of the hardware must be in
place. Replace any insulators that are cracked or
damaged in any way.
When installing the brush holders, they should be
rotated toward the brush retainer (clockwise rota-
tion when facing the brush holder mounting screw.)
until they stop. The edge of the brush holder plate
should be parallel with the surface of the commu-
tator and positioned .030 to .090 from the surface
of the commutator. The brush holder mounting
screw should be tightened to a torque of 24 to 28
Ft Lbs.
The brush holder plate and retainer assembly must
be clean and smooth. Nothing should prevent free
movement of the brushes. All electrical connec-
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.
If the brushes are worn out, replace them and
re-surface or clean the commutator as needed.
If the brush springs appear weak, or damaged
in any way, replace them as well. The brush
holder plates and retainers should be clean,
smooth, and undamaged so the brushes can
move freely as they wear.
•
Check the rocker position. Be certain that it is
aligned with or very close to the factory drill
IMPORTANT: If the rocker position requires adjust-
ment, do not over tighten the rocker clamping
screw. This screw should be tightened to a torque
of 70 to 75 Inch-Lbs. Over tightening can destroy
the rocker.
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.
CLASSIC® 300D & 300G
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F-56
F-56
NOTES
CLASSIC® 300D & 300G
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F-57
F-57
TROUBLESHOOTING AND REPAIR
SERIES COIL SHORT CIRCUIT TEST PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
CLASSIC® 300D & 300G
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F-58
F-58
TROUBLESHOOTING AND REPAIR
SERIES COIL SHORT CIRCUIT TEST PROCEDURE (continued)
PROCEDURE
7. Start the engine and read the current in the
shorting cable. It should read from 95 to 120
Amps.
1. Place the current range switch in the Max posi-
tion, connect the Classic® 300 to a load bank
and start the engine.
8. Stop the engine and move the selector switch to
the 80 to 130 Amp tap. Restart the engine and
read the current in the shorting cable. It should
read from 150 to 200 amps.
9. Stop the engine and move the selector switch to
the 120 to 190 Amp tap. Restart the engine and
read the current in the shorting cable. It should
read from 240 to 300 amps.
10. Stop the engine and move the selector switch
to the 160 to 240 Amp tap. Restart the engine
and read the current in the shorting cable. It
should read from 330 to 410 amps.
11. If the current is considerably higher than indi-
cated above for all of the tests, check engine
RPM.
2. Apply a load of 250 amps and allow the
machine to reach normal operating tempera-
ture, (about 30 minutes)
3. Move the fine current control to the max posi-
tion, and then adjust the load bank to obtain a
300 amp load.
4. Read the engine RPM and the voltage at the
output terminals. See the Engine RPM
Adjustment Tests for instructions on how to
check RPM.
Kubota powered models should read 1790 to 1810
RPM, and 34 to 48 VDC at the output terminals.
Classic® 300G should read 1780 to 1810 RPM
and 33 to 42 VDC at the output terminals.
Perkins powered models should read 1650 to 1750
12. If some, but not all of the values are signifi-
cantly higher than specified, the series coils are
likely shorted and should be replaced.
RPM, and 33 to 42 VDC at the output terminals.
5. Remove the load and place the range switch in
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.
CLASSIC® 300D & 300G
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F-59
F-59
TROUBLESHOOTING AND REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)
HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AT MAXIMUM
16.6 ms
CH1
0 volts
5 ms
50 volts
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
CLASSIC® 300D & 300G
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F-60
F-60
TROUBLESHOOTING AND REPAIR
NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM
HIGH IDLE – NO LOAD – FINE CURRENT CONTROL RHEOSTAT AND SELECTOR
SWITCH AT MAXIMUM
CH1
0 volts
5 ms
50 volts
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.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
CLASSIC® 300D & 300G
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F-61
F-61
TROUBLESHOOTING AND REPAIR
TYPICAL DC WELD OUTPUT VOLTAGE WAVEFORM
MACHINE LOADED – SELECTOR SWITCH AT MAXIMUM POSITION
CH1
0 volts
5 ms
20 volts
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.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
CLASSIC® 300D & 300G
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F-62
F-62
NOTES
CLASSIC® 300D & 300G
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F-63
F-63
TROUBLESHOOTING AND REPAIR
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
CLASSIC® 300D & 300G
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F-64
F-64
TROUBLESHOOTING AND REPAIR
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT PROCEDURE (continued)
PROCEDURE
1. Turn the engine off.
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
CLASSIC® 300D & 300G
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F-65
F-65
TROUBLESHOOTING AND REPAIR
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT PROCEDURE (continued)
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
CLASSIC® 300D & 300G
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F-66
F-66
TROUBLESHOOTING AND REPAIR
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT PROCEDURE (continued)
See Figure F.6 for steps 6 - 8.
6. With the 7/16" wrench, remove the two bolts,
nuts and washers mounting the brush holder
assembly to the stator frame.
8. With the 1-5/8" socket wrench, remove the
rotor locking nut, washer and sleeve collar.
NOTE: The sleeve collar will have to be
removed with a gear puller. Be careful
not to damage the rotor slip ring assem-
bly. Remove the rotor by pulling it free of
the generator shaft.
7. Bend the flat washer away from the rotor lock-
ing nut.
FIGURE F.6 – ROTOR REMOVAL
"BENT"
WASHER
STATOR
FRAME
SLEEVE
COLLAR
BRUSH
NUT
HOLDER
ASSEMBLY
CLASSIC® 300D & 300G
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F-67
F-67
TROUBLESHOOTING AND REPAIR
ALTERNATOR ROTOR REMOVAL
AND REPLACEMENT PROCEDURE (continued)
Replacement
9. Carefully mount the rotor onto the generator
shaft. Install a new sleeve collar (part num-
ber T14337), washer, and rotor locking nut.
d. The exciter brush spring must lie flat on
the corner of the brush and not touch
either side of the retainer.
e. With the brushes in place, insert one end
of a minimum 24" long piece of 180 grit
sandpaper between the slip rings and
brushes (abrasive against brushes). With
slight additional finger pressure on top of
brushes, pull the paper around the cir-
cumference of the rings in the direction of
rotation only. Repeat this procedure until
the entire face of the brush is contoured
to the radius of the slip ring.
NOTE: Be careful not to damage or deform
the new sleeve collar. Carefully tap
the new sleeve collar into position.
The rotor locking nut should be
torqued to 175 ft.-lbs.
After the rotor locking nut is properly
torqued, bend the washer down over the
locking nut.
Check rotor air gap. .017" minimum is
f. Check the brushes to be certain that there
is spring tension holding them firmly
against the slip rings.
allowed.
10. Mount the brush holder assembly to the sta-
tor frame using two bolts, washers, and nuts.
Installing and Seating Exciter Slip Ring Brushes
11. Install the alternator cover and wrap-around.
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.
CLASSIC® 300D & 300G
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F-68
F-68
NOTES
CLASSIC® 300D & 300G
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F-69
F-69
TROUBLESHOOTING AND REPAIR
ALTERNATOR STATOR REMOVAL AND REPLACEMENT PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
CLASSIC® 300D & 300G
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F-70
F-70
TROUBLESHOOTING AND REPAIR
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-
nect the black auxiliary power lead from
the current transformer. Cut any neces-
sary cable ties. See the Wiring Diagram
9. Remove the red auxiliary power lead from
the CB4 circuit breaker. See the Wiring
10. Remove the white auxiliary power lead
from the 115VAC receptacle. Cut any nec-
NOTE: The CB1 circuit breaker may have to
be removed to access the terminal for
the white lead.
11. Remove the red lead from the negative ter-
minal of the field rectifier bridge. See
12. Remove the black lead from the positive
terminal of the field rectifier bridge. See
2. Perform the Alternator Rotor Removal
procedure.
3. With the 1/2" wrench, remove the four nuts
and bolts holding the case top and doors
assembly to the welder frame. Carefully lift
up and remove the top and doors assembly.
4. With the 3/8" nut driver, remove the two
leads from the alternator brush holder
assembly. Note lead placement. Set brush
holder aside.
5. With the slot head screwdriver, remove the
commutator wraparound. See Figure F.7.
6. Disconnect the yellow and white wires at the
in-line connectors. See the Wiring Diagram
7. Disconnect the two yellow leads. One is
located at the field bridge and the other at
the field fuse holder. Cut any necessary
CLASSIC® 300D & 300G
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F-71
F-71
TROUBLESHOOTING AND REPAIR
ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued)
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
CLASSIC® 300D & 300G
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F-72
F-72
TROUBLESHOOTING AND REPAIR
ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued)
ALTERNATOR STATOR REMOVAL
AND REPLACEMENT (continued)
13. Clear the leads in preparation for remov-
ing the stator/end bracket.
14. Lift the eight brushes from the commuta-
tor. Note the position of the brushes for
reassembly.
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.
CLASSIC® 300D & 300G
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F-73
F-73
TROUBLESHOOTING AND REPAIR
ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued)
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
bolts mounting the stator/end bracket
assembly to the generator frame. Note
the "drill spot" for reassembly. See Figure
F.11.
17. With the 7/16" wrench, loosen (do not
remove) the generator brush holder
clamping bolt. Note the drill spot for
reassembly. See Figure F.11.
22. Connect the four heavy cables from the
generator frame coils to the generator
brush holders.
23. Install the eight commutator brushes
according to how you marked their posi-
tions at disassembly.
24. Attach the black lead to the positive termi-
nal of the field rectifier bridge. Attach the
red lead to the negative terminal.
25. Attach the white auxiliary power lead to
the 115 VAC receptacle. Attach the red
auxiliary power lead to the CB4 circuit
breaker. Attach the black auxiliary power
lead to the current transformer. Tape the
bolted connection.
26. Connect the two yellow leads to the field
bridge and to the field fuse holder.
Connect the white and yellow wires at the
in-line connectors.
27. Install the commutator wraparound, the
bottom alternator cover, the battery, and
the alternator brush holder assembly.
28. Install the alternator rotor according to the
reassembly directions in the Alternator
cedure. Before installing the case top and
sides, replace any cable ties cut for disas-
sembly.
18. Carefully pry the stator/end bracket
assembly away from the generator frame.
NOTE: The generator brush holder assembly
will also be removed.
Replacement
19. Mount the stator/end bracket assembly to
the generator frame. Line up the mating
parts at the stator end bracket drill spot.
Tighten the four mounting bolts with the
5/8" wrench.
20. Check armature air gap. Minimum gap is
.035." Loosen the four mounting bolts;
adjust and re-tighten if necessary.
21. Tighten the generator brush holder
assembly with the 7/16" wrench. Note
brush holder drill spot.
CLASSIC® 300D & 300G
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F-74
F-74
NOTES
CLASSIC® 300D & 300G
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F-75
F-75
TROUBLESHOOTING AND REPAIR
GENERATOR FRAME
REMOVAL AND REPLACEMENT PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
CLASSIC® 300D & 300G
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F-76
F-76
TROUBLESHOOTING AND REPAIR
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
tion (Diesel only).
8. With the 3/4" wrench, remove the copper
strap/reed switch assembly from the negative
output terminal. Clear the strap.
procedure.
3. Perform the Alternator Stator Removal
procedure.
See Figure F.12 for steps 4 - 9.
9. With the 3/4" wrench, remove the cable from
the positive output terminal.
4. Turn off the fuel at the fuel bowl and remove
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.
CLASSIC® 300D & 300G
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F-77
F-77
TROUBLESHOOTING AND REPAIR
GENERATOR FRAME
REMOVAL AND REPLACEMENT (continued)
FIGURE F.13 – WIRE AND SELECTOR SWITCH CONNECTIONS
IDLER PC BOARD
SELECTOR
SWITCH
FINE CURRENT
ADJUSTMENT
RHEOSTAT
FIELD BRIDGE
IN-LINE CONNECTORS
BLUE/BROWN LEADS
See Figure F.13 for steps 10 - 13.
10. Cut all necessary cable ties.
11. Disconnect the blue and the brown wires at the in-
line connectors. See Figure F.13 and the Wiring
Diagram.
12. Label the cables that are connected to the selector
switch. Otherwise, you will need to see the Wiring
Diagram during reassembly.
13. With the 1/2" wrench, remove the cables connect-
ed to the selector switch.
CLASSIC® 300D & 300G
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F-78
F-78
TROUBLESHOOTING AND REPAIR
GENERATOR FRAME
REMOVAL AND REPLACEMENT (continued)
FIGURE F.14 – CASE FRONT REMOVAL
STEP #16
STEP #15
STEP #14
See Figure F.14 for steps 14 - 16.
14. With the 9/16" wrench, remove the four bolts and
lock washers holding the case front to the welder
frame. 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.
CLASSIC® 300D & 300G
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F-79
F-79
TROUBLESHOOTING AND REPAIR
GENERATOR FRAME
REMOVAL AND REPLACEMENT (continued)
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
mounting bolts, nuts and spacers from the
feet of the generator frame.
18. With the rope sling around the generator
frame, carefully lift the frame and engine
assembly a small distance. Slide the wood
or steel block under the engine adapter
plate.
21. Support the generator frame with the rope
sling. Mount the generator frame to the
engine and armature assembly. Before
removing the rope sling, be careful to sup-
port the generator frame with the wood or
steel block under the engine adapter plate.
With the 9/16" wrench, install the bolts that
attach the generator frame to the engine.
22. With the 3/4" wrench, install the frame
mounting bolts, nuts, and spacers to the feet
of the generator frame. See Figure F.15.
19. With the 9/16" wrench, remove the bolts
mounting the engine to the generator frame.
20. Using the rope sling and pry bars, carefully
lift and “wiggle” the generator frame away
from the engine and armature assembly. Be
careful to support the generator frame as
you remove it.
23. Install the case front to the welder frame.
24. Connect the cables to the selector switch
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.
CLASSIC® 300D & 300G
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F-80
F-80
TROUBLESHOOTING AND REPAIR
GENERATOR FRAME
REMOVAL AND REPLACEMENT (continued)
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:
Before installing the machine case top and sides,
be sure to replace any cable ties cut during disas-
sembly.
CLASSIC® 300D & 300G
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F-81
F-81
TROUBLESHOOTING AND REPAIR
GENERATOR ARMATURE
REMOVAL AND REPLACEMENT PROCEDURE
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
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
CLASSIC® 300D & 300G
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F-82
F-82
TROUBLESHOOTING AND REPAIR
GENERATOR ARMATURE
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.16 – BLOWER PADDLE REMOVAL
ROPE SLING
BLOWER PADDLE
BLOWER
PADDLE/ARMATURE
MOUNTING BOLTS(8)
PROCEDURE
1. Turn the engine OFF.
CAUTION
The armature is now free to be removed from the
engine.
cedure.
Replacement:
cedure.
9. Support the armature with the rope sling.
Mount the armature to the engine, rotating it
1/8 of a turn in either direction to achieve
proper attachment. Before removing the
rope sling, be careful to support the arma-
ture with the wood or steel blocks under the
engine. With the 5/8" wrench, install the
eight bolts and lock washers that attach the
blower paddles and the armature to the
engine flywheel.
cedure.
5. Using the rope sling, support the armature.
6. Make sure the engine is supported with the
wood or steel blocks.
7. With the 5/8" wrench, remove the eight bolts
and lock washers holding the blower paddles
and the armature to the engine flywheel. See
Figure F.16.
8. With the armature supported and “balanced”
in the rope sling, carefully rotate the armature
1/8 turn in either direction to release.
10. Perform the replacement procedures accord-
ing to each of the following:
CLASSIC® 300D & 300G
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F-83
F-83
TROUBLESHOOTING AND REPAIR
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
No Load RPM
1325 - 1475
1780 - 1810
Mode
Load RPM
NA
Low Idle
High Idle
1650 - 1750
WELDER DC OUTPUT
Current Control
Rheostat
Current Selector
Open Circuit
Load Volts
Load Amps
Switch
Maximum
Maximum
Voltage
Maximum
91 - 98.5
91 - 98.5
36 - 45 Gas
350
350
Maximum
38 - 47 Diesel
AC AUXILIARY POWER RECEPTACLE OUTPUT
230 Volt Receptacle
115 Volt Receptacle
Open Circuit
Voltage
Load Volts
Load Amps
Open Circuit
Voltage
Load Volts
Load Amps
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
1780 - 1810
123 - 133
2.0 - 2.4
2.2 - 2.6
CLASSIC® 300D & 300G
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F-84
F-84
NOTES
CLASSIC® 300D & 300G
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G-1
G-1
TABLE OF CONTENTS - DIAGRAM SECTION
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
Wiring Diagram (Codes 111472, 11473) (M21684) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12
Wiring Diagram (Codes 111474, 11475) (M21563) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-13
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
Schematic – Complete Machine (Codes 11413, 11414) (L13097) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-19
Schematic – Complete Machine (Codes 11472, 11473) (L13672) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-20
Schematic – Complete Machine (Codes 11474, 11475) (L13351) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-21
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.
CLASSIC® 300D & 300G
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G-2
G-2
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - CODES 10545, 10546, 10657, 10658) (L10877)
CLASSIC
300D WIRING DIAGRAM
CONTRO
L
PANE
L
COMPONENTS
REAR.
FRAME
AU TI
ELECTRICA
L
SYMBOLS
SHOWN AS VIEWED FRO
NEUTRA
M
GLOW PLUGS
PER 1537
E
P10
J5
60A
L
BONDED
T
E
O
'
LEAD OLO
C
R
CODE
61
NEUTR
E
RACCORD
BA
9
8
2
1
11
6
5
4
12
7
3
10
R-RE OR
D
B-BLA K O
C
R
ENGINE
W
PINK
-BLUE
W-WHITE
Y-YELLO
G
R
AY
G-GREE
-BROWN
B
F
AILURE
+Y
1
U
N
7 8 9 10
NGINE
1 2 3 4 5 6
N
-W
LAMP
2
3
4
N
ROTOR
ALTERNATOR
U
IDLER/E
J1
W
60C
58
PROTECTION
P.C. BOARD
S
LIP RINGS
J2
-
R
+
CB1
B
610
610
S
LI
NEAREST
O IRON
P
RING
+
CIRCUIT BREAKER
CB1 APPEARS ON
EARLIER UNITS ONL
53
53B
602B
58A
R
T
AC
AC
Y
IDLER
SWITCH
57
56
600B
GLOW
PLUG
IDLER
56A
41
1
2
3
START
52
ENGINE
HOUR
SOLENOI
D
11
5
VOLT
RECEPTACLE
600A
42
23
0
VOLT
RECEPTACLE
G
-
15A.
M
ETER
PUMP SOLENOID
FUEL PUMP
B
4
5
G
-
IG
NITION
+
Y
FUSE
602A
RHEOSTAT
SWITCH
50B
54
6
51A
P9
J8
Y
60
B
SELECTOR
SWITCH
ELECTRIC FUEL
PUMP DOES NOT
APPEAR O
B
50A
R
N
EARLIER UNITS
G
54B
ALTERNATOR
AUXILIARY
POWER
CB2
CB3
W
CB4
CB1
OIL PRESSUR
SWITCH (N.C.
E
)
TEMPERATURE
GAUGE
WINDINGS
G
STARTING
MOTOR
GENERATOR
B
59
G
S
B
A
(GROUND SCREW
NEAR FUSE)
-
+
B
A
ALTERNATOR
50
5 4 3 2 1
B
CURRENT
TRANSFORMER
CR
2
REED
WELDER
LEAD LOCK
EXC
+
W
W
B
RELAY
51
N
R
U
-W
+Y
G
N
GROUND
(GROUND SCREW NEAR
ENGINE GAUGES)
POSITIVE
(CC+ (CV
TO ENGINE
NEGATIVE
GROUND
TO BASE
)
&
+
WITH W.F.M.)
(CC-)
K924-4 REMOTE CONTROL (OP
T
IONAL)
W
IRE FEED MO
DULE (OP
T
IONAL)
REMOT
E
CONTRO
L
RECEPTACLE & SWITCH
ON
CONNEC
M
ACHINE, REMOV
E
PLUG "P10" FRO
M
CONNECTOR "J5".
ACHINE.
PLU
REMOT
POTENTIOMETER
G
FOR
G
T
PLUG "P5" ON W.F.M. T
O
CONNECTOR "J5" O
N
M
E
CONTROL
12 11 10 9
P11
8
7
6
5
4
3
2
1
X
B
Y
SE
BELOW
E
*
R
60
SE BELOW
E
INLINE
PLUG
(P5)
**
W
0
41
CONNECTORS
X
R
Y
W.F.M.
W
1
2
3
CAUTION: DAMAGE CAN OCCUR
TO THE REMOTE CONTRO
SWITCH IF IT IS USED WITHOUT
THE "P11" PLUG INSTALLED OR A
WIRE FEED MODULE INSTALLED.
CONTROL
PANEL
R
L
SE
E
42
60
G
*
R
BELOW
4
5
2
#8 LEAD
CONNECT
CASE
602
W
POS.
NEG.
B
CONNEC
T
T
O
POS. & NEG.
W
IRE FEED
6
T
O
W
OUTPU
T
TERMINALS
P8
{
REMOTE SWITCH WIRED
THIS WAY ON EARLIER
UNITS
S
WITCH FOR LOCAL OR
REMOTE CONT OL SHOWN
IN LOCAL POSITION.
RESISTORS
R
MODULE
NEGATI
V
E
CV
TERMINAL
#2
HEAVY LEAD
OUTPU
T
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
CONNEC
T
T
O
NEG.
IF A WIRE FEED MODULE IS INSTALLED, WITH THE MACHINE OFF, DISPOSE OF THE
UNCONNECTED PLUG "P10" (IF ONE IS ON THE MACHINE). FASTEN THE NEW PLUG "P11"
NEARBY, LEAVING IT UNCONNECTED.
REMOT CONTROL
E
BRUSH HOLDER
#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.
25
0
AMP
MACHIN
E
MUST NOT BE RUNNING
*
THERMOSTAT
ASSEMBLY
THE RED AND BLACK LEADS ARE USED ON CLASSIC I MACHINES ONLY AND ARE NOT
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.
WHEN MAKI G THES CONNECTIONS.
N
E
7-13-2001
G
L10877
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.
CLASSIC® 300D & 300G
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G-3
G-3
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - (CODE 10659) (L11194)
CLASSIC 300G WIRING DIAGRAM
CONTROL PANEL COM
HO AS VIEWED FROM REAR.
NEUTRAL ONDED TO FRAM
NEUTR
PONENTS
ZENIT
H
THROTTLE
RPM CONTROL
92
3
EL
PE
E
R
CTRI
E1537
C
AL
S
YM
B
OLS
S
WN
BODY
CONTROLLER
4
1
0
K
P10
J5
B
E
5
1
3
'
WHIT
CONNECTOR
E
INJECTOR
90
72
14
15
19
21
22
E
R
ACCORDE A
U
BATI
9
8
2
1
11
6
5
4
12
7
3
10
2
LEA
D
COLO
- BLACK
G - GREEN
N - ROWN
R
CODE
91
#
B
W
B
97
+Y
BLACK
CONNECTOR
1
2
3
4
N
-W
+
-
97B
B
ROTOR
ALTERNATO
R
U
97A
R - RED
U - BLUE
2
3
1
4
5
8
9
11 12 13 17
FUEL
P
UMP
SLIP
RINGS
-
81
+
W
Y
O - OR
- WHIT
- YELLO
NGE
E
W
71
50
87
B
A
B
AC
61
61
600B
0
99A
87B
77
94
SLI RING
NEAREST
TO IRON
P
COIL
-
96
A
+
ALTERNATO
83
R
0
THROTTLE PLATE
MOTOR
A
+
602B
R
82
AC
B
99D
99B
A
97C
41
1
2
3
99C
EXC
WATER
TEMP.
SENSOR
+
-
-
115 VOLT
RECEPT CL
600A
42
230
VOLT
93
C
A
E
RECEPTACLE
95
PARTS SUPPLIED
ITH ENGINE
A
B
B
B
DISTRIBUTOR
87A
W
4
5
G
15A
FUSE
Y
AIR
76
B
602A
RHEOSTAT
E
NGIN
E
TEMP.
SENSOR
99E
HO
U
R METER
MAP SENSOR
ENGINE
6
FAILURE
LAMP
J8
EL
P9
Y
-
+
78
B
89
61
S
E
CTOR
CB5
74
OIL PRESSURE SWITCH & SENSOR
SENSOR
B
60
SWITCH
R
AMMETER
ST
ART
G
G
WK
SWITCH
ALTERNATO
AUXILIARY
POWER
R
51
73
IGNITIO
N
62
CB2
CB3
W
SWITCH
C
B4
CB1
WATER TEMP. SENDER
SENSOR
84
WINDINGS
G
GENERATO
R
B
W
AT
E
R TEMP.
IDLER
ST
ARTER
GAUG
E
SWITCH
MOTOR
G
69
A
(GROU
NEAR FU
B
ND
SCREW
E)
S
99
S
B
80
4
S
B
3
2
1
5
4
3
2
1
70
R
W
ELDER
45
67
LE
A
D
BLOCK
N
CURRENT
SENSOR
OIL PRESS.
G
CONTROL PANEL
GROUND SCREW
U
GAUG
E
-W
+Y
S
POSITIV
E
GROUND
TO BASE
GROUND
TO ENGIN
NEGATIVE
(CC+)
&
(CV+ WITH W.F.M.)
E
(CC-
)
K924-4 REMOTE CONTROL (OPTIONAL)
WIRE FEED MODULE (OPTIONAL)
REMOTE CONTROL RECEPTACLE & SWITCH
ON
M
ACHINE REMOVE PLUG "P10" FROM CONNECTOR "J5".
,
CONNECT PLUG "P5" ON
W.F.M. TO CONNECTOR "J5" ON MACHINE.
PLUG FOR
EMOTE CONTROL
OTENTIOMETER
12 11 10 9 8 7 6
P11
ELO
5
4 3 2 1
B
R
X
G
Y
R
P
SEE
*
INLINE
PLUG
B
ELOW
W
**SEE B
CONNECTOR
S
(P5
)
W
.F.M.
1
2
3
41
60
X
Y
CAUTION: DAMAGE
TO THE EMOTE CONTROL
SWITCH IF IT I SE ITHOUT
THE "P11" PLUG INSTALLE OR
IR FE D MODUL STALLED.
C
A
N
OCCUR
CONTROL
PANEL
0
R
SEE
ELO
S
U
D
W
G
42
60
*
B
W
D
A
#
8 LEAD
4
5
2
W
E
E
E
IN
POS.
NEG.
WIRE FEED
MODULE
CONNECT TO POS
OUTPUT TERMINAL
.
&
S
NEG.
CONNECT
TO CASE
{
W
W
B
6
NEGATIVE
CV
P8
RESISTORS
#
2 HEAVY LEAD
60
2 HEAVY LEAD
OUTPUT TERMINAL
PANEL
SWITCH FOR LO
C
AL OR REMOTE CONTROL
60
8
SHO N IN LOCAL POSITION.
W
9
CONNECT TO N
EG.
W
ITH MACHINE
NOT RUNNING
,
REMOVE PLUG "P9" ON MACHINE FROM CONNECTOR "J8".
CONNECT PLUG "P8" ON EMOTE CONTROL TO CONNECTOR "J8" ON MACHINE.
*
**
THE
N
R
BRUS HOLDER
H
R
P
EMOTE CONTROL
#
IF A WIR
E
FE D MODUL STALLED, ITH TH ACHINE OFF, DISPOSE OF TH
UNCONNECTE PLUG "P10" (IF ON N TH ACHI E) FAST N TH EW PLUG "P11"
NEARBY, LEAVING IT UNCONNECTED.
E
E
I
S
I
N
W
E
M
E
OTENTIOMET BOX
ER
D
E
I
S
O
E
M
N
E
E
N
250 AM
THERMOSTAT
ASSEMBL
P
IF NO
W
IR
M
E
FE
E
D MODUL
E
IS
I
N
STALLED,
W
ITH TH
E
M
ACHINE OFF, DI
S
CONNECT PLUG "P10"
Y
MACHINE MUST NOT BE RUNNING
ON TH
E
ACHINE FROM CONNECTOR "J5". CONNECT PLUG "P11" FROM TH
E
REMOTE CONTROL
K
IT TO CONNECTOR "J5" ON TH
E
M
ACHINE.
WHEN MAKING THESE CONNECTIONS.
THE
CONNECTE
ILL RESULT IF THE RE
R
E
D
AN
D
BLACK LEADS ARE
ON THI ACHINE
AN
U
SE
D
ON CLASSIC I MACHINES
EMOTE CONTROL AND/OR
ONNECTED IN TH CLASSIC 300G.
O
NLY AN
D
ARE
N
OT
D
S
M
.
D
AMAGE TO TH
E
R
MACHINE
W
D
D
BLACK LEADS ARE
C
E
A
L11194
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.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - (CODES 10911, 10927) (L11865)
CLASSI
C
300D WIRIN
G
DIAGRAM
CONTROL PANEL COMPONENTS
SHOWN AS VIEWED FROM REAR.
NEUTRAL BONDED TO FRAM
ELECTRICAL SYMBOLS
PER E1537
GLOW PLUG
S
E
P1
J5
0
6
0A
'
LEAD COLOR
C
OD
E
NEUTRE RACCORDE AU BATI
61
9
8
2
1
11
6
5
4
12
7
3
10
R-RED OR
B-BLACK OR
GRAY
P
INK
ENGIN
FAILURE
LAM
E
W
B
U-BLU
E
G-GREEN
+Y
1
2
3
4
7 8 9 10
1 2 3 4 5 6
IDLER/ENGIN
PROTECTION
N
W-WHITE
-W
N-BROWN
P
ROTOR
ALTERNATOR
U
E
J1
Y-YELLOW
60C
58
G
SLIP RINGS
- SLIP RING
J2
-
P.C. BOAR
D
R
X
+
610A
610
610
Y
+
53
NEARES
TO IRON
T
5
3B
W
602B
5
8A
600C
AC
600
41
AC
IDLER
SWITCH
57
56
600B
R
GLOW
IDLER
SOLENOID
5
6A
W
41
1
STAR
52
T
PLUG
ENGINE
HOUR
METER
2
3
115 VOLT
RECEPTACL
600A
42
230 VOLT
RECEPTACLE
G
-
21
E
42
PUMP
SOL
ENOID
B
1
5A.
602
G
4
5
-
IGNITION
SWITCH
+
FUSE
215
602A
58H
54B
RHEOSTAT
5
1C
54
6
51A
FUEL PUMP
J8
214
P8
60
B
5
4D
212A
SELECTO
SWITCH
R
WATER
TEMPERATURE
GAUG
1
5A
B
5
0A
S
810
E
2
0A
I
1
5A
1A
20A
SWITCH FOR LOCAL
OR REMOTE CONTROL
SHOWN IN LOCAL
POSITION.
GND-E
TEMPERATURE
SWIT H/SENDER
ALTERNATOR
AU ILIARY
POWE
WINDINGS
G
11
1
C
CB
2
CB3
820
X
212B
CB
4
CB
1
G
R
W
GND-N
S
G
I
STARTING
MOTOR
GENERATOR
B
OIL PRESSURE
SWIT H/SENDER
59
G
OIL PRESSURE
C
S
B
A
GAUG
E
G
(GROUN
NEA
D
SCREW
FUSE)
G
WK
-
+
R
11B
AMMETER
50
5 4
3
2 1
B
CURREN
TRANSFORMER
T
ALTERNATO
R
CR2 REED
RELAY
WELDER
LEAD BLOC
EXC
+
W
W
K
51
N
R
U
5
1G
-W
+Y
GND-M
G
N
GROUND
TO NGIN
(GROUN
D
SCREW NEAR
UG S)
POSITIV
E
E
E
NEGATIVE
GROUND
TO BASE
E
NGINE G
A
E
(CC+) & (CV+ WITH W.F.M.
)
(CC-
)
K924-5
REMOTE CONTRO (OPTIONAL)
L
WIRE
FEED MODULE (OPTIONAL)
PLUG FOR
REMOTE CONTROL
POTENTIOMETER
ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
X
Y
INLINE
CONNECTOR
PLUG
(P5)
S
W.F.M.
CONTRO
PANEL
G
L
CONNEC
TO CAS
T
W
B
E
#
8 LEAD
POS.
NEG.
CONNECT TO POS. & NEG.
OUTPUT TERMINALS
WIRE FEE
D
RESISTORS
{
MODULE
NEGATIVE C
OUTPUT TERMINA
PANEL
V
#
2 HEAVY LEA
609
2 HEAVY LEA
D
L
608
REMOTE CONTROL
POTENTIOMETER BO
X
CONNECT TO NEG.
BRUSH HOLDER
#
D
250 AM
THERMOSTAT
ASSEMBLY
P
MA
C
HINE UNNING
M
UST NOT BE
R
*
W
HE MAKING THESE CONNECTIONS.
N
C
L11865
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.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-5
G-5
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - (CODES 10912, 11135) (L11866)
CLASSIC 300G WIRING DIAGRAM
CONTROL PANEL COMPONENT
S
ZENITH THROTTLE
BODY
RPM CONTROL
92
3
SHOWN AS VIEWED FROM REAR.
4
1
0 K
P
ER E1537
P10
J5
CONTROLLER
NEUTRAL BONDED TO FRAME
5
1
3
'
WHITE
INJECTOR
90
72
14
15
19
21
22
NEUTRE RACCORD
E
AU BATI
9
8
2
1
11
6
5
4
7
3
12
10
2
LEAD COLOR CODE
B - BLACK OR GRAY
CONNECTOR
91
#
W
B
G
R
U
-
-
-
GREEN
RED OR PINK
BLUE
97
+Y
BLACK
CONNECTOR
1
2
3
4
N
-W
+
-
97B
ALTERNATOR ROTOR
-
U
97A
1
2
3
4
5
8
9
11 12 13 17
FUEL PUMP
SLIP RINGS
SLIP RING
W - WHITE
Y - YELLOW
81
+
71
50
87
B
A
B
61
61
600B
0
99A
8
7B
77
94
COIL
96
A
+
B
ALTERNATOR
83
0
THROTTLE PLATE
MOTOR
X
G
NEAREST
+
602B
R
82
AC
AC
TO IRON
B
99D
97C
41
1
41
42
9
9C
E
XC
WATER
TEMP.
SENSOR
+
-
-
115 VOLT
600A
42
2
3
230 VOLT
RECEPTACL
Y
9
9B
93
C
RECEPTACLE
600
E
95
PARTS SUPPLIED
WITH ENGINE
A
B
B
B
DISTRIBUTOR
87A
4
5
G
15A
FUSE
60
2
Y
AIR
76
A
B
602A
RHEOSTAT
ENGIN
E
TEMP.
SENSOR
W
99E
HOUR METER
MAP SENSOR
ENGINE
FAILURE
LAMP
6
J8
P8
Y
-
+
78
B
89
61
S
ELECTOR
CB5
74
OIL PRE
G
S
SUR
E
S
WITCH &
S
ENSOR
B
60
S
WITCH
R
SWITCH FOR LOCAL OR
REMOTE CONTROL SHOWN
IN LOCAL POSITION.
AMMETER
15A
15A
S
ENSOR
START
84
20A
B
20A
CB1
G
WK
ALTERNATOR
AUXILIAR
PO ER
WINDINGS
51
73
IGNITION
WITCH
62
CB2
CB3
SWITCH
W
Y
S
CB4
WATER TEMP. SENDER
W
S
ENSOR
G
GENERATOR
W
ATER TEMP.
IDLER
STARTER
MOTOR
GAUG
E
SWITCH
G
69
A
(GROUND SCRE
NEAR FUSE)
B
W
S
B
99
S
B
80
4
3
2
1
5
4
3
2 1
70
R
W
ELDER
45
67
LEAD BLOCK
N
CURRENT
ENSOR
OIL PRE
S
S.
G
S
CONTROL PANEL
GROUND SCREW
U
GAUG
E
-W
+Y
S
POSITIV
E
GROUND
TO BASE
GROUND
TO ENGINE
NEGATIV
E
(
CC+ & (CV+ WITH W.F.M.
)
)
(CC-)
WIRE FEED MODULE (OPTIONAL)
K924-5 REMOTE CONTROL (OPTIONAL)
ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
PLUG FOR
CONNECT PLUG "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
REMOTE CONTROL
POTENTIOMETER
INLINE
CONNECTORS
PLUG
X
Y
(P5
)
W.F.M.
CONTROL
ANEL
G
P
CONNECT
TO CAS
#
8
LEAD
W
B
E
POS.
NEG.
WIRE FEED
MODULE
CONNECT TO POS. & NEG.
OUTPUT TERMINALS
{
RESISTORS
NEGATIVE C
OUTPUT TERMINAL
ANEL
V
#
2 HEA
VY LEAD
P
60
8
60
9
REMOTE CONTROL
POTENTIOMETER BO
CONNECT TO NEG.
BRUSH HOLDER
X
#
2 HEAVY LEAD
250 AMP
THERMOSTAT
ASSEMBLY
MACHINE MUST NOT BE RUNNING
WHEN MAKING THESE CONNECTIONS.
*
B
L11866
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.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
G-6
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - (CODES 11110, 11111) (M20499)
CLASSIC 300D PERKINS WIRING DIAGRAM
LEAD COLOR COD
E
ON NEWE BOARDS,
J1 BECOMES J31,
J2 BECOMES J32,
R
CONTROL PANEL COMPONENTS SHOWN AS VIEWED
F
ROM REAR.
B-BLACK OR
GRAY
R-R
E
D O
IN
LU
HIT
Y-YELLO
R
LEADS CONNECTED
TO ENGINE
I
DLER/ENGINE P.C
.
BOARD SEE DETAIL
,
P
K
7
10
1 2 3 4 5
6
8 9
*
G-GREEN
U-
B
E
NEUTRAL BONDED
T
O
F
RAME.
NEUTRE RACCORDE AU BATI
B5
AND
B6 TERMINALS
J1
P
10
N-BROWN
W-
W
E
.
ARE
D
ELETED.
121110 9 8 6 5 4 3 2 1
7
W
IDL
ER/
E
NGINE PROT
E
CTION P.C. BD.
J5
1
2
3
4
400D
Y
J2
400
E
TO CURRENT
TRANSFORMER
W
48
LTERNATOR
U
B1 B2 B3 B4 B5 B6
N
SLIP RINGS
A
-
IDLER
OL NOID
55
A
60
A
+
+
610A
S
E
SLIP RING
NEAREST
GLO
W
S
844
844
212
55
57
E
B
PLUG
W
R
AC
*
AC
600C
TO
I
RON
*
115 VOLT GFCI
J8 P8
PUMP
W
R
600
230
RECEPTACL
VOLT
RECEPTACL
E
212
E
-
G
SOL
ENOID
41
1
2
3
4
5
6
41
E
GND-C
58
600
A
*
212C
212D
400F
HOT LINE HOT LOAD
21
7A
X
ENGIN
E
42
*
Y
*
53
GLO
HOUR
W
15
FUSE
A
*61
FUEL
IGNITION
WITCH
42
58H
602
A
METER
P
LUG
START
52
E
NGIN
E
PUMP
S
W
RHEOSTAT
CB4
10
-
FAILUR
LAMP
E
+
WHITE LINE
WHITE LOAD
A
215
56
212
51
*
844
214
REMOT
SWITCH AND
RECEPTACL
E
CONTRO
L
IDLER
WITCH
60C
TEMPERATUR
WITCH/SENDER
A
*93
51C
6A
S
U
Y
E
A
43
WATER
810
N
E
W
S
S
I
A
LT. AUX
POWER
INDING
TEMPERATURE
GAUGE
50
A
*44
SHUNT
FIELD
W
G
11A
W
S
G
CB3
15
CB2
15
CB1
20A
41
A
A
+
-
SERIES FIELD
60
820
SELECTO
SWITCH
R
A
MMETER
212B
GND-T
-
+
+
-
GND-N
200
*54
STARTING
MOTOR
90-MIN
130-80
190-120
240-160
220-MAX
G
WK
OIL PRESSUR
WITCH/SENDER
11
B
I
S
GROUN
CREW
NEAR FUSE
D
E
S
B
GND-
S
S
50
S
OIL
PRESSUR
GAUG
G
E
TO IDL
ROT
ER / ENGINE
E
11C
NT TRANSFORMER
GND-
*59
INTERPOL
E
COILS
EXC
P
E
CTION
P
.C.
Bd.
+
DIODE
AND
51
ALT
ERN
ATOR
WELDING GENERATOR
51G
CURR
E
MOV
*
844A
REED
SWITCH
GND-B
*60
A
BRUS
VIEWED FROM CONTRO
H
POSITION
S
HO
W
L
N
AS
PANEL
A
POSITIVE
GROUN
E
D
E
S
CR
E
W
UGES
NEAR
NEGATIVE
(CC-)
GROUND
TO BASE TO ENGINE
GROUND
NGIN
G
A
(CC+)
&
(C
V+
W
ITH W.F.M.)
K924-5 RE
MOTE CONTROL (OPTIONAL)
WIRE
FEED MODULE (OPTIONAL)
ON MACHINE
,
REMOVE PLUG "P10"
F
ROM CONNECTOR "J5".
PLUG
FOR REMOTE CONTROL
CONNEC
T
"P5" ON W.F.M
.
TO CONNECTOR "J5" ON MACHINE.
POTENTIOMETER
INLINE CONNECTORS
.F.M.
X
Y
PLUG P5
W
CONTROL
PANEL
G
B
W
#8 LEAD
#2 HEAVY LEAD
WIRE FEED
MODULE
CONNEC
OUTPU
NEGATIVE CV
OUTPU TERMINAL
PANEL
T
TO POS
.
& NEG.
POS.
NEG.
T
TERMINALS
RESISTORS
608
T
609
#2 HEAVY LEAD
REMOTE CONTOL
POTENTIOMETER BOX
CONNEC TO CASE
T
CONNEC
T
TO NEG.
250 AMP HERMOSTA
T
T
ASSEMBLY
BRUSH HOLDER
MACHINE
MUST NOT BE RUNNING
W
HEN MAKING THESE CONNECTIONS.
B
M20499
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.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - (CODES 11112, 11113) (M20432)
CLASSIC 300D KUBOTA WIRING DIAGRAM
LEAD COLOR CODE
ENGINE CONTROL UNIT CONNECTOR DETAIL
CONTROL PANEL COMPONENTS SHOWN AS VIEWED
FROM REAR.
B-BLACK OR
GRAY
G-GREEN
N-BROWN
R-RED OR
PINK
LEADS CONNECTED O ENGINE CONTROL UNIT SEE DETAIL
T
,
61
57
*
U-BLUE
93
51B
212D
NEUTRAL BONDED
NEUTRE RACCORDE AU BATI
T
O
FRAME.
P10
J5
W-WHIT
E
'
.
GLOW PLUGS
55
58
70B
844A
70A
121110 9 8
7 6 5 4 3
2 1
Y-YELLOW
NOTE
:
LEADS 70A & 70B ARE
LEFT OPEN AND WIRE
RPM CONTROL
400D
400E
Y
69
W
TIED
INTO HARNESS.
48
U
94
60E
52B
87
56
88
86
60F
44
54
64
N
SLIP RINGS
ALTERNATOR
-
57
+
+
*
610A
ACTUATOR
SLIP RING
1
2
3
56
NEAREST
*
ENGINE
FAILURE
LAMP
AC
AC
600C
WIRE-TIED TO WIRING
TO
IRON
87 86 88
*
*
*
HARNESS BEHIND
CONTROL PANEL
ENGINE HOUR METER
START
52B
P8
J8
W
R
600
230 VOLT
RECEPTACLE
-
115 VOLT
+
-
15A
G
1
41
41
58
61
841A
*
*
RECEPTACLE
*
2
3
4
5
6
600A
42
STAR RELAY
T
21
841
7A
X
212D
Y
*
TEMP.
WATER
841B TEMP
GAUGE
I
4A
52A
212C
IGNITION
SWITCH
42
602A
SWITCH/
55
FUSE
*
W
SENDER
RHEOSTAT
53
S
W
44
G
51B
*
400F
43
215
214
REMOTE CONTROL
SWITCH AND
RECEPTACLE
*
6A
U
Y
GLOW
PLUG
G
212A
62
810
N
W
51A
ALT. AUX
POWER
WINDINGS
OIL PRES.
SWITCH/
SENDER
SHUNT
FIELD
51C
CB2
20A
11
11A
CB3
15A
CB1
20A
CB4
15A
50A
41
I
S
200
54
*
SERIES
FIELD
820
SELECTOR
SWITCH
G
OIL
STARTING
MOTOR
WK
AMMETER
G
GND-T
-
+
+
-
PRESSURE
GAUGE
S
-
90-MIN
130-80
190-120
240-160
220-MAX
+
B
50
ALTERNATOR
L
GND-S
WATER
TEMP.
SENSOR
ENGINE
SPEED
SENSOR
11B
64
51
*
841
B
BATTERY
IG
69
212E
94
INTERPOLE COILS
WELDING GENERATOR
*
*
844A
2
3
TURNS
DIODE
AND
MOV
93
60
*
1
3
4
2
*
60A
11C
67A
GND-B
844
60E
60F
GROUND
TO
ENGINE
67B
GROUND
TO
BASE
*
842
*
BRUSH POSITION SHOWN AS
VIEWED ROM CONTROL PANEL
(CV+ WITH W.F.M.)
IDLER SWITCH
GROUND SCREW NEAR
ENGINE GAUGES
NEGATIVE
(CC-)
POSITIVE
(CC+
F
TURNS
)
&
K924-5 REMOTE CONTROL (OPTIONAL)
WIRE
FEED MODULE
(OPTIONAL)
ON MACHINE
,
REMOVE PLUG "P10"
F
ROM CONNECTOR "J5".
PLUG
FOR REMOTE CONTROL
CONNEC
T
"P5" ON W.F.M
.
TO CONNECTOR "J5" ON MACHINE.
POTENTIOMETER
INLINE CONNECTORS
.F.M.
X
Y
PLUG P5
W
CONTROL
PANEL
G
B
W
#8 LEAD
WIRE
MODULE
FEED
CONNEC
OUTPU
NEGATIVE CV
OUTPU TERMINAL
PANEL
T
TO POS
.
& NEG.
POS.
NEG.
T
TERMINALS
RESISTORS
#2 HEAVY LEAD
608
T
609
#2 HEAVY LEAD
REMOTE CONTOL
POTENTIOMETER BOX
CONNEC TO CASE
T
CONNEC
T
TO NEG.
250 AMP HERMOSTA
T
T
ASSEMBLY
BRUSH HOLDER
MACHINE
MUST NOT BE RUNNING
W
HEN MAKING THESE CONNECTIONS.
A
M20432
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.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-8
G-8
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - (CODES 11243, 11244) (M20432-1)
CLASSIC 300D KUBOTA WIRING DIAGRAM
LEAD COLOR CODE
ENGINE CONTROL UNIT CONNECTOR DETAIL
CONTROL PANEL COMPONENTS SHOWN AS VIEWED
FROM REAR.
B-BLACK OR
GRAY
G-GREEN
N-BROWN
R-RED OR
PINK
LEADS CONNECTED
T
O ENGINE CONTROL UNIT
,
SEE DETAIL
61
57
*
U-BLUE
93
51B
212D
NEUTRAL BONDED
T
O
F
RAME.
NEUTRE RACCORDE AU BATI
P10
J5
W-WHIT
E
'
.
GLOW PLUGS
55
58
70B
844A
70A
121110 9 8
7 6 5 4 3
2 1
Y-YELLOW
NOTE
:
LEADS 70A & 70B ARE
LEFT OPEN AND WIRE
RPM CONTROL
400D
Y
69
400E
W
TIED
INTO HARNESS.
48
U
94
60E
52B
87
56
88
86
60F
44
54
64
N
SLIP RINGS
ALTERNATOR
-
57
+
+
*
610A
ACTUATOR
SLIP RING
NEAREST
1
2
3
56
*
ENGINE
FAILURE
LAMP
AC
AC
600C
WIRE-TIED TO WIRING
TO
IRON
87 86 88
*
*
*
HARNESS BEHIND
CONTROL PANEL
ENGINE HOUR METER
START
52B
P8
J8
W
R
600
230 VOLT
RECEPTACLE
-
+
-
G
1
41
41
58
61
841A
*
115
RECEPTACL
VOLT GFCI
*
*
2
3
4
5
6
600A
42
STAR RELAY
T
21
841
WATER
7A
X
212D
E
400F
Y
*
TEMP.
52A
212C
15A
FUSE
IGNITION
SWITCH
400D
42
602A
SWITCH/
841B TEMP
55
HOT LINE HOT LOAD
*
W
SENDER
GAUGE
I
RHEOSTAT
53
S
W
44
G
51B
*
43
215
214
REMOTE CONTROL
SWITCH AND
RECEPTACLE
*
WHITE LINE
WHITE LOAD
6A
U
Y
GLOW
PLUG
G
212A
62
810
48
N
W
51A
400F
ALT. AUX
POWER
WINDINGS
OIL PRES.
SWITCH/
SENDER
SHUNT
FIELD
820
CB1
20A
51C
11A
CB3
15A
820
CB4
15A
50A
11C
41
I
S
GND-S
200
54
*
SERIES
FIELD
SELECTOR
SWITCH
G
OIL
STARTING
MOTOR
WK
AMMETER
G
GND-T
-
+
+
-
PRESSURE
GAUGE
S
-
90-MIN
130-80
190-120
240-160
220-MAX
+
B
50
ALTERNATOR
L
WATER
TEMP.
SENSOR
ENGINE
SPEED
SENSOR
11B
64
51
*
841
B
BATTERY
IG
69
212E
94
INTERPOLE COILS
WELDING GENERATOR
*
*
2
T
URNS
844A
DIODE
AND
MOV
93
60
*
1
3
4
2
*
60A
11C
GND-B
844
60E
60F
GROUND
TO
ENGINE
67B
GROUND
TO
BASE
*
842
*
3
T
URNS
BRUSH POSITION SHOWN AS
VIEWED ROM CONTROL PANEL
(CV+ WITH W.F.M.)
IDLER SWITCH
67A
GROUND SCREW NEAR
ENGINE GAUGES
NEGATIVE
(CC-)
POSITIVE
(CC+
F
)
&
K924-5 REMOTE CONTROL (OPTIONAL)
WIRE
FEED MODULE
(OPTIONAL)
ON MACHINE
,
REMOVE PLUG "P10"
F
ROM CONNECTOR "J5".
PLUG
FOR REMOTE CONTROL
CONNEC
T
"P5" ON W.F.M
.
TO CONNECTOR "J5" ON MACHINE.
POTENTIOMETER
INLINE CONNECTORS
.F.M.
X
Y
PLUG P5
W
CONTROL
PANEL
G
B
W
#8 LEAD
WIRE FEED
MODULE
CONNEC
OUTPU
NEGATIVE CV
OUTPU TERMINAL
PANEL
T
TO POS
.
& NEG.
POS.
NEG.
T
TERMINALS
RESISTORS
#2 HEAVY LEAD
608
T
609
#2 HEAVY LEAD
REMOTE CONTOL
POTENTIOMETER BOX
CONNEC TO CASE
T
CONNEC
T
TO NEG.
250 AMP HERMOSTA
T
T
ASSEMBLY
BRUSH HOLDER
MACHINE
MUST NOT BE RUNNING
W
HEN MAKING THESE CONNECTIONS.
B
M20432-1
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.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-9
G-9
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - (CODES 11248, 11249, 11280, 11281) (M20616)
CLASSIC 300D PERKINS WIRING DIAGRAM
LEAD COLOR COD
E
CONTROL PANEL COMPONENTS SHOWN AS VIEWED
F
ROM REAR.
B-BLACK OR
GRAY
R-R
E
D O
IN
LU
HIT
Y-YELLO
R
LEADS CONNECTED
TO ENGINE
I
DLER/ENGINE P.C
.
BOARD SEE DETAIL
,
ON OLD
J31 WAS J1,
J32 WAS J2.
E
R
BOARDS,
P
K
7
10
1 2 3 4 5 6
J31
8 9
*
G-GREEN
U-
B
E
NEUTRAL BONDED
T
O
F
RAME.
NEUTRE RACCORDE AU BATI
P
10
N-BROWN
W-
W
E
.
121110 9 8 6 5 4 3 2 1
7
W
IDL
E
R/
E
NGINE PROT
E
CTION P.C. BD.
J5
1
2
3
4
400D
Y
J32
400
E
TO CURRENT
TRANSFORMER
W
48
LTERNATOR
U
B1 B2 B3 B4
N
SLIP RINGS
A
-
IDLER
OL NOID
55
A
60
A
+
+
610A
S
E
SLIP RING
NEAREST
GLO
W
S
844
844
212
55
57
E
B
PLUG
W
R
AC
*
AC
600C
TO
I
RON
*
115 VOLT GFCI
J8 P8
PUMP
W
R
600
230
RECEPTACL
VOLT
RECEPTACL
E
212
E
-
G
SOL
ENOID
41
1
2
3
4
5
6
41
E
GND-C
58
600
A
*212C
400F
HOT LINE HOT LOAD
21
7A
X
E
HOU
NGIN
E
42
*
Y
*
212D
IGNITION
WITCH
53
GLO
R
W
15
FUSE
A
*
61
FUEL
42
58H
602
A
METER
P
LUG
START
52
E
NGIN
E
E
PUMP
S
W
RHEOSTAT
CB4
10
-
FAILUR
LAMP
+
WHITE LINE
WHITE LOAD
A
215
56
212
51
*
844
214
REMOT
SWITCH AND
RECEPTACL
E
CONTRO
L
IDLER
WITCH
60C
TEMPERATUR
WITCH/SENDER
A
*93
51C
6A
S
U
Y
E
A
43
WATER
810
N
E
W
S
S
I
A
LT. AUX
POWER
INDING
TEMPERATURE
GAUGE
50
A
*44
SHUNT
FIELD
W
G
11
A
W
S
G
CB3
15
CB2
15
CB1
20A
41
A
A
+
-
SERIES FIELD
60
820
SELECTO
SWITCH
90-MIN
130-80
190-120
240-160
220-MAX
R
A
MMETER
212B
GND-T
-
+
+
-
GND-N
200
*
54
STARTING
MOTOR
G
WK
OIL PRESSUR
WITCH/SENDER
11
B
I
S
GROUN
CREW
NEAR FUSE
D
E
S
B
GND-
S
S
50
S
OIL
PRESSUR
GAUG
G
E
TO IDL
ROT
E
E
R / ENGINE
D+
E
11C
NT TRANSFORMER
GND-
*
59
INTERPOL
E
COILS
P
CTION
P.C.
Bd.
DIODE
AND
51
B+
WELDING GENERATOR
A
LT
E
RN TOR
A
CURR
E
MOV
*
844A
REED
SWITCH
GND-
B
*60
A
BRUS
VIEWED FROM CONTRO
H
POSITION
SHO
W
N
AS
PANEL
A
L
POSITIVE
(CC+)
GROUN
D
S
CR
E
W
NEAR
NEGATIVE
(CC-)
GROUND
TO BASE TO ENGINE
GROUND
E
NGIN
E
G
A
UGES
&
(C
V+
W
ITH W.F.M.)
K924-5 RE
MOTE CONTROL (OPTIONAL)
WIRE
FEED MODULE (OPTIONAL)
ON MACHINE
,
REMOVE PLUG "P10"
F
ROM CONNECTOR "J5".
PLUG
FOR REMOTE CONTROL
CONNEC
T
"P5" ON W.F.M
.
TO CONNECTOR "J5" ON MACHINE.
POTENTIOMETER
INLINE CONNECTORS
.F.M.
X
Y
PLUG P5
W
CONTROL
PANEL
G
B
W
#8 LEAD
#2 HEAVY LEAD
WIRE
MODULE
FEED
CONNEC
OUTPU
NEGATIVE CV
OUTPU TERMINAL
PANEL
T
TO POS
.
& NEG.
POS.
NEG.
T
TERMINALS
RESISTORS
608
T
609
#2 HEAVY LEAD
REMOTE CONTOL
POTENTIOMETER BOX
CONNEC TO CASE
T
CONNEC
T
TO NEG.
250 AMP HERMOSTA
T
T
ASSEMBLY
BRUSH HOLDER
MACHINE
MUST NOT BE RUNNING
W
HEN MAKING THESE CONNECTIONS.
B
M20616
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.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-10
G-10
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - (CODES 11411, 11412) (M21292)
CLASSIC 300D PERKINS WIRING DIAGRAM
LEAD COLOR COD
E
CONTROL PANEL COMPONENTS SHOWN AS VIEWED
F
ROM REAR.
B-BLACK OR
GRAY
R-R
E
D O
IN
LU
HIT
Y-YELLO
R
LEADS CONNECTED
TO ENGINE
I
DLER/ENGINE P.C
.
BOARD SEE DETAIL
,
ON OLD
J31 WAS J1,
J32 WAS J2.
E
R
BOARDS,
P
K
7
10
1 2 3 4 5 6
J31
8 9
*
G-GREEN
U-
B
E
NEUTRAL BONDED
T
O
F
RAME.
NEUTRE RACCORDE AU BATI
P
10
N-BROWN
W-
W
E
.
121110 9 8 6 5 4 3 2 1
7
W
IDL
E
R/
E
NGINE PROT
E
CTION P.C. BD.
J5
1
2
3
4
400D
Y
J32
400
E
TO CURRENT
TRANSFORMER
W
48
LTERNATOR
U
B1 B2 B3 B4
N
SLIP RINGS
A
-
IDLER
OL NOID
55
A
60
A
+
+
610A
S
E
SLIP RING
NEAREST
GLO
W
S
844
844
212
55
57
E
B
PLUG
W
R
AC
*
AC
600C
TO
I
RON
*
115 VOLT GFCI
J8 P8
PUMP
W
R
600
230
RECEPTACL
VOLT
RECEPTACL
E
212
E
-
G
SOL
ENOID
41
1
2
3
4
5
6
41
E
GND-C
58
600
A
*212C
400F
HOT LINE HOT LOAD
21
7A
X
E
HOU
NGIN
E
42
*
Y
*
212D
IGNITION
WITCH
53
GLO
R
W
15
FUSE
A
*
61
FUEL
42
58H
602
A
METER
P
LUG
START
52
E
NGIN
E
E
PUMP
S
W
RHEOSTAT
CB4
10
-
FAILUR
LAMP
+
WHITE LINE
WHITE LOAD
A
215
56
212
51
*
844
214
REMOT
SWITCH AND
RECEPTACL
E
CONTRO
L
IDLER
WITCH
60C
TEMPERATUR
WITCH/SENDER
A
*93
51C
S
6A
U
Y
E
A
43
WATER
810
7A
N
E
W
S
S
I
A
LT. AUX
POWER
INDING
CB2
15A
TEMPERATURE
GAUGE
50
A
*44
SHUNT
FIELD
W
G
11
A
W
S
G
CB1
20A
41
+
-
SERIES FIELD
60
820
SELECTO
SWITCH
90-MIN
130-80
190-120
240-160
220-MAX
R
A
MMETER
212B
GND-T
-
+
+
-
GND-N
200
*
54
STARTING
MOTOR
G
WK
OIL PRESSUR
WITCH/SENDER
11
B
I
S
GROUN
CREW
NEAR FUSE
D
E
S
B
GND-
S
S
50
S
OIL
PRESSUR
GAUG
G
E
TO IDL
ROT
E
E
R / ENGINE
D+
E
11C
*
59
INTERPOL
E
COILS
P
CTION
P.C.
Bd.
DIODE
AND
51
B+
WELDING GENERATOR
A
LT
E
RN TOR
A
CURR
E
NT TRANSFORMER
MOV
*
844A
REED
SWITCH
GND-
B
*60
A
BRUS
VIEWED FROM CONTRO
H
POSITION
SHOW
N
L
AS
PANEL
GND-
A
POSITIVE
GROUN
D
S
CR
UGES
E
W
NEAR
NEGATIVE
(CC-)
GROUND
GROUND
TO BASE TO ENGINE
E
NGIN
E
G
A
(CC+)
&
(C
V+
W
ITH W.F.M.)
K924-5 RE
MOTE CONTROL (OPTIONAL)
WIRE
FEED MODULE (OPTIONAL)
ON MACHINE
,
REMOVE PLUG "P10"
F
ROM CONNECTOR "J5".
PLUG
FOR REMOTE CONTROL
CONNEC
T
"P5" ON W.F.M
.
TO CONNECTOR "J5" ON MACHINE.
POTENTIOMETER
INLINE CONNECTORS
.F.M.
X
Y
PLUG P5
W
CONTROL
PANEL
G
B
W
#8 LEAD
#2 HEAVY LEAD
WIRE FEED
MODULE
CONNEC
OUTPU
NEGATIVE CV
OUTPU TERMINAL
PANEL
T
TO POS
.
& NEG.
POS.
NEG.
T
TERMINALS
RESISTORS
608
T
609
#2 HEAVY LEAD
REMOTE CONTOL
POTENTIOMETER BOX
CONNEC TO CASE
T
CONNEC
T
TO NEG.
250 AMP HERMOSTA
T
T
ASSEMBLY
BRUSH HOLDER
MACHINE
MUST NOT BE RUNNING
W
HEN MAKING THESE CONNECTIONS.
A
M21292
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.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-11
G-11
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - (CODES 11413, 11414) (M21293)
CLASSIC 300D KUBOTA WIRING DIAGRAM
LEAD COLOR CODE
ENGINE CONTROL UNIT CONNECTOR DETAIL
CONTROL PANEL COMPONENTS SHOWN AS VIEWED
FROM REAR.
B-BLACK OR
GRAY
G-GREEN
N-BROWN
R-RED OR
PINK
LEADS CONNECTED
T
O ENGINE CONTROL UNIT
,
SEE DETAIL
61
57
*
U-BLUE
93
51B
212D
NEUTRAL BONDED
T
O
F
RAME.
NEUTRE RACCORDE AU BATI
P10
J5
W-WHIT
E
'
.
GLOW PLUGS
55
58
70B
844A
70A
121110 9 8
7 6 5 4 3
2 1
Y-YELLOW
NOTE
:
LEADS 70A & 70B ARE
LEFT OPEN AND WIRE
RPM CONTROL
400D
Y
69
400E
W
TIED
INTO HARNESS.
48
U
94
60E
52B
87
56
88
86
60F
44
54
64
N
SLIP RINGS
ALTERNATOR
-
57
+
+
*
610A
ACTUATOR
SLIP RING
NEAREST
TO IRON
1
2
3
56
*
ENGINE
FAILURE
LAMP
AC
AC
600C
WIRE-TIED TO WIRING
87 86 88
*
*
*
HARNESS BEHIND
CONTROL PANEL
ENGINE HOUR METER
START
52B
P8
J8
W
R
600
230 VOLT
RECEPTACLE
-
+
-
G
1
41
41
58
61
841A
*
115
RECEPTACL
VOLT GFCI
*
*
2
3
4
5
6
600A
42
STAR RELAY
T
21
841
WATER
7A
X
212D
E
400F
Y
*
50A
52A
TEMP.
212C
15A
FUSE
IGNITION
SWITCH
N
N
W
W
400D
42
602A
SWITCH/
841B TEMP
55
Y
Y
U
U
HOT LINE HOT LOAD
*
W
SENDER
GAUGE
RHEOSTAT
53
S
W
44
G
I
51B
*
43
GND-M
212A
215
214
REMOTE CONTROL
SWITCH AND
RECEPTACLE
*
WHITE LINE
WHITE LOAD
6A
CB2
15A
GLOW
PLUG
G
62
810
7A
48
51A
400F
ALT. AUX
POWER
WINDINGS
OIL PRES.
SWITCH/
SENDER
SHUNT
FIELD
820
11A
51C
CB1
20A
50A
11C
41
I
S
GND-S
200
54
*
SERIES
FIELD
820
SELECTOR
SWITCH
G
OIL
STARTING
MOTOR
WK
AMMETER
G
GND-T
-
+
+
-
PRESSURE
GAUGE
S
-
90-MIN
130-80
190-120
240-160
220-MAX
+
B
50
ALTERNATOR
L
WATER
TEMP.
SENSOR
ENGINE
SPEED
SENSOR
11B
64
51
*
B
BATTERY
IG
69
212E
94
INTERPOLE COILS
WELDING GENERATOR
*
*
2
T
URNS
11C
URNS
844A
DIODE
AND
MOV
93
60
841
*
1
3
4
2
*
60A
60E
60F
GND-B
844
842
GROUND
TO
ENGINE
67B
GROUND
TO
BASE
*
842
*
3
T
BRUSH POSITION SHOWN AS
VIEWED ROM CONTROL PANEL
(CV+ WITH W.F.M.)
IDLER SWITCH
67A
GROUND SCREW NEAR
ENGINE GAUGES
NEGATIVE
(CC-)
POSITIVE
(CC+
F
)
&
K924-5 REMOTE CONTROL (OPTIONAL)
WIRE
FEED MODULE
(OPTIONAL)
ON MACHINE
,
REMOVE PLUG "P10"
F
ROM CONNECTOR "J5".
PLUG
FOR REMOTE CONTROL
CONNEC
T
"P5" ON W.F.M
.
TO CONNECTOR "J5" ON MACHINE.
POTENTIOMETER
INLINE CONNECTORS
.F.M.
X
Y
PLUG P5
W
CONTROL
PANEL
G
B
W
#8 LEAD
WIRE
MODULE
FEED
CONNEC
OUTPU
NEGATIVE CV
OUTPU TERMINAL
PANEL
T
TO POS
.
& NEG.
POS.
NEG.
T
TERMINALS
RESISTORS
#2 HEAVY LEAD
608
T
609
#2 HEAVY LEAD
REMOTE CONTOL
POTENTIOMETER BOX
CONNEC TO CASE
T
CONNEC
T
TO NEG.
250 AMP HERMOSTA
T
T
ASSEMBLY
BRUSH HOLDER
MACHINE
MUST NOT BE RUNNING
W
HEN MAKING THESE CONNECTIONS.
A
M21293
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.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-12
G-12
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - (CODES 11472, 11473) (M21684)
CLASSIC 300D PERKINS WIRING DIAGRAM
LEAD COLOR COD
E
CONTROL PANEL COMPONENTS SHOWN AS VIEWED
LEADS CONNECTED O ENGINE DLER/ENGINE P.C
F
ROM REAR.
B-BLACK OR
GRAY
R-R
E
D O
IN
LU
HIT
Y-YELLO
R
T
I
.
BOARD SEE DETAIL
,
ON OLD
J31 WAS J1,
J32 WAS J2.
E
R
BOARDS,
P
K
7
10
1 2 3 4 5 6
J31
8 9
*
G-GREEN
N-BROWN
U-
B
E
NEUTRAL BONDED
NEUTRE RACCORDE AU BATI
T
O
FRAME.
P
10
W-W
E
.
121110 9 8 6 5 4 3 2 1
7
W
IDL
E
R/
E
NGINE PROT
E
CTION P.C. Bd.
J5
1
2
3
4
400D
Y
J32
400
E
TO CURRENT
TRANSFORMER
W
48
LTERNATOR
U
B1 B2 B3 B4
N
S
LI RINGS
P
A
-
IDLER
OL NOID
55
A
60
A
+
+
610A
S
E
S
LIP RING
GLO
W
S
844
844
212
55
57
E
B
NEAREST
TO IRON
PLUG
W
R
AC
*
AC
600C
*
115
RECEPTACL
VOLT GFCI
J8 P8
P
UM
E
P
W
R
600
230 VOLT
RECEPTACL
E
400F
212
E
-
G
S
OL NOID
1
2
3
4
5
6
41
41
E
GND-C
600
A
*212C
21
7A
X
E
NGIN
HOU
METER
E
42
*58
Y
*
212D
IGNITION
WITCH
CB4
10
HOT LINE HOT LOAD
53
GLO
R
W
15A
*
61
42
602
A
E
NGINE
P
LUG
START
52
FUSE
S
W
RHEOSTAT
FAILUR
LAMP
E
-
+
WHITE LINE
WHITE LOAD
A
IDLER
WITCH
215
56
212
51
*
844
214
REMOT
SWITCH AND
RECEPTACL
E
CONTROL
S
60C
TEMPERATUR
A
*93
51C
6A
U
Y
E
A
43
810
7A
WATER
TEMPERATURE
N
E
W
S
WITCH/SENDER
S
I
A
LT. AUX
POWER
INDING
CB2
15A
50
A
*44
SHUNT
FI LD
GAUGE
W
G
11
A
W
S
E
G
CB1
20A
41
+
-
SERIES FIELD
60
820
SELECTO
SWITCH
90-MIN
130-80
190-120
240-160
220-MAX
R
A
MMETER
212B
GND-T
GND-
-
+
+
-
GND-N
*
54
200
STARTING
MOTOR
G
WK
OIL PRESSUR
WITCH/SENDER
11
B
I
S
E
GROUN
CREW
NEAR FUSE
D
S
B
S
OIL
S
S
50
PRESSUR
GAUG
E
G
E
TO IDL
ER / ENGIN
E
d.
D+
11C
*
59
INTERPOL
E
COILS
P
ROT CTION
E
P.C.
B
DIODE
AND
MO
51
B+
WELDING GENERATOR
ALT
E
RN TOR
A
CURR
E
NT TRANSFORMER
V
*844A
REED
SWITCH
GND-B
*60
A
BRUS
VIEWED FROM CONTRO
H
POSITION
SHOW
N
AS
GND-
A
L
PANEL
POSITIVE
(CC+)
GROUN
D
S
CR
E
W
NEAR
NEGATIVE
(CC-)
GROUND
TO BASE TO ENGINE
GROUND
E
NGIN
E
G
A
UGES
&
(C
V+
W
ITH W.F.M.)
K924-5 RE
MOTE CONTROL (OPTIONAL)
WIRE
FEED MODULE (OPTIONAL)
ON MACHINE
,
REMOVE PLUG "P10"
F
ROM CONNECTOR "J5".
PLUG
FOR REMOTE CONTROL
CONNEC
T
"P5" ON W.F.M
.
TO CONNECTOR "J5" ON MACHINE.
POTENTIOMETER
INLINE CONNECTORS
.F.M.
X
Y
PLUG P5
W
CONTROL
PANEL
G
B
W
#8 LEAD
#2 HEAVY LEAD
WIRE FEED
MODULE
CONNEC
OUTPU
NEGATIVE CV
T
TO POS
.
& NEG.
POS.
NEG.
T
TERMINALS
RESISTORS
608
OUTPU
T
TERMINAL
PANEL
609
#2 HEAVY LEAD
REMOTE CONTOL
POTENTIOMETER BOX
CONNEC TO CASE
T
CONNEC
T
TO NEG.
250 AMP HERMOSTA
T
T
ASSEMBLY
BRUSH HOLDER
MACHINE
MUST NOT BE RUNNING
W
HEN MAKING THESE CONNECTIONS.
A
M21684
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.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-13
G-13
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - (CODES 11474, 11475) (M21563)
CLASSIC 300D KUBOTA WIRING DIAGRAM
LEAD COLOR CODE
ENGINE CONTROL UNIT CONNECTOR DETAIL
CONTROL PANEL COMPONENTS SHOWN AS VIEWED
FROM REAR.
B-BLACK OR
GRAY
G-GREEN
N-BROWN
R-RED OR
PINK
LEADS CONNECTED O ENGINE CONTROL UNIT SEE DETAIL
T
,
61
57
*
U-BLUE
93
51B
212D
NEUTRAL BONDED
NEUTRE RACCORDE AU BATI
T
O
FRAME.
P10
J5
NOTE
:
LEADS 70A & 70B ARE
LEFT OPEN AND WIRE
W-WHIT
E
'
.
GLOW PLUGS
55
58
70B
844A
70A
121110 9 8
7 6 5 4 3
2 1
Y-YELLOW
RPM CONTROL
TIED
INTO HARNESS.
400D
Y
69
400E
W
48
U
94
60E
52B
87
56
57
88
86
60F
*
*
44
54
64
N
ACTUATOR
SLIP RINGS
ALTERNATOR
56
-
ENGINE
FAILURE
LAMP
+
+
610A
SLIP RING
NEAREST
TO IRON
1
2
3
ENGINE HOUR METER
AC
AC
600C
WIRE-TIED TO WIRING
HARNESS BEHIND
CONTROL PANEL
-
+
87
88
86
*
*
58
*
61
841A
START
52B
P8
J8
*
*
W
R
600
230 VOLT
RECEPTACLE
-
15A
G
1
41
41
841
115
VOLT GFCI
TEMP SWITCH
.
*
2
3
4
5
6
600A
42
STAR RELAY
T
21
7A
X
212D
RECEPTACL
E
Y
*
50A
52A
841B
44
212C
*
IGNITION
400F
HOT LINE HOT LOAD
N
N
W
W
42
602A
55
Y
Y
U
U
FUSE
SWITCH
WATER
TEMP
GAUGE
*
W
TEMP
.
SENDER
43
GND-M
RHEOSTAT
53
S
I
51B
*
215
214
REMOTE CONTROL
SWITCH AND
RECEPTACLE
WHITE LINE
WHITE LOAD
6A
GLOW
PLUG
212A
G
62
810
7A
51A
ALT. AUX
POWER
WINDINGS
OIL PRES.
SHUNT
FIELD
SWITCH/
SENDER
11A
CB2
15A
51C
CB1
20A
50A
I
S
200
OIL
PRESSURE
GAUGE
54
*
SERIES
FIELD
820
SELECTOR
SWITCH
G
STARTING
MOTOR
WK
AMMETER
G
-
+
+
-
S
-
90-MIN
130-80
190-120
240-160
220-MAX
+
B
ALTERNATOR
L
50
WATER
TEMP.
SENSOR
ENGINE
SPEED
SENSOR
64
51
*
B
BATTERY
IG
69
212E
94
INTERPOLE COILS
WELDING GENERATOR
*
*
2
T
URNS
11C
URNS
844A
DIODE
AND
MOV
93
60
841
*
1
3
4
2
*
60A
60E
60F
GND-B
844
GROUND
TO
ENGINE
67B
GROUND
TO
BASE
*
842
842
3
T
*
IDLER SWITCH
BRUSH POSITION SHOWN AS
VIEWED ROM CONTROL PANEL
(CV+ WITH W.F.M.)
67A
GROUND SCREW NEAR
ENGINE GAUGES
NEGATIVE
(CC-)
POSITIVE
(CC+
F
)
&
K924-5 REMOTE CONTROL (OPTIONAL)
WIRE
FEED MODULE
(OPTIONAL)
ON MACHINE
,
REMOVE PLUG "P10"
F
ROM CONNECTOR "J5".
PLUG
FOR REMOTE CONTROL
CONNEC
T
"P5" ON W.F.M
.
TO CONNECTOR "J5" ON MACHINE.
POTENTIOMETER
INLINE CONNECTORS
.F.M.
X
Y
PLUG P5
W
CONTROL
PANEL
G
B
W
#8 LEAD
WIRE FEED
MODULE
CONNEC
OUTPU
NEGATIVE CV
OUTPU TERMINAL
PANEL
T
TO POS
.
& NEG.
POS.
NEG.
T
TERMINALS
RESISTORS
#2 HEAVY LEAD
608
T
609
#2 HEAVY LEAD
REMOTE CONTOL
POTENTIOMETER BOX
CONNEC TO CASE
T
CONNEC
T
TO NEG.
250 AMP HERMOSTA
T
T
ASSEMBLY
BRUSH HOLDER
MACHINE
MUST NOT BE RUNNING
W
HEN MAKING THESE CONNECTIONS.
A
M21563
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.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-14
G-14
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - (CODES 11110, 11111) (L12412)
2
1 2 L 4 1
CHANG
E
DET
A
IL: SLI
P
RINGS
,
CHANGED
POSITIVE TO NEGATIVE
ENGINEERING CONTROLLED
MANUFACTURER:
No
K924-5 REMOTE CONTROL
(OPTIONAL)
CENTE
R
OF CONTROL PANEL
BACK, LEFT SID
55 AM / 12 OLT
ALTERNATO
E
OF
E
NGINE
THI
S
LE
A
D
P
RO
V
IDES FLASH
AND
OUTPUT
FOR ALTERNATO
R
12 VOLT - NORMALLY OFF
AMMET
DISCHARGE WHILE PRESSIN
GLO PLUG SWITCH
E
R
SHOWS FULL
IDLER / ENGINE PROTECTION PC BOARD
P
V
SENSES ALTERNATO
R
G
RE
ROT
LIGHT
D
E
E
NGIN
E
LOCAT
ED
BEHIND
UPPER
PORTIO
N
OF CONTROL PANEL
GLO PLUG
SWITCH
W
R
W
P
CTIO
N
SCHEMATI
C
G4828-1
J1-4
61
60C
59
J1-3
FLAS
AT
AT
H
ENGIN
E
53
BACK
,
RIGHT
S
ID
E
OF
ENGINE
B
SHUTDOWN
N.C.
B
B3
55
57
WHITE
IDLE SOLENOID
REMOTE CONTROL PLUG
P
ULL COIL
51C
-
RI NJ SCTEIOONF
E
IN
E
BY
I
GHTEID
PUNMG
P
TY
RESISTANCE:
HOL COIL: 1
ULL COIL: 40A, LESS TH
PICAL CURRENT DRAW AND
G
J1-8
40 TO 40 AMPS
AMMETER
RED
HOL COIL
D
N.O.
E
INJ
E
CTIO
N
BLACK
D
A, 10-15 OHMS
J1-9
58
GND-C
FLYBACK
DIODES
51
51A
Y
PUMP
+
-
P
AN
.1 OHM
212E
51G
GLO
W
PLUGS
E
NGIN
S
OLENOID
APPRO IMAT
RESISTANCE: 3.3 OHM
TY ICAL CURRENT DRAW: 3.3
X
RUNNING
212C
56
TY
DRAW
PICAL CURRENT
J1-2
J1-1
58H
X
E
10A
B4
IS
40 +/- 3 AMPS
IGNITIO
SWITCH
HO
N
212D
25+/-1.25 OHMS EACH
S
W
C
50A
CLOOWE EFT OF
NTRROLL PANEL
P
A
S
W
N IN "OFF"
212A
BACK, LEFT SID
E
OF
ENGINE
50
POSITION
RIGOHITL SFIIDLLE
E
OF
ENGINE
S
I
J1-6
43
44
BY
R
ST
SWITCH
ART
CCW
TEMPERATURE
W
G
/
64+/-6.4 OHM MAX
S
G
FUEL
P
UM
IMAT
RESISTANCE: 3-4 OHM
P
GAUG
E
E
NGIN
ROT CTIO
CIRCUIT
ELO
LOGIC)
E
OBAFCMKA
B
TOM
, CHOITNE
TEMPERATURE SWITCH
SWITCH CLOSES
SENDER
OPERATION:
-> 134+/-13.5 OHMS
APPRO
X
E
P
E
N
52
CLOOWE EFT OF
NTRROLL PANEL
SENDE
R
ST
S
ARTER
OLENOID
212B
S
S
(SEE
FOR
+
AT 230v+/-6vF
140v
F
B
W
BATTERY
RHEOSTAT
TY
PICAL CURRENT DRAW: 3
A
194v
F
-> 51.2+/-4.3 OHM
-> 38.5+/-3 OHM
E
S
2N12Gv
F
S
S
G
SENDE
R
IS APPROX.
AT 70vF
+
J1-10
60
93
12.6 VOLTS MIN
AT REST
ST
A
RTE
MOTOR
R
BACK, TO
P
OF
E
IN
500 OHM
S
REMOTE CONTROL BOX
HOUR METER
OIL PRESSURE
J1-7
20
0
I
14
-14.5 VOLTS
54
CCEONNTTEROL
R
OF
J1-5
J2-1
J2-2
GAUG
E
WHIL
E
RUNNING
PANEL
WK
G
UNUSED
CLOOWE EFT OF
NTRROLL PANEL
OIL PRESSURE SWITCH
SWITCH CLOSES
SENDE
AT 6 /-2 PSI
0 P I -> 10
40PSI -> 105+/-5 OHMS
/
SENDER
OPERATION:
/-5 OHMS
B1
REVERSE VOLTAG
E
R
P
ROT CTION DIODE
E
IDL
OLENOID
CI UIT
(SEE BELO
FOR LOGIC)
E
60A
+
S
+
S
AUX LO
B2
AD
SENSIN
G
B4
B5
B6
FLYBACK DIODE PREVENTS
OLTAGE SPIKES SHUNT FIELD
FROM AM GING LOCAL/ EMOTE
TOGGLE SWITCH WHE SWITCHED
R
S
80 PSI -> 187+/-5 OHMS
UNUSED
W
V
IN
W
ELD LO SENSING
A
D
THE P10 PLUG
THE IR FE
MODUL AS A
I
S
O
NL
Y
ON UNITS WITHOUT
D
A
R
J2-3
W
E
E
D MODUL
E
. THE WIR
E
FEED
P10
J5
E
NGINE PROT
E
CTION CIRCUIT LOGIC
J2-4
N
E
H
H
ARNESS THAT PLUG
S
ON
J1 B
B5 AN
N
EWE
R
BOARDS,
12 11 10
48
9
8
7
6
5
4
3
2
1
DIRECTLY INTO J5.
1. U
IGNITIO
FUEL UMP AN
ENERGIZED.
PON
RE
CIEVING POWER FROM TH
SWITCH, TH FUEL OLENOID
HO R MET ARE
E
S
HO
W
N IN "AUTO
IDLE" POSITION
JUMPE
TO WIR
R
E
PLUG
FEED MODULE
I
S
FOR CONNECTIO
N
E
COMES J31, J2 B
E
COMES J32,
GND-B
400D
84
4
N
E
U
S
ER
,
D
B6 T
ERMINALS ARE ELET
D
ED.
IDLER
SWITCH
20A
P
D
JUMPE
R
PLUAGLISWIRE-TIED
U
P
400E
RBEIGHHINTD LIDOC
/
R
EMOTE SWITCH
O
N
DC EXCITER
61
0
2.
FOR ONE MI
PRESSURE BUILDUP
ST RTE ITHI ON
TURNING IGNITIO SWITCH ON OR TH
E
NGINE PROT
UTE TO ALLO
NGIN
MI UTE OF
E
CTIO
N
IS BYPASSED
OIL
MUST BE
S
FROM CO EOF MPANEL)
NTROL ACHINE (AS VIEWED
W
INDING SPEC: ALT
-
241-3A
+
15A
B3
61
0
N
W
+
610A
40.5 - 42.5 OHM
S
AT 25C
C
U
U
N
N
Y
Y
W
W
DILOODE
AC
.
E
E
E
AC
CB1
EXCIT
E
R
REVOLVING
WER, RIGHT
SID
E
OF CONTROL PANEL
A
D
W
N
N
11A
FIELD (ROTOR)
N
E
600B
-
600C
-
FUEL
MET
S
R
OLENOID, FUEL
ILL TURN OFF. AFTER
IGNITIO
OFF A BACK
P
UMP AN
D
HOUR
ONE
SWITCH MUST BE
N TO ST RT
21
SLI
NEGATIVE SLI
IS EAREST TO IRO
P
RINGS
600A
400F
115 VOLT GFCI
7A
E
W
TOP,
R
NIGTHRTOPLORTIO
N
FUSE
P
RIN
G
N
RECEPTACLE
MINUTE, TH
CYCL
NGINE.
E
N
OF CO
PANEL
15A
N
EXCIT
EAD 21
INDING SPEC: ALT
.488 OHM AX AT 25C
E
R CIRCUIT
HOT
L
IN
E
HOT
L
OAD
215
ED
N
D
O
A
RHEOSTAT
64+/-6.4 OHM
LOGWHTERO,F
CCW
L
W
A
TO 21B
E
S
MAX
RI
-214-2B
W
HI
T
E
LINE
W
HI
T
E
LOAD
230 VOLT
RECEPT CL
602B
21
4
CONTROL
PANEL
S
M
A
E
3. AFTER
CURRENT IS SUPPLI
ALTERNATOR.
ENGIN
E
ST
ARTS, FLA
SHING
D TO THE ENGINE
GND-E
41
42
602A
4
E
6A
81
0
115 VOLT CIRCUIT
EAD 810 TO 820
INDING SPEC: ALT
.230 OHM AX AT 25C
J8
GND-
T
15A
B2
L
W
11C
GND-S
C
EXCIT
(ALTER
E
N
R
STATO
R
6
5
3
1
2
-214-2C
4. AFTER
OUT. IF OIL PRESSURE
COOLANT TEMPERATURE
ALTERNATO IS OT CHARGING, TH
NGINE WILL S UT DOW AND TH
NGINE PROT CTION LIGHT ILL COM
ON
ONE MI
N
UTE, TIM
LOW,
HIGH OR
E
R
IS TIMED
ATOR)
P9
82
0
S
M
I
S
JUIRMPE
R
PLUG ISHI
IN-LINE BOLTED CONNECTIO
N
41
60
Y
0
IS
W
E-TIED
U
PBE ND
BEHI
N
D
CONTROL PANEL
115 VOLT CIRCUIT
EAD 820 TO 830
INDING SPEC: ALT-214-2D
G
42
60
2
R
N
E
LOC
/
ITCH RENMROITE
SW AL
11B
GENERATOR LEA
L
W
.424 OHM
E
E
H
E
N
E
S
ID
E
OF OMACHGINHET
D
BLOCK
ITH
CTIO
W
E
X
844A
S
HO
WN
AS VIEWE
D
W
S
M
AX AT 25C
OF COLENFTTROPOL PANEL
.
TOP,
RTION
ENGIN
E
IN THIS DIR
E
N
W
IDLE SOLENOID CIRUIT LOGIC
1. WHEN THE ENGIN UNNING N HIGH
OR NDER LO D, THE SOLENOID OT
ENERGIZED.
REMOTE
MOUNTE
NEGATIVE
BRUS
H
HDOLTDOER
RECEPTACLE
E
I
S
R
I
IDLE
SHUNT
FIELD
SERIES FIEL
D
S
ELECTOR SWITCH
LOCAL
/
REMOTE
U
A
IS
N
-
+
-
SWITCH
DIODE AND MOV ASSEMBL
Y
90-MIN
130-80
190-12
S
HO N IN LOCAL
W
FJW-5AP
COIL PAIR
25.2 - 26.7
THI CIR UIT USES TH
S
C
E
+
2. IF N
LOA
IDL
HOL
O
AUXILIARY
IS SENSED FOR 15 SECONDS AND THE
SWITCH
COIL OF TH
C
URRENT DRAW OR
WEL
D
POSITION
0
:
RESID AL M GNETISM OF
THE ENERATOR TO FLASH
THE EXCIT TH OTOR
HI H IN TUR RO IDES
THE EXCITATION FOR TH
U
A
D
G
240-16
0
E
R
IS
O
E
PEN (AUTO), THE
DL OLENOID ARE
E-ENERGIZED
PULL AND
INTERPOLE
COILS
OHMS EACH
E
E
R
220-MAX
D
I
ER
S
W
C
N
P
V
ENERGIZED. THE PULL COIL I
S
D
E
AFTER ALF A SECO D.
H
N
GENERATO
R
COM
CAPACITOR: MFD/
RESISTOR: OHMS/WATTS
PONENT
V
ALUE
UNITS:
3. IF AN AUXILIARY CURRENT DRAW OR WELD
LOAD IS SENSED OR THE IDLER SWITCH IS CLOSED
(HIGH), THE IDLE SOLENOID IS DE-ENERGIZED.
V
OLTS
BACK OF OUTPUT STU
REE SWITCH
SWITCH CLOSES
D
WELDING
GENERATOR
BRUS
VIEWED FROM CONTROL PANEL
H
POSITION
S
HO
W
N
AS
D
CONNECTOR PIN NUMBERS:
W
ITH FLO
W
C
OF
URRENT
GND-A
WELDING
LE
A
D
COLOR CODE:
EX.
12
PIN CONNECTOR
LA
BELS:
_
+
B-BLACK OR GRAY
G-GREEN
2
1
7
PROPRIETARY & CONFIDENTIAL:TTO OT
6
HIS DOCUME
N
T CONTAINS P
R
OPRIETARY INFORMATIO
FOR ANY P RPOSE WITHOUT THE E
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
N
D MAY NOT BE
N
D
UPLICATED,
COMMUNICATE
D
POSITIV
TERMINAL
E
O
UTPUT
HER PA
RTIES O USE
R
D
U
X
PRESS
W
RITTEN PERMISSIO OF LINCOLN GLOBAL, INC.
NEGATIVE OUTPUT
COMMON
FRAM ROUND
EARTH GROUND
U
NLESS OTHERWISE SPE
MANUFACTURIN TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS .02
ON 3 PLACE D CIMALS I .002
CIFIED TOLERANCE
R-RE
U-BLU
W- HIT
Y-YELLO
N-BROWN
D
E
OR
P
INK
TERMINAL
RM MACHI E):
99.0 VOLTS AT MAX HEOSTAT
54.5 VOLTS AT MI RHEOSTAT
DESIGN INFORM
A
TION
REFERENCE:
L12020
G
EQUIPMENT TYPE
SUBJECT:
MATERIAL
DISPOSITION:
:
_1__
_1__
OF
CLASSIC 300D PERKINS 404C-22
MACHINE SCHEMATIC
PAGE
DOCUMENT
UMB R:
E
G
TYPICAL OC
V
(W
A
N
12
LATC
DM / DFM
J.STAPP
DRAWN BY:
E
S
DOCUMENT
REVISION:
W
E
ON ALL ANGLES IS .5 OF A DEGREE
94
44
-
-
R
U
NDER LEFT DOO
R
H
N
E
MATERIAL TOLERANCE (" ") TO AGREE
t
E
NGINEER:
SCALE:
W
N
WITH PUBLISHED STANDARDS.
APPROVAL
09/21/2006
PROJECT
NUMBER:
VIEW O
F
CONNECTOR ON PC BOARD
L12412
C
C
RM22115-FZ
UF
APPROVED:
NA
DATE:
DO NOT SCALE THIS
DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-15
G-15
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - (CODES 11112, 11113) (L12265)
5
1 2 L 2 6
CHANG
E
DETAIL: Released A.05 from X
ENGINEERING CONTROLLED
JUMPER PLUG IS BEHIND LOWER
RIGHT SIDE OF CONTROL PANEL
MANUFACTURER:
No
LOWER RIGHT OF CONTROL PANEL
AMMETER SHOWS FULL
DISCHARGE WHILE PRESSING
GLOW PLUG SWITCH
RPM CONTROL POTENTIOMETER
K924-5 REMOTE CONTROL
(OPTIONAL)
12 VOLT SUPPLY
11
2
87
86
88
1
GLOW PLUG
BUTTON
10,000 +/- 1,000 OHMS MAX
94
93
20
17
ENGINE
SPEED
SENSOR
TURN POT COUNTERCLOCKWISE TO
REDUCE RESISTANCE AND SUBSEQUENTLY
REDUCE RPM BY UP TO 150RPM
BACK, LEFT SIDE OF ENGINE
ALTERNATOR
RATED VOLTAGE: 12V
RATED CURRENT: 22mA MAX
2
ENGINE CONTROL UNIT (ECU)
53
CCW
GLOW PLUGS
LOCATED BEHIND UPPER PORTION OF CONTROL PANEL
3
3
4
BACK, RIGHT
60A
RATED VOLTAGE: 12V
51C
SIDEOFENGINE
TYPICAL CURRENT
DRAW IS 40 AMPS
RATED CURRENT: 4.5A(MAX.)-TERMINAL #15
LEAKAGE CURRENT 10micro A (MAX.)-TERMINAL #16
40 AMP / 12 VOLT
REMOTE CONTROL PLUG
L
26
64
69
13
34
G
SENSES ALTERNATOR OUTPUT
SENSOR OPERATION:
-4vF -> 18.80 kOHMS
104vF -> 1.14 kOHMS
212vF -> .16 kOHMS
IG
B
WATER
TEMP.
FLASHES ALTERNATOR
212E
SENSOR
-40 TO 40 AMPS
AMMETER
Y
16
15
51B
60
IGNITION
SWITCH
BACK, LEFT
51
BACK, BOTTOM
X
STARTER
SOLENOID
SIDE OF ENGINE
-
OF MACHINE
RATED VOLTAGE: 12V
RATED CURRENT: 2A
COIL RESISTENCE:
2.8 +/- .28 OHMS AT 20vC
ENERGIZED FOR RUN
DE-ENERGIZED FOR STOP
ACTUATOR CONTROLS RPM
MECHANICAL STOP WILL SHUT
DOWN THE ENGINE AT 115%
OF RATED SPEED.
1
10
9
17
212D
51A
50
+
SHOWN IN "OFF"
POSITION
+
W
25+/-1.25 OHMS EACH
BATTERY
57
18
26
25
34
12.6 VOLTS MIN
AT REST
14-14.5 VOLTS
WHILE RUNNING
12 VOLT
SUPPLY
STARTER
MOTOR
BACK, LEFT SIDE OF ENGINE
212A
I
S
ACTUATOR
50A
28
43
44
BACK, RIGHT
CCW
TEMPERATURE
GAUGE
W
G
G
SIDE OF ENGINE
56
18
9
64+/-6.4 OHM MAX
S
START
BUTTON
TEMPERATURE SWITCH / SENDER
LOWER LEFT OF
ECU CONNECTOR DETAIL
ENGINE
212B
CONTROL PANEL
SENDER OPERATION:
RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY
OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED
WHEN THE IGNITION SWITCH IS "ON" AND THE ECU
SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT
SWITCH CLOSES
PROTECTION
LIGHT
140vF -> 134+/-13.5 OHMS
194vF -> 51.2+/-4.3 OHMS
212vF -> 38.5+/-3 OHMS
COLOR: RED
12 VOLT
NORMALLY OFF
AT 230v+/-6vF
62
61
SENDER IS APPROX.
500 OHMS AT 70vF
RHEOSTAT
CENTER OF
THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING THE ENGINE
PROTECTION LIGHT IN A CODED SEQUENCE, SEE CHART FOR FAULT
CODES AND CORRECTIVE MEASURES. WHEN THE ENGINE IS SHUT
DOWN DUE TO A FAULT, THE IGNITION SWITCH WILL NEED TO BE
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
841A
CONTROL PANEL
FRONT, LEFT SIDE OF ENGINE
212C
DOWN DUE TO A FAULT (EVEN IF T
DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING
OUT OF UEL), THE IGNITION SWITCH WILL NEED TO BE
HAT CONDITION
S
OIL PRESSURE
GAUGE
200
I
54
27
12
REMOTE CONTROL BOX
+
58
6
WK
G
F
G
HOUR METER
52A
LOWER LEFT OF
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
CENTER OF
CONTROL PANEL
OIL PRESSURE SWITCH / SENDER
1
19
31
30
32
7
CONTROL PANEL
SWITCH CLOSES
AT 6+/-2 PSI
SENDER OPERATION:
0 PSI -> 10+/-5 OHMS
40PSI -> 105+/-5 OHMS
80 PSI -> 187+/-5 OHMS
STARTER
RELAY
THE P10 PLUG IS ONLY ON UNITS
WITHOUT THE WIRE FEED MODULE.
THE WIRE FEED MODULE HAS A
HARNESS THAT PLUGS DIRECTLY
INTO J5.
CONNECT TO
GROUND FOR
1600RPM, LEAVE
UNCONNECTED
FOR 1800RPM
CONNECT TO
GROUND FOR
800RPM
60E
70B
70A
60F
WIRE-TIEDTOHARNESS
BEHIND CONTROL PANEL
52B
P10
844A
55
12 11 10
48
9
8
7
6
5
4
3
2
1
FLYBACK DIODE PREVENTS
BOTH OPEN LEADS ARE WIRE-TIED INSIDE THE HARNESS BEHIND CONTROL PANEL
841B
VOLTAGE SPIKES IN SHUNT FIELD
FROM DAMAGING LOCAL/REMOTE
TOGGLE SWITCH WHEN SWITCHED
J5
400D
400E
GND-B
JUMPER PLUG IS FOR CONNECTION
TO WIRE FEED MODULE
610
WINDING SPEC: ALT-241-3A
40.5 - 42.5 OHMS AT 25C
+
20
A
20
A
CB2
15
CB3
A
610A
600C
610
+
-
CB1
U
U
N
N
W
W
Y
Y
DIODE
AC
AC
JUMPER PLUG IS WIRE-TIED UP
BEHIND LOCAL / REMOTE SWITCH ON
RIGHT SIDEOFMACHINE(ASVIEWED
FROM CONTROL PANEL)
EXCITER REVOLVING
FIELD (ROTOR)
LOWER, RIGHT SIDE OF CONTROL PANEL
IDLER SWITCH
SHOWN IN "AUTO
IDLE" POSITION
11
A
600B
600A
11
-
21
SLIP RINGS
POSITIVE SLIP RING
IS NEAREST TO IRON
400F
7A
4A
FUSE
15A
115 VOLT
RECEPTACLE
EXCITER CIRCUIT
LEAD 21A TO 21B
WINDING SPEC: ALT-214-2B
.488 OHMS MAX AT 25C
21
5
RHEOSTAT
LOWER,
CCW
64+/-6.4 OHMS MAX
GND-S
RIGHT OF
CONTROL
PANEL
230 VOLT
RECEPTACLE
21
4
602B
GND-E
41
42
602A
4
6A
81
82
0
115
EAD
WINDING SPEC: ALT-214-2
V
OLT CIRCUIT
JUMPER PLUG IS
WIRE-TIEDUP
841
844
J8
CB4
15
L
8
10 TO 20
8
A
EXCITER STATOR
(ALTERNATOR)
6
5
3
1
2
C
BEHIND LOCAL /
REMOTE SWITCH
P9
0
.230
O
HM
S
M
AX AT 25C
IN-LINE BOLTED CONNECTION
BEHIND CONTROL PANEL
GND-T
41
G
ON RIGHT SIDE OF
MACHINE
600
Y
11C
115
V
OLT CIRCUIT
20 TO 30
WINDING SPEC: ALT-214-2
42
602
11B
LEAD
8
8
D
WITH AC AUXILIARY POWER,
ROUTING DIRECTIONS OF THESE
LEADS DOES NOT MATTER
GENERATOR LEAD BLOCK
SHOWN AS VIEWED WITH
LOCATED BEHIND UPPER LEFT
PORTION OF CONTROL PANEL
SENSOR GROUNDS LEAD
ON SENSE OF WELD OR
AUXILIARY LOAD
X
.424
O
HM
S
M
AX AT 25C
2 TURNS
ENGINE IN THIS DIRECTION
W
REMOTE
RECEPTACLE
DIODE AND MOV ASSEMBLY
CURRENT SENSING PC BOARD
SHUNT
FIELD
SERIES FIELD
SELECTOR SWITCH
LOCAL / REMOTE
SWITCH
MOUNTED TO NEGATIVE
BRUSH HOLDER
SCHEMATIC S25973
-
+
90-MIN
4
3
2
DRIVER
CIRCUITS
130-80
190-120
240-160
220-MAX
SHOWN IN LOCAL
POSITION
FJW-5AP
THIS CIRCUIT USES THE
RESIDUAL MAGNETISM OF
THE GENERATOR TO FLASH
THE EXCITE THE ROTOR
WHICH IN TURN PROVIDES
THE EXCITATION FOR THE
GENERATOR
-
+
COIL PAIR:
67B
842
12 VOLT SUPPLY
25.2 - 26.7
INTERPOLE
COILS
OHMS EACH
1
LIGHT CODE
FAILURE DETECTED
POSSIBLE CAUSE - CORRECTIVE MEASURE
3 TURNS
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
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED - CHECK
BROKEN OR LOOSE BELT - INSPECT
WELDING
GENERATOR
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
"L" TERMINAL IS GROUNDED ON ALTERNATOR
COM
CAPACITOR: MFD/
RESISTOR: OHMS/WATTS
P
ON
E
NT
V
ALUE
UNITS:
67A
LONG 1, SHORT 3
FOR 1 SECOND
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE SHORTED TO GROUND - CHECK
FAULTY ALTERNATOR - CHECK
_
VOLTS
AMOUNT OR QUALITY OF COOLANT INCORRECT - CHECK
+
HIGH WATER TEMPERATURE DETECTED FOR 1
LONG 1, SHORT 4
SECOND
FAULTY WATER TEMPERATURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING
LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED - CHECK
NEGATIVE OUTPUT
TERMINAL
POSITIVE OUTPUT
TERMINAL
CONNECTOR PIN NUMBERS:
LONG 1, SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS
TYPICAL OCV (WARM MACHINE):
94-99.0 VOLTS AT MAX RHEOSTAT
44-54.5 VOLTS AT MIN RHEOSTAT
0 RPM IS DETECTED AND 12V IS DETECTED
LONG 2, SHORT 1
FAULTY RPM SENSOR - CHECK FOR GOOD CONNECTION
LE
A
D
COLOR CODE:
EX.
12
PIN CONNECTOR
LABELS:
FROM "L" TERMINAL ON ALTERNATOR
FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU
FAULTY ACTUATOR - CHECK FOR PROPER COIL RESISTANCE
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK
B-BLACK OR GRAY
G-GREEN
2
1
7
6
LONG 2, SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT
LONG 2, SHORT3 NOT ENABLED FOR LINCOLN PRODUCTS
LONG 2, SHORT4 -50C WATER TEMPERATURE DETECTED
UNDER LEFT DOOR
COMMON
FRAM ROUND
EARTH GROUND
R-RE
U-BLU
W- HIT
Y-YELLO
N-BROWN
D
OR
PINK
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN - CHECK FOR CONTINUITY
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN - CHECK FOR CONTINUITY
BROKEN OR LOOSE BELT - INSPECT
E
E
G
12
LATC
W
E
W
H
LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED
VIEW O
F
CONNECTOR ON PC BOARD
0 VOLTS DETECTED FROM "L" TERMINAL ON
LONG 2, SHORT 6
HIS DOCUME
N
T CONTAINS P
R
OPRIETARY INFORMATIO
FOR ANY P RPOSE WITHOUT THE E
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
RITTEN PERMISSIO
N
D MAY NOT BE UPLICATED,
D
COMMUNICATE
D
ALTERNATOR FOR 1 SECOND
PROPRIETARY & CONFIDENTIAL:TTO OT
HER PA
R
TIES O USE
R
D
U
X
PRESS
W
N
OF LIN
C
OLN GLOBAL, INC.
FAULTY ALTERNATOR - CHECK
U
NLESS OTHERWISE SPE
CIFIED TOLERANCE
TOLERANCE PER E2056
INCORRECT BATTERY - INSPECT
DESIGN INFORM
A
TION
REFERENCE:
L12020
MANUFACTURIN
G
LONG 2, SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR
EQUIPMENT TYPE
SUBJECT:
:
_1__
_1__
OF
CLASSIC 300D (KUBOTA V2203M)
MACHINE SCHEMATIC
PAGE
DOCUMENT
UMB R:
FAULTY ALTERNATOR - CHECK
ON 2 PLACE DECIMALS IS .02
ON 3 PLACE D CIMALS I .002
DM
DRAWN BY:
E
S
DOCUMENT
REVISION:
LESS THAN 4 VOLTS TO RPM SENSOR AND/OR
LONG 2, SHORT 8
ON ALL ANGLES IS .5 OF A DEGREE
N
E
E
NGINEER:
J.STAPP
MATERIAL TOLERANCE (" ") TO AGREE
t
SCALE:
ACTUATOR SENSED BY ECU
FAULTY ECU - CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU
WITH PUBLISHED STANDARDS.
MATERIAL
DISPOSITION:
APPROVAL
DATE:
PROJECT
NUMBER:
L12265
A
CRM35580
UF
APPROVED:
NONE
06/08/2004
DO NOT SCALE THIS
DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-16
G-16
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - (CODES 11243, 11244) (L12265-1)
1
2 6 1 5 2 - L
CHANG
E
DETAIL: New
ENGINEERING CONTROLLED
JUMPER PLUG IS BEHIND LOWER
RIGHT SIDE OF CONTROL PANEL
MANUFACTURER:
No
LOWER RIGHT OF CONTROL PANEL
AMMETER SHOWS FULL
DISCHARGE WHILE PRESSING
GLOW PLUG SWITCH
RPM CONTROL POTENTIOMETER
K924-5 REMOTE CONTROL
(OPTIONAL)
12 VOLT SUPPLY
11
2
87
86
88
1
GLOW PLUG
BUTTON
10,000 +/- 1,000 OHMS MAX
94
93
20
17
ENGINE
SPEED
SENSOR
TURN POT COUNTERCLOCKWISE TO
REDUCE RESISTANCE AND SUBSEQUENTLY
REDUCE RPM BY UP TO 150RPM
BACK, LEFT SIDE OF ENGINE
ALTERNATOR
RATED VOLTAGE: 12V
RATED CURRENT: 22mA MAX
2
ENGINE CONTROL UNIT (ECU)
53
CCW
GLOW PLUGS
LOCATED BEHIND UPPER PORTION OF CONTROL PANEL
3
3
4
BACK, RIGHT
60A
RATED VOLTAGE: 12V
51C
SIDEOFENGINE
TYPICAL CURRENT
DRAW IS 40 AMPS
RATED CURRENT: 4.5A(MAX.)-TERMINAL #15
LEAKAGE CURRENT 10micro A (MAX.)-TERMINAL #16
40 AMP / 12 VOLT
REMOTE CONTROL PLUG
L
26
64
69
13
34
G
SENSES ALTERNATOR OUTPUT
SENSOR OPERATION:
-4vF -> 18.80 kOHMS
104vF -> 1.14 kOHMS
212vF -> .16 kOHMS
IG
B
WATER
TEMP.
FLASHES ALTERNATOR
212E
SENSOR
-40 TO 40 AMPS
AMMETER
Y
16
15
51B
60
IGNITION
SWITCH
BACK, LEFT
51
BACK, BOTTOM
X
SIDE OF ENGINE
-
OF MACHINE
RATED VOLTAGE: 12V
RATED CURRENT: 2A
COIL RESISTENCE:
2.8 +/- .28 OHMS AT 20vC
ENERGIZED FOR RUN
DE-ENERGIZED FOR STOP
ACTUATOR CONTROLS RPM
MECHANICAL STOP WILL SHUT
DOWN THE ENGINE AT 115%
OF RATED SPEED.
1
10
9
17
212D
51A
50
STARTER
SOLENOID
+
SHOWN IN "OFF"
POSITION
+
W
25+/-1.25 OHMS EACH
BATTERY
57
18
26
25
34
12.6 VOLTS MIN
AT REST
14-14.5 VOLTS
WHILE RUNNING
12 VOLT
SUPPLY
212A
STARTER
MOTOR
BACK, LEFT SIDE OF ENGINE
S
I
ACTUATOR
50A
28
43
44
BACK, RIGHT
CCW
TEMPERATURE
GAUGE
W
G
G
SIDE OF ENGINE
56
18
9
64+/-6.4 OHM MAX
S
START
BUTTON
TEMPERATURE SWITCH / SENDER
LOWER LEFT OF
ECU CONNECTOR DETAIL
ENGINE
212B
CONTROL PANEL
SENDER OPERATION:
RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY
OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED
WHEN THE IGNITION SWITCH IS "ON" AND THE ECU
SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT
SWITCH CLOSES
PROTECTION
LIGHT
140vF -> 134+/-13.5 OHMS
194vF -> 51.2+/-4.3 OHMS
212vF -> 38.5+/-3 OHMS
COLOR: RED
12 VOLT
NORMALLY OFF
AT 230v+/-6vF
62
61
SENDER IS APPROX.
500 OHMS AT 70vF
RHEOSTAT
CENTER OF
THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING THE ENGINE
PROTECTION LIGHT IN A CODED SEQUENCE, SEE CHART FOR FAULT
CODES AND CORRECTIVE MEASURES. WHEN THE ENGINE IS SHUT
DOWN DUE TO A FAULT, THE IGNITION SWITCH WILL NEED TO BE
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
841A
CONTROL PANEL
FRONT, LEFT SIDE OF ENGINE
212C
DOWN DUE TO A FAULT (EVEN IF T
DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING
OUT OF UEL), THE IGNITION SWITCH WILL NEED TO BE
HAT CONDITION
S
I
OIL PRESSURE
GAUGE
200
54
27
12
REMOTE CONTROL BOX
+
58
6
WK
G
F
G
HOUR METER
52A
LOWER LEFT OF
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
CENTER OF
CONTROL PANEL
OIL PRESSURE SWITCH / SENDER
1
19
31
30
32
7
CONTROL PANEL
SWITCH CLOSES
AT 6+/-2 PSI
SENDER OPERATION:
0 PSI -> 10+/-5 OHMS
40PSI -> 105+/-5 OHMS
80 PSI -> 187+/-5 OHMS
STARTER
RELAY
THE P10 PLUG IS ONLY ON UNITS
WITHOUT THE WIRE FEED MODULE.
THE WIRE FEED MODULE HAS A
HARNESS THAT PLUGS DIRECTLY
INTO J5.
CONNECT TO
GROUND FOR
1600RPM, LEAVE
UNCONNECTED
FOR 1800RPM
CONNECT TO
GROUND FOR
800RPM
60E
70B
70A
60F
WIRE-TIEDTOHARNESS
BEHIND CONTROL PANEL
52B
P10
844A
55
12 11 10
48
9
8
7
6
5
4
3
2
1
FLYBACK DIODE PREVENTS
BOTH OPEN LEADS ARE WIRE-TIED INSIDE THE HARNESS BEHIND CONTROL PANEL
841B
VOLTAGE SPIKES IN SHUNT FIELD
FROM DAMAGING LOCAL/REMOTE
TOGGLE SWITCH WHEN SWITCHED
J5
400D
400E
GND-B
JUMPER PLUG IS FOR CONNECTION
TO WIRE FEED MODULE
610
WINDING SPEC: ALT-241-3A
40.5 - 42.5 OHMS AT 25C
+
20
A
15
CB3
A
610A
600C
610
+
-
CB1
U
U
N
N
W
W
Y
Y
DIODE
AC
AC
JUMPER PLUG IS WIRE-TIED UP
BEHIND LOCAL / REMOTE SWITCH ON
RIGHT SIDEOFMACHINE(ASVIEWED
FROM CONTROL PANEL)
EXCITER REVOLVING
FIELD (ROTOR)
LOWER, RIGHT SIDE OF CONTROL PANEL
IDLER SWITCH
SHOWN IN "AUTO
IDLE" POSITION
11
A
600B
600A
-
21
SLIP RINGS
POSITIVE SLIP RING
IS NEAREST TO IRON
400F
7A
FUSE
15A
HOT
L
I
NE
HOT LOAD
EXCITER CIRCUIT
LEAD 21A TO 21B
WINDING SPEC: ALT-214-2B
.488 OHMS MAX AT 25C
21
5
115 VOLT GFCI
RECEPTACLE
RHEOSTAT
LOWER,
GND-S
CCW
64+/-6.4 OHMS MAX
RIGHT OF
CONTROL
PANEL
WHITE
L
I
NE WHITE LOAD
230 VOLT
RECEPTACLE
21
4
602B
GND-E
41
42
GND-T
602A
4
6A
81
82
0
115
EAD
WINDING SPEC: ALT-214-2
V
OLT CIRCUIT
JUMPER PLUG IS
WIRE-TIEDUP
841
844
J8
CB4
15
L
8
10 TO 20
8
A
EXCITER STATOR
(ALTERNATOR)
6
5
3
1
2
C
BEHIND LOCAL /
REMOTE SWITCH
P9
0
.230
O
HM
S
M
AX AT 25C
IN-LINE BOLTED CONNECTION
BEHIND CONTROL PANEL
41
G
ON RIGHT SIDE OF
MACHINE
600
Y
11C
115
V
OLT CIRCUIT
20 TO 30
WINDING SPEC: ALT-214-2
42
602
11B
LEAD
8
8
D
WITH AC AUXILIARY POWER,
ROUTING DIRECTIONS OF THESE
LEADS DOES NOT MATTER
GENERATOR LEAD BLOCK
LOCATED BEHIND UPPER LEFT
PORTION OF CONTROL PANEL
SENSOR GROUNDS LEAD
ON SENSE OF WELD OR
AUXILIARY LOAD
X
SHOWN AS VIEWED WITH
.424
O
HM
S
M
AX AT 25C
2 TURNS
ENGINE IN THIS DIRECTION
W
REMOTE
RECEPTACLE
DIODE AND MOV ASSEMBLY
CURRENT SENSING PC BOARD
SHUNT
FIELD
SERIES FIELD
SELECTOR SWITCH
LOCAL / REMOTE
SWITCH
MOUNTED TO NEGATIVE
BRUSH HOLDER
SCHEMATIC S25973
-
+
90-MIN
4
3
2
DRIVER
CIRCUITS
130-80
190-120
240-160
220-MAX
SHOWN IN LOCAL
POSITION
FJW-5AP
THIS CIRCUIT USES THE
RESIDUAL MAGNETISM OF
THE GENERATOR TO FLASH
THE EXCITE THE ROTOR
WHICH IN TURN PROVIDES
THE EXCITATION FOR THE
GENERATOR
-
+
COIL PAIR:
67B
3 TURNS
842
12 VOLT SUPPLY
25.2 - 26.7
INTERPOLE
COILS
OHMS EACH
1
LIGHT CODE
FAILURE DETECTED
POSSIBLE CAUSE - CORRECTIVE MEASURE
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
WELDING
GENERATOR
FAULTY OIL PRESSURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS RUNNING
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED - CHECK
BROKEN OR LOOSE BELT - INSPECT
"L" TERMINAL IS GROUNDED ON ALTERNATOR
COM
CAPACITOR: MFD/
RESISTOR: OHMS/WATTS
P
ON
E
NT
V
ALUE
UNITS:
67A
LONG 1, SHORT 3
LONG 1, SHORT 4
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE SHORTED TO GROUND - CHECK
FAULTY ALTERNATOR - CHECK
FOR 1 SECOND
_
VOLTS
AMOUNT OR QUALITY OF COOLANT INCORRECT - CHECK
+
HIGH WATER TEMPERATURE DETECTED FOR 1
SECOND
FAULTY WATER TEMPERATURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING
LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED - CHECK
NEGATIVE OUTPUT
TERMINAL
POSITIVE OUTPUT
TERMINAL
CONNECTOR PIN NUMBERS:
LONG 1, SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS
TYPICAL OCV (WARM MACHINE):
94-99.0 VOLTS AT MAX RHEOSTAT
44-54.5 VOLTS AT MIN RHEOSTAT
0 RPM IS DETECTED AND 12V IS DETECTED
LONG 2, SHORT 1
FAULTY RPM SENSOR - CHECK FOR GOOD CONNECTION
LE
A
D
COLOR CODE:
EX.
12
PIN CONNECTOR
LABELS:
FROM "L" TERMINAL ON ALTERNATOR
FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU
FAULTY ACTUATOR - CHECK FOR PROPER COIL RESISTANCE
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK
B-BLACK OR GRAY
G-GREEN
2
1
7
6
LONG 2, SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT
LONG 2, SHORT3 NOT ENABLED FOR LINCOLN PRODUCTS
LONG 2, SHORT4 -50C WATER TEMPERATURE DETECTED
UNDER LEFT DOOR
COMMON
FRAM ROUND
EARTH GROUND
R-RE
U-BLU
W- HIT
Y-YELLO
N-BROWN
D
OR
PINK
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN - CHECK FOR CONTINUITY
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN - CHECK FOR CONTINUITY
BROKEN OR LOOSE BELT - INSPECT
E
E
G
12
LATC
W
E
W
H
LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED
VIEW O
F
CONNECTOR ON PC BOARD
0 VOLTS DETECTED FROM "L" TERMINAL ON
LONG 2, SHORT 6
HIS DOCUME
N
T CONTAINS P
R
OPRIETARY INFORMATIO
FOR ANY P RPOSE WITHOUT THE E
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
RITTEN PERMISSIO
N
D MAY NOT BE UPLICATED,
D
COMMUNICATE
D
ALTERNATOR FOR 1 SECOND
PROPRIETARY & CONFIDENTIAL:TTO OT
HER PA
R
TIES O USE
R
D
U
X
PRESS
W
N
OF LIN
C
OLN GLOBAL, INC.
FAULTY ALTERNATOR - CHECK
U
NLESS OTHERWISE SPE
CIFIED TOLERANCE
TOLERANCE PER E2056
INCORRECT BATTERY - INSPECT
DESIGN INFORM
A
TION
REFERENCE:
L12265
MANUFACTURIN
G
LONG 2, SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR
EQUIPMENT TYPE
SUBJECT:
:
_1__
_1__
OF
CLASSIC 300D (KUBOTA V2203M)
MACHINE SCHEMATIC
PAGE
DOCUMENT
UMB R:
FAULTY ALTERNATOR - CHECK
ON 2 PLACE DECIMALS IS .02
ON 3 PLACE D CIMALS I .002
Maglietta
DRAWN
NGINEER: N. TAYLOR
APPROVED:
BY:
E
S
DOCUMENT
REVISION:
LESS THAN 4 VOLTS TO RPM SENSOR AND/OR
LONG 2, SHORT 8
ON ALL ANGLES IS .5 OF A DEGREE
N
E
MATERIAL TOLERANCE (" ") TO AGREE
t
E
SCALE:
ACTUATOR SENSED BY ECU
FAULTY ECU - CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU
WITH PUBLISHED STANDARDS.
MATERIAL
DISPOSITION:
APPROVAL
DATE:
PROJECT
NUMBER:
L12265-1
A
CRM34902
NA
NONE
03/11/2005
DO NOT SCALE THIS
DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-17
SCHEMATIC - COMPLETE MACHINE - (CODES 11248, 11249, 11280, 11281) (L12561)
G-17
ELECTRICAL DIAGRAMS
1
1 2 L 5 6
CHANG
E
DET
AIL: ADDED "ON
NEWER BOARDS..."
ENGINEERING CONTROLLED
MANUFACTURER:
No
K924-5 REMOTE CONTROL
(OPTIONAL)
CENTE
R
OF CONTROL PANEL
THI
S
LE
A
D
P
RO
V
IDES FLASH
AND
OUTPUT
BACK, LEFT SID
65 AM / 12 OLT
ALTERNATO
E
OF
E
NGINE
FOR ALTERNATO
R
12 VOLT - NORMALLY OFF
AMMET
DISCHARGE WHILE PRESSIN
GLO PLUG SWITCH
E
R
SHOWS FULL
IDLER / ENGINE PROTECTION PC BOARD
P
V
R
SENSES ALTERNATO
R
G
RE
ROT
LIGHT
D
E
E
NGIN
E
LOCAT
ED
BEHIND
UPPER
PORTIO
N
OF CONTROL PANEL
GLO PLUG
SWITCH
W
W
P
CTIO
N
SCHEMATI
C
G4828-1
J1-4
61
60C
59
J1-3
D+
ENGIN
E
53
BACK
,
RIGHT
S
ID
E
OF
E
NGINE
SHUTDOWN
N.C.
B+
B3
55
57
WHITE
IDLE SOLENOID
REMOTE CONTROL PLUG
P
ULL COIL
51C
-
RI NJ SCTEIOONF
E
IN
E
BY
I
GHTEID
PUNMG
P
TY
RESISTANCE:
HOL COIL: 1
ULL COIL: 40A, LESS TH
PICAL CURRENT DRAW AND
G
J1-8
40 TO 40 AMPS
AMMETER
RED
HOL COIL
D
N.O.
E
INJ
E
CTIO
N
BLACK
D
A, 10-15 OHMS
J1-9
58
GND-C
FLYBACK
DIODES
Y
PUMP
+
-
P
A
N
.1 OHM
212E
GLO
W
PLUGS
51
E
NGIN
S
OLENOID
APPRO IMAT
RESISTANCE: 3.3 OHM
TY ICAL CURRENT DRAW: 3.3
X
RUNNING
51A
212C
56
TY
DRAW
PICAL CURRENT
J1-2
J1-1
58H
X
E
10A
B4
IS
40 +/- 3 AMPS
IGNITIO
SWITCH
HO
N
212D
25+/-1.25 OHMS EACH
S
W
C
50A
CLOOWE EFT OF
NTRROLL PANEL
P
A
S
W
N IN "OFF"
212A
BACK, LEFT SID
E
OF
ENGINE
50
POSITION
RIGOHITL SFIIDLLE
E
OF
ENGINE
S
I
J1-6
43
44
BY
R
ST
ART
CCW
TEMPERATURE
W
G
/
64+/-6.4 OHM MAX
S
G
SWITCH
FUEL
P
UM
IMAT
RESISTANCE: 3-4 OHM
P
GAUG
E
E
NGIN
ROT CTIO
CIRCUIT
ELO
LOGIC)
E
OBAFCMKA
B
TOM
, CHOITNE
TEMPERATURE SWITCH
SWITCH CLOSES
SENDER
OPERATION:
-> 134+/-13.5 OHMS
APPRO
X
E
P
E
N
52
CLOOWE EFT OF
NTRROLL PANEL
SENDE
R
ST
S
ARTER
OLENOID
212B
S
S
(SEE
FOR
+
AT 230v+/-6vF
140v
F
B
W
BATTERY
RHEOSTAT
TY
PICAL CURRENT DRAW: 3
A
194v
F
-> 51.2+/-4.3 OHM
-> 38.5+/-3 OHM
E
S
2N12Gv
F
S
S
G
SENDE
500 OHM
R
IS APPROX.
AT 70vF
+
J1-10
60
93
12.6 VOLTS MIN
AT REST
ST
A
RTE
MOTOR
R
BACK, TO
P
OF
E
IN
S
REMOTE CONTROL BOX
HOUR METER
OIL PRESSURE
GAUG
J1-7
20
0
I
14
-14.5 VOLTS
54
CCEONNTTEROL
R
OF
J1-5
J2-1
J2-2
E
WHIL
E
RUNNING
PANEL
WK
G
UNUSED
CLOOWE EFT OF
NTRROLL PANEL
OIL PRESSURE SWITCH
SWITCH CLOSES
SENDE
AT 6 /-2 PSI
0 P I -> 10
40PSI -> 105+/-5 OHMS
/
SENDER
OPERATION:
/-5 OHMS
B1
REVERSE VOLTAG
E
R
P
ROT CTION DIODE
E
IDL
OLENOID
CI UIT
(SEE BELO
FOR LOGIC)
E
60A
+
S
+
S
AUX LO
B2
AD
SENSIN
G
B4
B5
B6
FLYBACK DIODE PREVENTS
OLTAGE SPIKES SHUNT FIELD
FROM AM GING LOCAL/ EMOTE
TOGGLE SWITCH WHE SWITCHED
R
S
80 PSI -> 187+/-5 OHMS
UNUSED
W
V
IN
W
ELD LO SENSING
A
D
THE P10 PLUG
THE IR FE
MODUL AS A
I
S
O
NL
Y
ON UNITS WITHOUT
D
A
R
J2-3
W
E
E
D MODUL
E
. THE WIR
E
FEED
P10
J5
E
NGINE PROT
E
CTION CIRCUIT LOGIC
J2-4
N
E
H
H
ARNESS THAT PLUG
S
ON
J1 B
B5 AN
N
EWE
R
BOARDS,
12 11 10
48
9
8
7
6
5
4
3
2
1
DIRECTLY INTO J5.
1. U
IGNITIO
FUEL UMP AN
ENERGIZED.
PON
RE
CIEVING POWER FROM TH
SWITCH, TH FUEL OLENOID
HO R MET ARE
E
S
HO
W
N IN "AUTO
IDLE" POSITION
JUMPE
TO WIR
R
E
PLUG
FEED MODULE
I
S
FOR CONNECTIO
N
E
COMES J31, J2 B
E
COMES J32,
GND-B
400D
84
4
N
E
U
S
ER
,
D
B6 T
ERMINALS ARE ELET
D
ED.
IDLER
SWITCH
20A
P
D
JUMPE
R
PLUAGLISWIRE-TIED
U
P
400E
RBEIGHHINTD LIDOC
/
R
EMOTE SWITCH
O
N
DC EXCITER
61
0
2.
FOR ONE MI
PRESSURE BUILDUP
ST RTE ITHI ON
TURNING IGNITIO SWITCH ON OR TH
E
NGINE PROT
UTE TO ALLO
NGIN
MI UTE OF
E
CTIO
N
IS BYPASSED
OIL
MUST BE
S
FROM CO EOF MPANEL)
NTROL ACHINE (AS VIEWED
W
INDING SPEC: ALT
-
241-3A
+
15A
B3
61
0
N
W
+
610A
40.5 - 42.5 OHM
S
AT 25C
C
U
U
N
N
Y
Y
W
W
DILOODE
AC
.
E
E
E
AC
CB1
EXCIT
E
R
REVOLVING
WER, RIGHT
SID
E
OF CONTROL PANEL
A
D
W
N
N
11A
FIELD (ROTOR)
N
E
600B
-
600C
-
FUEL
MET
S
R
OLENOID, FUEL
ILL TURN OFF. AFTER
IGNITIO
OFF A BACK
P
UMP AN
D
HOUR
ONE
SWITCH MUST BE
N TO ST RT
21
SLI
POSITIV
IS EAREST TO IRO
P
E
RINGS
P
600A
400F
115 VOLT GFCI
7A
E
W
TOP,
R
NIGTHRTOPLORTIO
N
FUSE
SLI RING
RECEPTACLE
MINUTE, TH
CYCL
NGINE.
E
N
OF CO
PANEL
15A
N
N
EXCIT
EAD 21
INDING SPEC: ALT
.488 OHM AX AT 25C
E
R CIRCUIT
HOT
L
IN
E
HOT
L
OAD
215
ED
N
D
O
A
RHEOSTAT
64+/-6.4 OHM
LOGWHTERO,F
CCW
L
W
A
TO 21B
E
S
MAX
RI
-214-2B
W
HI
T
E
LINE
W
HI
T
E
LOAD
230 VOLT
RECEPT CL
602B
21
4
CONTROL
PANEL
S
M
A
E
3. AFTER
CURRENT IS SUPPLI
ALTERNATOR.
ENGIN
E
ST
ARTS, FLA
SHING
D TO THE ENGINE
GND-E
41
42
602A
4
E
6A
81
0
115 VOLT CIRCUIT
EAD 810 TO 820
INDING SPEC: ALT
.230 OHM AX AT 25C
J8
GND-
T
15A
B2
L
W
11C
GND-S
C
EXCIT
(ALTER
E
N
R
STATO
R
6
5
3
1
2
-214-2C
4. AFTER
OUT. IF OIL PRESSURE
COOLANT TEMPERATURE
ALTERNATO IS OT CHARGING, TH
NGINE WILL S UT DOW AND TH
NGINE PROT CTION LIGHT ILL COM
ON
ONE MI
N
UTE, TIM
LOW,
HIGH OR
E
R
IS TIMED
ATOR)
P9
82
0
S
M
I
S
JUIRMPE
R
PLUG ISHI
IN-LINE BOLTED CONNECTIO
N
41
60
Y
0
IS
W
E-TIED
U
PBE ND
BEHI
N
D
CONTROL PANEL
115 VOLT CIRCUIT
EAD 820 TO 830
INDING SPEC: ALT-214-2D
G
42
60
2
R
N
E
LOC
/
ITCH RENMROITE
SW AL
11B
GENERATOR LEA
L
W
.424 OHM
E
E
H
E
N
E
S
ID
E
OF OMACHGINHET
D
BLOCK
ITH
CTIO
W
E
X
844A
S
HO
WN
AS VIEWE
D
W
S
M
AX AT 25C
OF COLENFTTROPOL PANEL
.
TOP,
RTION
ENGIN
E
IN THIS DIR
E
N
W
IDLE SOLENOID CIRUIT LOGIC
1. WHEN THE ENGIN UNNING N HIGH
OR NDER LO D, THE SOLENOID OT
ENERGIZED.
REMOTE
MOUNTE
NEGATIVE
BRUS
H
HDOLTDOER
RECEPTACLE
E
I
S
R
I
IDLE
SHUNT
FIELD
SERIES FIEL
D
S
ELECTOR SWITCH
LOCAL
/
REMOTE
U
A
IS
N
-
+
-
SWITCH
DIODE AND MOV ASSEMBL
Y
90-MIN
130-80
190-12
S
HO N IN LOCAL
W
FJW-5AP
COIL PAIR
25.2 - 26.7
THI CIR UIT USES TH
S
C
E
+
2. IF N
LOA
IDL
HOL
O
AUXILIARY
IS SENSED FOR 15 SECONDS AND THE
SWITCH
COIL OF TH
C
URRENT DRAW OR
WEL
D
POSITION
0
:
RESID AL M GNETISM OF
THE ENERATOR TO FLASH
THE EXCIT TH OTOR
HI H IN TUR RO IDES
THE EXCITATION FOR TH
U
A
D
G
240-16
0
E
R
IS
O
E
PEN (AUTO), THE
DL OLENOID ARE
E-ENERGIZED
PULL AND
INTERPOLE
COILS
OHMS EACH
E
E
R
220-MAX
D
I
ER
S
W
C
N
P
V
ENERGIZED. THE PULL COIL I
S
D
E
AFTER ALF A SECO D.
H
N
GENERATO
R
COM
CAPACITOR: MFD/
RESISTOR: OHMS/WATTS
PONENT
V
ALUE
UNITS:
3. IF AN AUXILIARY CURRENT DRAW OR WELD
LOAD IS SENSED OR THE IDLER SWITCH IS CLOSED
(HIGH), THE IDLE SOLENOID IS DE-ENERGIZED.
V
OLTS
BACK OF OUTPUT STU
REE SWITCH
SWITCH CLOSES
D
WELDING
GENERATOR
BRUS
VIEWED FROM CONTROL PANEL
H
POSITION
S
HO
W
N
AS
D
CONNECTOR PIN NUMBERS:
W
ITH FLO
W
C
OF
URRENT
GND-A
WELDING
LE
A
D
COLOR CODE:
EX.
12
PIN CONNECTOR
LA
BELS:
_
+
B-BLACK OR GRAY
G-GREEN
2
1
7
PROPRIETARY & CONFIDENTIAL:TTO OT
6
HIS DOCUME
N
T CONTAINS P
R
OPRIETARY INFORMATIO
FOR ANY P RPOSE WITHOUT THE E
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
N
D MAY NOT BE
N
D
UPLICATED,
COMMUNICATE
D
POSITIV
TERMINAL
E
O
UTPUT
HER PA
RTIES O USE
R
D
U
X
PRESS
W
RITTEN PERMISSIO OF LINCOLN GLOBAL, INC.
NEGATIVE OUTPUT
COMMON
FRAM ROUND
EARTH GROUND
U
NLESS OTHERWISE SPE
MANUFACTURIN TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS .02
ON 3 PLACE D CIMALS I .002
CIFIED TOLERANCE
R-RE
U-BLU
W- HIT
Y-YELLO
N-BROWN
D
E
OR
P
INK
TERMINAL
RM MACHI E):
99.0 VOLTS AT MAX HEOSTAT
54.5 VOLTS AT MI RHEOSTAT
DESIGN INFORM
A
TION
REFERENCE:
L12412
G
EQUIPMENT TYPE
SUBJECT:
MATERIAL
DISPOSITION:
:
_1__
_1__
OF
CLASSIC 300D PERKINS 404C-22
MACHINE SCHEMATIC
PAGE
DOCUMENT
UMB R:
E
G
TYPICAL OC
V
(W
A
N
12
LATC
DFM
DRAWN
NGINEER: N. TAYLOR
APPROVED:
BY:
E
S
DOCUMENT
REVISION:
W
E
ON ALL ANGLES IS .5 OF A DEGREE
94
44
-
-
R
U
NDER LEFT DOO
R
H
N
E
MATERIAL TOLERANCE (" ") TO AGREE
t
E
SCALE:
W
N
WITH PUBLISHED STANDARDS.
APPROVAL
11/12/2004
PROJECT
NUMBER:
VIEW O
F
CONNECTOR ON PC BOARD
L12561
B
C
RM36948
UF
NA
DATE:
DO NOT SCALE THIS
DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-18
G-18
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - (CODES 11411, 11412) (L13096)
6
1 3 L 0 9
CHANG
E
DETAIL: New
ENGINEERING CONTROL
MANUFACTURER:
LED
No
CENTE
12 VOLT - NORMALLY OFF
R
OF CONTROL PANEL
THI
S
LE
A
D
P
RO
V
IDES FLASH
AND
OUTPUT
BACK, LEFT SID
65 AM / 12 OLT
ALTERNATO
E
OF
ENGINE
K924-5 REMOTE CONTROL
(OPTIONAL)
FOR ALTERNATO
R
AMMET
DISCHARGE WHILE PRESSIN
GLO PLUG SWITCH
E
R
SHOWS FULL
IDLER / ENGINE PROTECTION PC BOARD
P
V
R
SENSES ALTERNATO
R
G
RE
ROT
LIGHT
D
E
NGINE
LOCAT
ED
BEHIND
UPPE
R
P
ORTIO
N
OF CONTROL PANEL
GLO
SWITCH
W
PLUG
W
P
E
CTION
SCHEMATI
C
G4828-1
J1-4
60C
61
59
J1-3
D+
E
NGINE
53
BACK
,
RIGHT
S
ID
E
OF
E
NGINE
SHUTDOWN
N.C.
B+
B3
55
57
WHITE
IDLE SOLENOID
P
ULL COIL
51C
-
RI NJ SCTEIOONF
E
IN
E
BY
I
GHTEID
PUNMG
P
TY
RESISTANCE:
HOL COIL: 1
ULL COIL: 40A, LESS TH
PICAL CURRENT DRAW AND
REMOTE CONTROL PLUG
J1-8
40 TO 40 AMPS
AMMETER
RED
G
HOL COIL
D
N.O.
INJ
E
CTIO
N
BLACK
D
A, 10
-15 OHM
S
J1-9
E
GND-C
FLYBACK
DIODES
58
PUM
P
+
-
P
A
N
.1 OHM
212E
GLO
W
PLUGS
51
NGIN
E
Y
S
OLENOID
APPRO IMAT
RESISTANCE: 3.3 OHM
TY ICAL CURRENT DRAW: 3.3
RUNNING
51A
212C
56
TY
DRAW
PICAL CURRENT
J1-2
J1-1
58H
X
X
E
10A
B4
IS
40 +/- 3 AMPS
IGNITIO
SWITCH
HO
N
212D
S
C
50A
W
25+/-1.25 OHMS EACH
CLOOWE EFT OF
NTRROLL PANEL
P
A
S
W
N IN "OFF"
POSITION
212A
BACK, LEFT SID
E
OF
ENGINE
50
RIGOHITL SFIIDLLE
E
OF
E
NGINE
S
I
J1-6
43
44
BY
R
START
TEMPERATURE
W
G
/
CCW
G
SWITCH
FUEL
APPRO
P
X
UM
IMAT
RESISTANCE: 3-4 OHM
P
GAUG
E
E
NGIN
ROT CTIO
CIRCUIT
ELO
LOGIC)
E
OBAFCMKA
B
TOM
, CHOITNE
64+/-6.4 OHM MAX
S
TEMPERATURE SWITCH
SWITCH CLOSES
AT 230v+/-6vF
SENDER
OPERATION:
-> 134+/-13.5 OHMS
E
P
E
N
52
CLOOWE EFT OF
NTRROLL PANEL
SENDE
R
ST
S
ARTER
OLENOID
212B
S
S
(SEE
FOR
+
140v
F
B
W
B
ATTERY
TY
PICAL CURRENT DRAW: 3
A
194v
F
-> 51.2+/-4.3 OHM
S
RHEOSTAT
2N12Gv
F
-> 38.5+/-3 OHM
S
S
G
SENDE
R
IS APPROX.
AT 70vF
+
J1-10
60
93
12.6 VOLTS MIN
AT REST
ST
A
RTER
BACK, TO
P
OF
E
IN
E
500 OHMS
HOUR METER
MOTOR
R
EMOTE CONTROL BOX
OIL PRESSURE
J1-7
20
0
I
14
-
14.5 VOLTS
R
54
CCOENNTTEROL
R
OF
J1-5
J2-1
J2-2
GAUG
E
WHIL
E
UNNING
PANEL
WK
G
UNUSED
CLOOWE EFT OF
NTRROLL PANEL
OIL PRESSURE SWITCH
SWITCH CLOSES
SENDE
AT 6 /-2 PSI
0 P I -> 10
40PSI -> 105+/-5 OHMS
/
SENDER
OPERATION:
/-5 OHMS
B1
REVERSE VOLTAG
E
R
P
ROT CTION DIODE
E
IDL
OLENOID
CI UIT
(SEE BELO
FOR LOGIC)
E
60A
+
S
+
S
AUX LO
AD
SENSIN
G
B4
B5
B6
FLYBACK DIODE PREVENTS
OLTAGE SPIKES SHUNT FIELD
FROM AM GING LOCAL/ EMOTE
TOGGLE SWITCH WHE SWITCHED
R
S
80 PSI -> 187+/-5 OHMS
UNUSED
W
V
IN
W
ELD LO SENSING
A
D
THE P10 PLUG
THE IR FE
MODUL AS A
I
S
O
NL
Y
ON UNITS WITHOUT
D
A
R
J2-3
B2
W
E
E
D MODUL
E
. THE WIR
E
FEED
P10
J5
E
NGINE PROT
E
CTION CIRCUIT LOGIC
J2-4
N
E
H
H
ARNESS THAT PLUG
S
ON
J1 B
B5 AN
N
EWE
R
BOARDS,
12 11 10
48
9
8
7
6
5
4
3
2
1
DIRECTLY INTO J5.
1. U
IGNITIO
FUEL UMP AN
ENERGIZED.
PON
RE
CIEVING POWER FROM TH
SWITCH, TH FUEL OLENOID
HO R MET ARE
E
S
HO
W
N IN "AUTO
IDLE" POSITION
JUMPE
R
PLUG
IS
FOR CONNECTIO
N
E
COMES J31, J2 B
E
COMES J32,
GND-B
400D
84
4
N
E
U
S
ER
,
D
B6 T
ERMI
NALS ARE ELETED.
D
TO WIR
E
FEED MODULE
IDLE
R
SWITCH
20A
P
D
JUMPE
R
PLUAGLISWIRE-TIED
U
P
400E
15A
RBEIGHHINTD LIDOC
/
R
EMOTE SWITCH
O
N
DC EXCITER
61
0
2.
FOR ONE MI
PRESSURE BUILDUP
ST RTE ITHI ON
TURNING IGNITIO SWITCH ON OR TH
E
NGINE PROT
UTE TO ALLO
NGIN
MI UTE OF
E
CTIO
N
IS BYPASSED
OIL
MUST BE
S
FROM CO EOF MPANEL)
NTROL ACHINE (AS VIEWED
W
INDING SPEC: ALT
-
241-3A
+
61
0
N
W
+
610A
40.5 - 42.5 OHM
S
AT 25C
CB2
U
U
N
N
Y
Y
W
W
DILOODE
AC
.
E
E
E
C
B1
AC
EXCIT
E
R
REVOLVING
WER, RIGHT
SID
E
OF CONTROL PANEL
A
D
W
N
N
FIELD (ROTOR)
11A
7A
N
E
600B
-
P
600C
-
FUEL
MET
S
R
OLENOID, FUEL
ILL TURN OFF. AFTER
IGNITIO
OFF A BACK
P
UMP AN
D
HOUR
ONE
SWITCH MUST BE
N TO ST RT
21
SLI
P
RINGS
SLI RING
600A
400F
115 VOLT GFCI
E
W
TOP,
R
NIGTHRTOPLORTIO
N
POSITIV
E
FUS
E
6A
RECEPTACLE
MINUTE, TH
CYCL
NGINE.
E
N
OF CO
PANEL
15A
IS NEAREST TO IRONLO
EXCIT
EAD 21
INDING SPEC: ALT
.488 OHM AX AT 25C
E
R CIRCUIT
81
0
HOT
L
IN
E
HOT
L
OAD
215
ED
N
D
O
A
RHEOSTAT
64+/-6.4 OHM
GWHTERO,F
CCW
L
W
A
TO 21B
GND-E
E
S
MAX
RI
-214-2B
W
HI
T
E
LINE
W
HI
T
E
LOAD
602B
21
4
CONTROL
PANEL
S
M
230 VOLT
RECEPT CL
3. AFTER
CURRENT IS SUPPLI
ALTERNATOR.
ENGIN
E
ST
ARTS, FLA
SHING
D TO THE ENGINE
6A
41
42
A
E
602A
4
E
81
0
115 VOLT CIRCUIT
EAD 810 TO 820
INDING SPEC: ALT
.230 OHM AX AT 25C
82
0
J8
GND-
T
L
W
11C
GND-S
EXCIT
(ALTER
E
N
R
STATO
R
6
5
3
1
2
-214-2C
4. AFTER
OUT. IF OIL PRESSURE
COOLANT TEMPERATURE
ALTERNATO IS OT CHARGING, TH
NGINE WILL S UT DOW AND TH
NGINE PROT CTION LIGHT ILL COM
ON
ONE MI
N
UTE, TIM
LOW,
HIGH OR
E
R
IS TIMED
ATOR)
P9
82
0
S
M
I
S
JUIRMPE
R
PLUG ISHI
IN-LINE BOLTED CONNECTIO
N
41
60
Y
0
IS
W
E-TIED
U
PBE ND
BEHI
ND
CONTROL PANEL
115 VOLT CIRCUIT
EAD 820 TO 830
INDING SPEC: ALT-214-2D
G
42
60
2
R
N
E
LOC
/
ITCH RENMROITE
SW AL
11B
GENERATOR LEA
HO AS VIEWE
NGIN N THIS DIR
L
W
.424 OHM
E
E
H
E
N
E
S
ID
E
OF OMACHGINHET
D
BLOCK
ITH
CTIO
W
E
X
844A
S
E
W
N
D
W
S
M
AX AT 25C
OF COLENFTTROPOL PANEL
.
TOP,
RTION
E
I
E
N
W
IDLE SOLENOID CIRUIT LOGIC
1. WHEN THE ENGIN UNNING N HIGH
OR NDER LO D, THE SOLENOID OT
ENERGIZED.
REMOTE
MOUNTE
NEGATIVE
BRUS
H
HDOLTDOER
RECEPTACLE
E
IS
R
I
I
DLE
SHUNT
FIELD
SERIES FIEL
D
S
ELECTOR SWITCH
LOCAL
/
REMOTE
U
A
IS
N
-
+
-
SWITCH
DIODE AND MOV ASSEMBL
Y
90-MIN
130-80
190-12
S
HO N IN LOCAL
W
FJW-5AP
COIL PAIR
25.2 - 26.7
THI CIR UIT USES TH
S
C
E
+
2. IF N
LOA
IDL
HOL
O
AUXILIARY
C
URRENT DRAW OR
WEL
D
POSITION
0
:
RESID AL M GNETISM OF
THE ENERATOR TO FLASH
THE EXCIT TH OTOR
HI H IN TUR RO IDES
THE EXCITATION FOR TH
U
A
D
IS SENSED FOR 15 SECONDS AND TH
SWITCH PEN (AUTO), THE ULL AND
COIL OF TH DL OLENOID ARE
E-ENERGIZE
E
G
240-16
0
ER
IS
O
P
INTERPOLE
COILS
OHMS EACH
E
E
R
220-MAX
D
E
I
ER
S
W
C
N
P
V
ENERGIZED. THE PULL COIL I
S
D
D
E
AFTER ALF A SECO D.
H
N
GENERATO
R
COM
CAPACITOR: MFD/
RESISTOR: OHMS/WATTS
P
ON
E
NT
V
ALUE
UNITS:
3. IF AN AUXILIARY CURRENT DRAW OR WELD
LOAD IS SENSED OR THE IDLER SWITCH IS CLOSED
(HIGH), THE IDLE SOLENOID IS DE-ENERGIZED.
BACK OF OUTPUT STU
REE SWITCH
SWITCH CLOSES
ITH FLO OF
ELDING URRENT
GND-A
D
WELDING
GENERATOR
BRUS
VIEWED FROM CONTROL PANEL
H
POSITION
S
HO
W
N
AS
VOLTS
D
W
W
W
C
CONNECTOR PIN NUMBERS:
_
LE
AD
COLOR CODE:
EX.
12
PIN CONNECTOR
LABELS:
+
B-BLACK OR GRAY
G-GREEN
POSITIV
TERMINAL
E
OUTPUT
2
NEGATIVE OUTPUT
1
7
PROPRIETARY & CONFIDENTIAL:TTO OT
6
HIS DOCUME
N
T CONTAINS P
R
OPRIETARY INFORMATIO
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
N
D MAY NOT BE
D
UPLICATED,
COMMUNICATE
D
HER PA
RTIES O USE
R
D
FOR ANY P RPOSE WITHOUT THE E
U
XPRESS
W
RITTEN PERMISSIO
N
OF LINCOLN GLOBAL, INC.
TERMINAL
RM MACHI E):
99.0 VOLTS AT MAX HEOSTAT
54.5 VOLTS AT MI RHEOSTAT
COMMON
FRAM ROUND
EARTH GROUND
U
NLESS OTHERWISE SPE
MANUFACTURIN TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS .02
ON 3 PLACE D CIMALS I .002
CIFIED TOLERANCE
R-RE
U-BLU
W- HIT
Y-YELLO
N-BROWN
D
OR
PINK
DESIGN INFORM
A
TION
REFERENCE:
L12561
TY
P
ICAL OC
V
(W
A
N
G
EQUIPMENT TYPE
SUBJECT:
MATERIAL
DISPOSITION:
:
_1__
_1__
OF
CLASSIC 300D PERKINS 404C-22
MACHINE SCHEMATIC
PAGE
DOCUMENT
UMB R:
E
E
G
12
LATC
94
-
-
R
U
NDER LEFT DOO
R
Maglietta
DRAWN
NGINEER: D. BENDER
APPROVED:
BY:
E
S
DOCUMENT
REVISION:
W
E
ON ALL ANGLES IS .5 OF A DEGREE
H
44
N
N
E
MATERIAL TOLERANCE (" ") TO AGREE
t
E
SCALE:
W
WITH PUBLISHED STANDARDS.
APPROVAL
10/05/2006
PROJECT
NUMBER:
VIEW O
F
CONNECTOR ON PC BOARD
L13096
A
CRM37529
NA
NA
DATE:
DO NOT SCALE THIS
DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-19
G-19
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - (CODES 11413, 11414) (L13097)
7
1 3 L 0 9
CHANG
E
D
ET
A
IL: REVISED 115 VOLT GFCI RECEPT
A
CL
E
GRAPHICS
ENGINEERING CONTROLLED
JUMPER PLUG IS BEHIND LOWER
RIGHT SIDE OF CONTROL PANEL
MANUFACTURER:
No
LOWER RIGHT OF CONTROL PANEL
AMMETER SHOWS FULL
DISCHARGE WHILE PRESSING
GLOW PLUG SWITCH
RPM CONTROL POTENTIOMETER
K924-5 REMOTE CONTROL
(OPTIONAL)
12 VOLT SUPPLY
11
2
87
86
88
1
GLOW PLUG
BUTTON
10,000 +/- 1,000 OHMS MAX
94
93
20
17
ENGINE
SPEED
SENSOR
TURN POT COUNTERCLOCKWISE TO
REDUCE RESISTANCE AND SUBSEQUENTLY
REDUCE RPM BY UP TO 150RPM
BACK, LEFT SIDE OF ENGINE
ALTERNATOR
RATED VOLTAGE: 12V
RATED CURRENT: 22mA MAX
2
ENGINE CONTROL UNIT (ECU)
LOCATED BEHIND UPPER PORTION OF CONTROL PANEL
53
CCW
GLOW PLUGS
3
3
4
BACK, RIGHT
60A
RATED VOLTAGE: 12V
51C
SIDEOFENGINE
TYPICAL CURRENT
DRAW IS 40 AMPS
RATED CURRENT: 4.5A(MAX.)-TERMINAL #15
LEAKAGE CURRENT 10micro A (MAX.)-TERMINAL #16
40 AMP / 12 VOLT
REMOTE CONTROL PLUG
L
26
64
69
13
34
G
SENSES ALTERNATOR OUTPUT
SENSOR OPERATION:
-4vF -> 18.80 kOHMS
104vF -> 1.14 kOHMS
212vF -> .16 kOHMS
IG
B
WATER
TEMP.
FLASHES ALTERNATOR
212E
SENSOR
-40 TO 40 AMPS
AMMETER
Y
16
15
51B
60
IGNITION
SWITCH
BACK, LEFT
51
BACK, BOTTOM
X
SIDE OF ENGINE
-
OF MACHINE
RATED VOLTAGE: 12V
RATED CURRENT: 2A
COIL RESISTENCE:
2.8 +/- .28 OHMS AT 20vC
ENERGIZED FOR RUN
DE-ENERGIZED FOR STOP
ACTUATOR CONTROLS RPM
MECHANICAL STOP WILL SHUT
DOWN THE ENGINE AT 115%
OF RATED SPEED.
1
9
212D
51A
50
STARTER
SOLENOID
+
SHOWN IN "OFF"
POSITION
+
10
17
W
25+/-1.25 OHMS EACH
BATTERY
57
18
26
25
34
STARTER
MOTOR
12.6 VOLTS MIN
AT REST
14-14.5 VOLTS
WHILE RUNNING
12 VOLT
SUPPLY
BACK, LEFT SIDE OF ENGINE
212A
I
S
ACTUATOR
50A
28
43
44
BACK, RIGHT
CCW
TEMPERATURE
GAUGE
W
G
G
SIDE OF ENGINE
56
18
9
64+/-6.4 OHM MAX
S
START
BUTTON
TEMPERATURE SWITCH / SENDER
LOWER LEFT OF
ECU CONNECTOR DETAIL
ENGINE
212B
CONTROL PANEL
SENDER OPERATION:
RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY
OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED
WHEN THE IGNITION SWITCH IS "ON" AND THE ECU
SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT
SWITCH CLOSES
PROTECTION
LIGHT
140vF -> 134+/-13.5 OHMS
194vF -> 51.2+/-4.3 OHMS
212vF -> 38.5+/-3 OHMS
COLOR: RED
12 VOLT
NORMALLY OFF
AT 230v+/-6vF
62
61
SENDER IS APPROX.
500 OHMS AT 70vF
RHEOSTAT
CENTER OF
THE ECU WILL INDICATE FAULT CONDITIONS BY FLASHING THE ENGINE
PROTECTION LIGHT IN A CODED SEQUENCE, SEE CHART FOR FAULT
CODES AND CORRECTIVE MEASURES. WHEN THE ENGINE IS SHUT
DOWN DUE TO A FAULT, THE IGNITION SWITCH WILL NEED TO BE
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
841A
CONTROL PANEL
FRONT, LEFT SIDE OF ENGINE
212C
DOWN DUE TO A FAULT (EVEN IF T
DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING
OUT OF UEL), THE IGNITION SWITCH WILL NEED TO BE
HAT CONDITION
S
OIL PRESSURE
GAUGE
200
I
54
27
12
REMOTE CONTROL BOX
+
58
6
WK
G
F
G
HOUR METER
52A
LOWER LEFT OF
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
CENTER OF
CONTROL PANEL
OIL PRESSURE SWITCH / SENDER
1
19
31
30
32
7
CONTROL PANEL
SWITCH CLOSES
AT 6+/-2 PSI
SENDER OPERATION:
0 PSI -> 10+/-5 OHMS
40PSI -> 105+/-5 OHMS
80 PSI -> 187+/-5 OHMS
STARTER
RELAY
THE P10 PLUG IS ONLY ON UNITS
WITHOUT THE WIRE FEED MODULE.
THE WIRE FEED MODULE HAS A
HARNESS THAT PLUGS DIRECTLY
INTO J5.
CONNECT TO
GROUND FOR
1600RPM, LEAVE
UNCONNECTED
FOR 1800RPM
CONNECT TO
GROUND FOR
800RPM
60E
70B
70A
60F
WIRE-TIEDTOHARNESS
BEHIND CONTROL PANEL
52B
P10
844A
55
12 11 10
48
9
8
7
6
5
4
3
2
1
FLYBACK DIODE PREVENTS
BOTH OPEN LEADS ARE WIRE-TIED INSIDE THE HARNESS BEHIND CONTROL PANEL
841B
VOLTAGE SPIKES IN SHUNT FIELD
FROM DAMAGING LOCAL/REMOTE
TOGGLE SWITCH WHEN SWITCHED
J5
400D
400E
GND-B
WINDING SPEC: ALT-241-3A
40.5 - 42.5 OHMS AT 25C
JUMPER PLUG IS FOR CONNECTION
TO WIRE FEED MODULE
610
+
15A
CB2
602B
20A
CB1
610A
600C
610
+
-
U
U
N
N
W
W
Y
Y
DIODE
EXCITER REVOLVING
FIELD (ROTOR)
AC
AC
JUMPER PLUG IS WIRE-TIED UP
BEHIND LOCAL / REMOTE SWITCH ON
RIGHT SIDEOFMACHINE(ASVIEWED
FROM CONTROL PANEL)
LOWER, RIGHT SIDE OF CONTROL PANEL
IDLER SWITCH
SHOWN IN "AUTO
IDLE" POSITION
11A
400F
7A
600B
600A
400D
-
21
SLIP RINGS
FUSE
15A
POSITIVE SLIP RING
IS NEAREST TO IRON
6A
RHEOSTAT
CCW 64+/-6.4 OHMS MAX
EXCITER CIRCUIT
LEAD 21A TO 21B
WINDING SPEC: ALT-214-2B
.488 OHMS MAX AT 25C
810
21
5
HOT LINE HOT LOA
D
LOWER,
115 VOLT GFCI
RECEPTACLE
GND-E
RIGHT OF
CONTROL
PANEL
602B
21
4
WHITE LINE WHITE LOA
D
230 VOLT
RECEPTACLE
6A
41
42
602A
4
81
82
0
115
EAD
WINDING SPEC: ALT-214-2
V
OLT CIRCUIT
JUMPER PLUG IS
WIRE-TIEDUP
GND-S
841
844
J8
L
8
10 TO 20
8
GND-
T
EXCITER STATOR
(ALTERNATOR)
6
5
3
1
2
C
BEHIND LOCAL /
REMOTE SWITCH
P9
82
0
0
.230
O
HM
S
M
AX AT 25C
IN-LINE BOLTED CONNECTION
BEHIND CONTROL PANEL
41
G
ON RIGHT SIDE OF
MACHINE
600
Y
11C
115
V
OLT CIRCUIT
20 TO 30
WINDING SPEC: ALT-214-2
42
602
11B
LEAD
8
8
D
WITH AC AUXILIARY POWER,
ROUTING DIRECTIONS OF THESE
LEADS DOES NOT MATTER
GENERATOR LEAD BLOCK
LOCATED BEHIND UPPER LEFT
PORTION OF CONTROL PANEL
SENSOR GROUNDS LEAD
ON SENSE OF WELD OR
AUXILIARY LOAD
X
SHOWN AS VIEWED WITH
.424
O
HM
S
M
AX AT 25C
2 TURNS
ENGINE IN THIS DIRECTION
W
REMOTE
RECEPTACLE
DIODE AND MOV ASSEMBLY
CURRENT SENSING PC BOARD
SHUNT
FIELD
SERIES FIELD
SELECTOR SWITCH
LOCAL / REMOTE
SWITCH
MOUNTED TO NEGATIVE
BRUSH HOLDER
SCHEMATIC S25973
-
+
90-MIN
4
3
2
DRIVER
CIRCUITS
130-80
190-120
240-160
220-MAX
SHOWN IN LOCAL
POSITION
FJW-5AP
THIS CIRCUIT USES THE
RESIDUAL MAGNETISM OF
THE GENERATOR TO FLASH
THE EXCITE THE ROTOR
WHICH IN TURN PROVIDES
THE EXCITATION FOR THE
GENERATOR
-
+
COIL PAIR:
67B
842
12 VOLT SUPPLY
25.2 - 26.7
INTERPOLE
COILS
OHMS EACH
1
LIGHT CODE
FAILURE DETECTED
POSSIBLE CAUSE - CORRECTIVE MEASURE
3 TURNS
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
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED - CHECK
BROKEN OR LOOSE BELT - INSPECT
WELDING
GENERATOR
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
"L" TERMINAL IS GROUNDED ON ALTERNATOR
COM
CAPACITOR: MFD/
RESISTOR: OHMS/WATTS
P
ON
E
NT
V
ALUE
UNITS:
67A
LONG 1, SHORT 3
FOR 1 SECOND
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE SHORTED TO GROUND - CHECK
FAULTY ALTERNATOR - CHECK
_
VOLTS
AMOUNT OR QUALITY OF COOLANT INCORRECT - CHECK
+
HIGH WATER TEMPERATURE DETECTED FOR 1
LONG 1, SHORT 4
SECOND
FAULTY WATER TEMPERATURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING
LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED - CHECK
NEGATIVE OUTPUT
TERMINAL
POSITIVE OUTPUT
TERMINAL
CONNECTOR PIN NUMBERS:
LONG 1, SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS
TYPICAL OCV (WARM MACHINE):
94-99.0 VOLTS AT MAX RHEOSTAT
44-54.5 VOLTS AT MIN RHEOSTAT
0 RPM IS DETECTED AND 12V IS DETECTED
LONG 2, SHORT 1
FAULTY RPM SENSOR - CHECK FOR GOOD CONNECTION
LE
A
D
COLOR CODE:
EX.
12
PIN CONNECTOR
LABELS:
FROM "L" TERMINAL ON ALTERNATOR
FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU
FAULTY ACTUATOR - CHECK FOR PROPER COIL RESISTANCE
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK
B-BLACK OR GRAY
G-GREEN
2
1
7
6
LONG 2, SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT
LONG 2, SHORT3 NOT ENABLED FOR LINCOLN PRODUCTS
LONG 2, SHORT4 -50C WATER TEMPERATURE DETECTED
UNDER LEFT DOOR
COMMON
FRAM ROUND
EARTH GROUND
R-RE
U-BLU
W- HIT
Y-YELLO
N-BROWN
D
OR
PINK
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN - CHECK FOR CONTINUITY
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN - CHECK FOR CONTINUITY
BROKEN OR LOOSE BELT - INSPECT
E
E
G
12
LATC
W
E
W
H
LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED
VIEW O
F
CONNECTOR ON PC BOARD
0 VOLTS DETECTED FROM "L" TERMINAL ON
LONG 2, SHORT 6
HIS DOCUME
N
T CONTAINS P
R
OPRIETARY INFORMATIO
FOR ANY P RPOSE WITHOUT THE E
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
RITTEN PERMISSIO
N
D MAY NOT BE UPLICATED,
D
COMMUNICATE
D
ALTERNATOR FOR 1 SECOND
PROPRIETARY & CONFIDENTIAL:TTO OT
HER PA
R
TIES O USE
R
D
U
X
PRESS
W
N
OF LIN
C
OLN GLOBAL, INC.
FAULTY ALTERNATOR - CHECK
U
NLESS OTHERWISE SPE
CIFIED TOLERANCE
TOLERANCE PER E2056
INCORRECT BATTERY - INSPECT
DESIGN INFORM
A
TION
REFERENCE:
L12265
MANUFACTURIN
G
LONG 2, SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR
EQUIPMENT TYPE
SUBJECT:
:
_1__
_1__
OF
CLASSIC 300D (KUBOTA V2203M)
MACHINE SCHEMATIC
PAGE
DOCUMENT
UMB R:
FAULTY ALTERNATOR - CHECK
ON 2 PLACE DECIMALS IS .02
ON 3 PLACE D CIMALS I .002
Maglietta
DRAWN
NGINEER: D. BENDER
APPROVED:
BY:
E
S
DOCUMENT
REVISION:
LESS THAN 4 VOLTS TO RPM SENSOR AND/OR
LONG 2, SHORT 8
ON ALL ANGLES IS .5 OF A DEGREE
N
E
MATERIAL TOLERANCE (" ") TO AGREE
t
E
SCALE:
ACTUATOR SENSED BY ECU
FAULTY ECU - CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU
WITH PUBLISHED STANDARDS.
MATERIAL
DISPOSITION:
APPROVAL
DATE:
PROJECT
NUMBER:
L13097
B
CRM37535
UF
NONE
04/13/2007
DO NOT SCALE THIS
DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-20
G-20
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - (CODES 11472, 11473) (L13672)
2
1 3 L 6 7
C
HANGE DETAIL: Ne
w
ENGINEERING CONTROL
MANUFACTURER: No
LED
AMMET
DISCHARGE WHILE PRESSIN
GLO PLUG SWITCH
E
R
SHOWS FULL
THIS
FOR A
SENSE
LEAD PROVIDES FLASH
BACK, LEFT SID
65 AM / 12 OLT
ALTERNATO
E
OF
E
NGINE
LTERNATOR AND
G
IDLERD/ BEENGINE PROTECTION PC BOARD
GLO
SWITCH
W
PLUG
K924-5 REMOTE CONTROL
(OPTIONAL)
P
V
R
CENTE
R
OF CONTROL PANEL
S
ALTERNATOR OUTPUT
W
LOCAT
E
HI
N
D
UPPER
P
ORTIO
N
OF CONTROL PANEL
G4828-1
12 VOLT - NORMALLY OFF
59
J1-3
D+
B+
E
NGIN
E
RE
ROT
LIGHT
D
ENGIN
E
J1-4
60C
61
53
SCHEMATI
C
BACK
,
RIGHT
S
ID
E
OF
E
NGINE
SHUTDOWN
N.C.
P
ECTION
B3
55
57
WHITE
IDLE SOLENOID
P
ULL COIL
51C
-
TY
RESISTANCE:
HOL COIL: 1
ULL COIL: 40A, LESS TH
PICAL CURRENT DRAW AND
J1-8
40 TO 40 AMPS
AMMETER
RED
NJ SCTEIOONF
E
PUNMG
IN
E
HOL COIL
D
N.O.
Y
I
EID
P
BLACK
D
A, 10
-15 OHM
S
J1-9
E
GND-C
FLYBACK
DIODES
58
R
EMOTE CONTROL PLUG
+
-
INJE
CTIO
N
P
A
N
.1 OHM
G
212E
GLO
W
PLUGS
51
NGIN
E
PUMP
RUNNING
51A
212C
56
TY
DRAW
PICAL CURRENT
J1-2
J1-1
S
OLENOID
APPRO IMAT
RESISTANCE: 3.3 OHM
TY ICAL CURRENT DRAW: 3.3
10A
B4
IS
40 +/- 3 AMPS
Y
IGNITIO
SWITCH
HO
N
212D
C
X
E
50A
X
CLOOWE EFT OF
NTRROLL PANEL
S
S
W
N IN "OFF"
212A
BACK, LEFT SID
E
OF
ENGINE
P
A
50
POSITION
S
W
25+/-1.25 OHMS EACH
I
J1-6
43
44
START
TEMPERATURE
W
G
/
G
SWITCH
GAUG
E
E
NGIN
ROT CTIO
CIRCUIT
ELO
LOGIC)
E
OBAFCMKA
B
TOM
, CHOITNE
TEMPERATURE SWITCH
SENDER
P
E
N
52
CLOOWE EFT OF
NTRROLL PANEL
CCW
SWITCH CLOSE
AT 230v+/-6vF
SSENDER OPERATION:
140vF -> 1
ST
S
ARTER
OLENOID
212B
S
(SEE
6
4+/-6.
4
OHM
S
MA
X
+
3
4+/-13.5 OHM
S
B
W
FOR
BATTERY
CENTE
HO
R
OF CONTROL PANEL
194vF -> 51.2+/-4. OHM
3
S
212vF -> 38.5+/-3 OHMS
SENDER I
500 OHMS
S
APPROX.
+
J1-10
60
93
12.6 VOLTS MIN
AT REST
ST
A
RTE
MOTOR
R
BACK, TO
P
OF
E
NGIN
E
AT 70vF
U
R METER
S
RHEOSTAT
EMOTE CONTROL BOX
OIL PRESSURE
GAUG
J1-7
20
0
I
14
-14.5 VOLTS
54
J1-5
J2-1
J2-2
E
WHIL
E
RUNNING
WK
G
G
R
UNUSED
CLOOWE EFT OF
NTRROLL PANEL
OIL PRESSURE SWITCH
SWITCH CLOSES SENDE
AT 6 /-2 PSI
0 P I -> 10
40PSI -> 105+/-5 OHMS
80 P I -> 187+/-5 OHMS
/
SENDER
OPERATION:
/-5 OHMS
B1
REVERSE VOLTAG
E
R
P
ROT CTION DIODE
E
IDL
OLENOID
CI UIT
(SEE BELO
FOR LOGIC)
E
60A
+
S
+
S
AUX LO
AD
SENSIN
G
B4
B5
B6
FLYBACK DIODE PREVENTS
OLTAGE SPIKES SHUNT FIELD
FROM AM GING LOCAL/ EMOTE
TOGGLE SWITCH WHE SWITCHED
R
S
S
UNUSED
W
V
IN
W
ELD LO SENSING
A
D
THE P10
THE IRE FEED MODULE. THE
MODULE HAS HARNESS THA
DIRECTLY INTO J5.
P
W
ITHOUT
IRE FEED
LUG
D
A
R
J2-3
B2
W
P10
J5
E
NGINE PROT
1. U ON CIEVING POWER FROM TH
IGNITIO SWITCH, TH FUEL OLENOID
FUEL UMP AN HO R MET ARE
ENERGIZED.
E
CTION CIRCUIT LOGIC
J2-4
N
S
P
R
N
E
E
ON NE
J1 BECOMES J31, J
B5 AND B ERMINA
W
ER BOARDS,
12 11 10
48
9
8
7
6
5
4
3
2
1
E
U
S
ER
,
S
HO
W
N IN "AUTO
IDLE" POSITION
JUMPE
R
PLUG
IS
FOR CONNECTION
2
BECOMES J32,
GND-B
400D
84
4
P
D
TO WIR
E
FEED MODULE
6
T
L
S
ARE DE
L
ETED.
IDLE
R
SWITCH
20A
JUMPE
R
PLUAGLISWIRE-TIED
U
P
400E
15A
RBEIGHHINTD LIDOC
/
R
EMOTE SWITCH
O
N
2.
FOR ONE MI
PRESSURE BUILDUP
ST RTE ITHI ON
TURNING IGNITIO SWITCH ON OR TH
E
NGINE PROT
UTE TO ALLO
NGIN
MI UTE OF
E
CTIO
N
IS BYPASSED
OIL
MUST BE
DC EXCITER
61
0
S
FROM CO EOF MPANEL)
NTROL ACHINE (AS VIEWED
N
W
W
INDING SPEC: ALT
-
241-3A
+
61
0
+
610A
.
E
E
E
40.5 - 42.5 OHM
S
AT 25C
CB2
U
U
N
N
Y
Y
W
W
DILOODE
C
B1
AC
AC
A
D
W
N
N
EXCIT
E
R
REVOLVING
WER, RIGHT
SIDE
OF CONTROL PANEL
N
E
FIELD (ROTOR)
11A
7A
600B
FUEL
MET
S
R
OLENOID, FUEL
ILL TURN OFF. AFTER
IGNITIO
OFF A BACK
P
UMP AN
D
O
HOUR
NE
SWITCH MUST BE
N TO ST RT
-
P
600C
-
21
E
W
SLI
P
RINGS
SLI RING
600A
400F
115 VOLT GFCI
TOP,
R
NIGTHRTOPLORTIO
N
POSITIV
E
MINUTE, TH
CYCL
NGINE.
E
N
FUS
E
6A
RECEPTACLE
OF CO
PANEL
15A
IS NEAREST TO IRONLO
ED
ND
O
A
EXCIT
EAD 21
INDING SPEC: ALT
.488 OHM AX AT 25C
ER CIRCUIT
81
0
HOT
L
IN
E
HOT
L
OAD
215
RHEOSTAT
64+/-6.4 OHM
E
GWHTERO,F
CCW
L
W
A
TO 21B
GND-E
S
MAX
RI
-214-2B
W
HI
T
E
LINE
W
HI
T
E
LOAD
602B
21
4
3. AFTER
CURRENT IS SUPPLI
ALTERNATOR.
E
NGINE
ST
ARTS, FLA
SHING
D TO THE ENGINE
CONTROL
PANEL
S
M
230 VOLT
RECEPT CL
6A
41
E
42
A
E
602A
4
81
0
115 VOLT CIRCUIT
EAD 810 TO 820
INDING SPEC: ALT
.230 OHM AX AT 25C
82
0
J8
P9
GND-
T
L
W
11C
GND-S
4. AFTER
OUT. IF OIL PRESSURE
COOLANT TEMPERATURE
ALTERNATO IS OT CHARGING, TH
NGINE WILL S UT DOW AND TH
NGINE PROT CTION LIGHT ILL COM
ON
O
NE MIN
UTE, TIM
LOW,
HIGH OR
E
R
IS TIMED
EXCIT
(ALTER
E
N
R
STATO
R
5
3
1
2
-214-2C
I
S
ATOR)
82
0
S
M
JUIRMPE
R
PLUG ISHI
IS
IN-LINE BOLTED CONNECTION
BEHIND CONTROL PANEL
41
60
Y
0
W
E-TIED
U
PBE ND
R
N
E
115 VOLT CIRCUIT
EAD 820 TO 830
INDING SPEC: ALT-214-2D
G
42
60
2
LOC
/
ITCH RENMROITE
SW AL
E
E
H
E
N
E
11B
L
W
GENERATOR
SHO
L
EAD
B
LOC
K
S
ID
E
OF OMACHGINHET
W
E
W
N AS VIE
W
ED
W
ITH
X
844A
OF COLENFTTROPOL PANEL
.
TOP,
RTION
W
.424 OHM
S
MAX AT 25C
ENGINE IN THIS DIRECTION
IDLE SOLENOID CIRUIT LOGIC
1. WHEN THE ENGIN UNNING N HIGH
OR NDER LO D, THE SOLENOID OT
ENERGIZED.
REMOTE
MOUNTE
NEGATIVE
BRUS
H
HDOLTDOER
RECEPTACLE
E
IS
R
I
I
DLE
SHUNT
FIELD
SERIES FIEL
D
S
ELECTOR SWITCH
LOCAL
/
REMOTE
U
A
IS
N
-
+
-
SWITCH
DIODE AND MOV ASSEMBL
Y
90-MIN
130-80
190-12
S
HO N IN LOCAL
W
FJW-5AP
COIL PAIR
25.2 - 26.7
THI CIR UIT USES TH
S
C
E
+
2. IF N
LOA
IDL
HOL
O
AUXILIARY
C
URRENT DRAW OR
WEL
D
POSITION
0
:
RESID AL M GNETISM OF
THE ENERATOR TO FLASH
THE EXCIT TH OTOR
HI H IN TUR RO IDES
THE EXCITATION FOR TH
U
A
D
IS SENSED FOR 15 SECONDS AND TH
SWITCH PEN (AUTO), THE ULL AND
COIL OF TH DL OLENOID ARE
E-ENERGIZE
E
G
240-16
0
ER
IS
O
P
INTERPOLE
COILS
OHMS EACH
E
E
R
220-MAX
D
E
I
ER
S
W
C
N
P
V
ENERGIZED. THE PULL COIL I
S
D
D
E
AFTER ALF A SECO D.
H
N
GENERATO
R
COM
CAPACITOR: MFD/
RESISTOR: OHMS/WATTS
P
ON
E
NT
V
ALUE
UNITS:
3. IF AN AUXILIARY CURRENT DRAW OR WELD
LOAD IS SENSED OR THE IDLER SWITCH IS CLOSED
(HIGH), THE IDLE SOLENOID IS DE-ENERGIZED.
BACK OF OUTPUT STU
REE SWITCH
SWITCH CLOSES
ITH FLO OF
ELDING URRENT
GND-A
D
WELDING
GENERATOR
BRUS
VIEWED FROM CONTROL PANEL
H
POSITION
S
HO
W
N
AS
VOLTS
D
W
W
W
C
CONNECTOR PIN NUMBERS:
_
LE
AD
COLOR CODE:
EX.
12
PIN CONNECTOR
LABELS:
+
B-BLACK OR GRAY
G-GREEN
POSITIV
TERMINAL
E
OUTPUT
2
NEGATIVE OUTPUT
1
7
PROPRIETARY & CONFIDENTIAL:TTO OT
6
HIS DOCUME
N
R
T CONTAINS P
R
OPRIETARY INFORMATIO
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
N
D MAY NOT BE
D
UPLICATED,
COMMUNICATED
HER PA
TIES O USE
R
D
FOR ANY P RPOSE WITHOUT THE E
U
XPRESS
W
RITTEN PERMISSIO
N
OF LINCOLN GLOBAL, INC.
TERMINAL
RM MACHI E):
99.0 VOLTS AT MAX HEOSTAT
54.5 VOLTS AT MI RHEOSTAT
COMMON
FRAM ROUND
EARTH GROUND
MANUFACTURIN
NLESS OTHERWISE SPE
N 2 PLACE DECIMALS IS .02 in. ( 0.5 mm)
G
TOLERANCE PER E2056
R-RE
U-BLU
W- HIT
Y-YELLO
N-BROWN
D
OR
PINK
SCALE:
CONTROL:
CLEVELAN
D
TY
P
ICAL OC
V
(W
A
N
U
C
IFIE TOLERA CE:
D
N
EQUIPMENT TYPE
SUBJECT:
:
_1__
1
C
LASSIC 300D (PERKINS
PAGE
DOCUMENT
OF ___
E
O
NONE
IF PRINTED
E
G
12
LATC
94
-
-
R
U
NDER LEFT DOO
R
DR
NGINEER:
APPROVED:
A
WN BY:
C. Kocsi
s
ON
N ALL ANGLES IS .5 OF A DEGREE
MATERIAL TOLERANCE ( ") TO A REE
3
PLA
CE
DECIMALS IS .002
in.
(
0.05 mm)
DOCUMENT
REVIS ON:
W
E
O
H
NUMBER:
44
N
@
A2
S
IZE
I
MACHIN SCHEMATIC
E
E
D. BE DE
N
R
"
G
t
W
U
NITS:
WITH PUBLISHED STANDARDS.
REFERE
NCE:
APPROVAL
DATE:
MATERIAL
PROJECT
NUMBER:
VIEW O
F
CONNECTOR ON PC BOARD
L13672
NA
1/
1
1/2008
A
-
CRM37573
INC
H
DISPOSITION:
L13096
DO NOT SCALE THIS
DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-21
G-21
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - (CODES 11474, 11475) (L13351)
1
1 3 L 3 5
C
HANGE DETAIL: Ne
w
ENGINEERING CONTROL
MANUFACTURER: No
LED
JUMPER PLUG IS BEHIND LOWER
LOWER RIGHT OF CONTROL PANEL
RIGHT SIDE OF CONTROL PANEL
AMMETER SHOWS FULL
DISCHARGE WHILE PRESSING
GLOW PLUG SWITCH
K924-5 REMOTE CONTROL
(OPTIONAL)
RPM CONTROL POTENTIOMETER
12 VOLT SUPPLY
11
2
87
86
88
1
2
GLOW PLUG
BUTTON
10,000 +/- 1,000 OHMS MAX
94
20
17
ENGINE
TURN POT COUNTERCLOCKWISE TO
REDUCE RESISTANCE AND SUBSEQUENTLY
REDUCE RPM BY UP TO 150RPM
RATED VOLTAGE: 12V
RATED CURRENT: 22mA MAX
SPEED
SENSOR
BACK, RIGHT
ENGINE CONTROL UNIT (ECU)
93
60A
53
CCW
GLOW PLUGS
LOCATED BEHIND UPPER PORTION OF CONTROL PANEL
3
3
4
BACK, LEFT SIDE OF ENGINE
RATED VOLTAGE: 12V
51C
SIDEOFENGINE
TYPICAL CURRENT
DRAW IS 40 AMPS
ALTERNATOR
RATED CURRENT: 4.5A(MAX.)-TERMINAL #15
LEAKAGE CURRENT 10micro A (MAX.)-TERMINAL #16
40 AMP / 12 VOLT
REMOTE CONTROL PLUG
L
26
64
G
69
13
34
S
ENSE
S
S
A
LTERNATOR OUTPU
T
S
ENSOR OPERATION:
-4 -> 18. 0 kOHMS
104v -> 1.14 kOHM
212v -> .16 kOHMS
IG
B
WATER
TEMP.
vF
8
FL
51B
A
SH
E
A
LTERNATOR
F
F
S
212E
Y
SENSOR
-40 TO 40 AMPS
AMMETER
16
15
60
IGNITION
SWITCH
BACK, LEFT
X
51
BACK, BOTTOM
SIDE OF ENGINE
-
OF MACHINE
RATED VOLTAGE:
RATED CURRENT:
COIL RESISTENCE:
1
2V
1
10
9
17
212D
51A
50
STARTER
SOLENOID
+
SHOWN IN "OFF"
POSITION
W
2
5+/-1.25 OHM
S
EACH
2
A
+
BATTERY
57
BACK, RIGHT
18
26
25
34
2.8 +/- .28 OH
MS
AT 20vC
FRONT, RIGHT SIDE
OF ENGINE
44
BACK, LEFT SIDE
SIDE OF ENGINE
STARTER
MOTOR
12.6 VOLTS MIN
AT REST
14-14.5 VOLTS
1
2 VOLT
SUPPLY
212A
I
ENERGIZED FOR RUN
OF ENGINE
ACTUATOR
S
DE-ENERGIZED FOR STOP
50A
28
43
CCW
ACTUATOR CONTROLS RPM
DOWN THE ENGINE AT 115%
OF RATED SPEED.
TEMPERATURE
GAUGE
WHILE RUNNING
G
6
4+/-6.
4
OHM
S
MAX
56
18
9
START
BUTTON
TEMPERATURE
SWITCH
TEMPERATURE
SENSOR
LOWER LEFT OF
ECU CONNECTOR DETAIL
ENGINE
212B
CONTROL PANEL
RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY
OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED
WHEN THE IGNITION SWITCH IS "ON" AND THE ECU
SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT
S
ENDER OPERATION:
C
SWITCH CLOSES
PROTECTION
LIGHT
COLOR: RED
12 VOLT
NORMALLY OFF
90v -> 51.2+/-4.3 OHMS
AT 110v+/-3vC
62
61
RHEOSTAT
EMOTE CONTROL BOX
THE ECU WI
ENGINE PROTECTION LIGHT IN A CODED SEQUENCE, S
FOR FAULT CODE AND CORRECTIV MEASUR S. WHEN TH
ENGINE IS SHUT DOWN DUE TO A FAULT, THE IGNITION
WITCH WI L NEED TO BE TURNED OFF THEN BACK ON
LL INDICATE FAULT CONDITIONS BY FLASHING THE
CENTER OF
E
E CHAR
T
841A
CONTROL PANEL
FRONT, LEFT SIDE OF ENGINE
200
212C
DOWN DUE TO A FAULT (EVEN IF T
DOES NOT RESULT IN A FLASH CODE, SUCH AS RUNNING
OUT OF UEL), THE IGNITION SWITCH WILL NEED TO BE
HAT CONDITION
S
S
E
E
E
OIL PRESSURE
GAUGE
R
I
54
27
+
58
6
WK
G
F
G
HOUR METER
S
L
52A
LOWER LEFT OF
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
TO RESTART THE ENGINE.
CENTER OF
CONTROL PANEL
OIL PRESSURE SWITCH / SENDER
1
19
31
30
7
12
32
CONTROL PANEL
SWITCH CLOSES
AT 6+/-2 PSI
SENDER OPERATION:
0 PSI -> 10+/-5 OHMS
40PSI -> 105+/-5 OHMS
80 PSI -> 187+/-5 OHMS
STARTER
RELAY
THE P10 PLUG IS ONLY ON UNITS
WITHOUT TH WIRE FEED MODU
THE WIRE FEED MODU E HA
HARNE S THAT LUGS DIRECTLY
INTO J5.
E
LE.
CONNECT TO
GROUND FOR
1600RPM, LEAVE
UNCONNECTED
FOR 1800RPM
CONNECT TO
GROUND FOR
800RPM
L
S
A
60E
70B
70A
60F
WIRE-TIED TO HARNESS
BEHIND CONTROL PANEL
S
P
52B
P10
J5
844A
55
12 11 10
48
9
8
7
6
5
4
3
2
1
FLYBACK DIODE PREVENTS
BOTH OPEN LEADS ARE WIRE-TIED INSIDE THE HARNESS BEHIND CONTROL PANEL
841B
VOLTAGE SPIKES IN SHUNT FIELD
FROM DAMAGING LOCAL/REMOTE
TOGGLE SWITCH WHEN SWITCHED
400D
400E
GND-B
WINDING SPEC: ALT-241-3A
40.5 - 42.5 OHMS AT 25C
JUMPER PLUG IS FOR CONNECTION
TO WIRE FEED MODULE
610
+
15A
CB2
602B
20A
CB1
610A
600C
610
+
-
U
U
N
N
W
W
Y
Y
DIODE
EXCITER REVOLVING
FIELD (ROTOR)
AC
AC
JUMPER PLUG IS WIRE-TIED UP
BEHIND LOCAL / REMOTE SWITCH ON
RIGHT SIDEOFMACHINE(ASVIEWED
FROM CONTROL PANEL)
LOWER, RIGHT SIDE OF CONTROL PANEL
IDLER SWITCH
SHOWN IN "AUTO
IDLE" POSITION
11A
400F
7A
600B
600A
400D
-
21
SLIP RINGS
FUSE
15A
POSITIVE SLIP RING
IS NEAREST TO IRON
6A
RHEOSTAT
CCW 64+/-6.4 OHMS MAX
EXCITER CIRCUIT
LEAD 21A TO 21B
WINDING SPEC: ALT-214-2B
.488 OHMS MAX AT 25C
810
21
5
HOT LINE HOT LOA
D
LOWER,
115 VOLT GFCI
RECEPTACLE
GND-E
RIGHT OF
CONTROL
PANEL
602B
21
4
WHITE LINE WHITE LOA
D
230 VOLT
RECEPTACLE
6A
41
42
602A
4
81
82
0
115
EAD
WINDING SPEC: ALT-214-2
V
OLT CIRCUIT
JUMPER PLUG IS
WIRE-TIEDUP
GND-S
841
844
J8
L
8
10 TO 20
8
GND-
T
EXCITER STATOR
(ALTERNATOR)
6
5
3
1
2
C
BEHIND LOCAL /
REMOTE SWITCH
P9
82
0
0
.230
O
HM
S
M
AX AT 25C
IN-LINE BOLTED CONNECTION
EHIND CONTROL PANEL
41
G
ON RIGHT SIDE OF
MACHINE
600
Y
B
11C
115
V
OLT CIRCUIT
20 TO 30
WINDING SPEC: ALT-214-2
42
602
11B
LEAD
8
8
D
WITH AC AU
X
ILIARY POWER,
ROUTING DIRECTIONS OF THES
LEADS DOES NOT ATTER
GENERATOR LEAD BLOCK
LOCATED BEHIND UPPER LEFT
X
.424
O
HM
S
M
AX AT 25C
E
SHOWN AS VIEWED WITH
DIODE AND MOV ASSEMBLY
PORTION OF CONTROL PANEL
2 TURN
S
M
ENGINE IN THIS DIRECTION
W
REMOTE
RECEPTACLE
SENSOR GROUNDS LEAD
ON SENSE OF WELD OR
AUXILIARY LOAD
MOUNTED TO NEGATIVE
BRUSH HOLDER
CURRENT SENSING PC BOARD
SHUNT
FIELD
SERIES FIELD
SELECTOR SWITCH
LOCAL / REMOTE
SWITCH
SCHEMATIC S25973
-
+
THIS CIRCUIT USES THE
RESIDUAL MAGNETISM OF
THE GENERATOR TO FLASH
THE EXCITE THE ROTOR
WHICH IN TURN PROVIDES
THE EXCITATION FOR THE
GENERATOR
90-MIN
4
130-80
190-120
240-160
220-MAX
SHOWN IN LOCAL
POSITION
DRIVER
CIRCUITS
FJW-5AP
-
3
2
+
COIL PAIR:
25.2 - 26.7
OHMS EACH
67B
842
1
2 VOLT SUPPLY
INTERPOLE
COILS
1
LIGHT CODE
POSSIBLE CAUSE - CORRECTIVE MEASURE
FAILURE DETECTED
LONG 1, SHORT 1
ACTUATOR IS STUCK - REMOVE ACTUATOR AND VERIFY PLUNGER PULLS IN WHEN ENERGIZED
LOW OIL - CHECK OIL LEVEL ON DIPSTICK
3 TURN
S
RPM IS OVER 115% OF RATED RPM (2070 RPM)
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
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED - CHECK
COM
CAPACITOR: MFD/
RESISTOR: OHMS/WATTS
P
ON
E
NT
V
ALUE
UNITS:
WELDING
GENERATOR
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
BROKEN OR LOOSE BELT - INSPECT
VOLTS
"L" TERMINAL IS GROUNDED ON ALTERNATOR
LONG 1, SHORT 3
LONG 1, SHORT 4
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE SHORTED TO GROUND - CHECK
FAULTY ALTERNATOR - CHECK
FOR 1 SECOND
67A
AMOUNT OR QUALITY OF COOLANT INCORRECT - CHECK
_
HIGH WATER TEMPERATURE DETECTED FOR 1
SECOND
FAULTY WATER TEMPERATURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS NOT RUNNING
LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED - CHECK
CONNECTOR PIN NUMBERS:
+
NEGATIVE OUTPUT
TERMINAL
POSITIVE OUTPUT
TERMINAL
LE
A
D
COLOR CODE:
EX.
12
PIN CONNECTOR
LABELS:
LONG 1, SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS
0 RPM IS DETECTED AND 12V IS DETECTED
LONG 2, SHORT 1
FAULTY RPM SENSOR - CHECK FOR GOOD CONNECTION
B-BLACK OR GRAY
G-GREEN
2
1
7
6
TYPICAL OCV (WARM MACHINE):
94-99.0 VOLTS AT MAX RHEOSTAT
44-54.5 VOLTS AT MIN RHEOSTAT
FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU
FAULTY ACTUATOR - CHECK FOR PROPER COIL RESISTANCE
LEADS TO ACTUATOR MAY BE OPEN OR GROUNDED - CHECK
FROM "L" TERMINAL ON ALTERNATOR
COMMON
FRAM ROUND
EARTH GROUND
LONG 2, SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT
LONG 2, SHORT3 NOT ENABLED FOR LINCOLN PRODUCTS
LONG 2, SHORT4 -50C WATER TEMPERATURE DETECTED
R-RE
U-BLU
W- HIT
Y-YELLO
N-BROWN
D
OR
PINK
E
E
G
12
LATC
UNDER LEFT DOOR
W
E
W
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE OPEN - CHECK FOR CONTINUITY
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSOR MAY BE GROUNDED - CHECK
LEAD TO "L" TERMINAL ON ALTERNATOR MAY BE OPEN - CHECK FOR CONTINUITY
BROKEN OR LOOSE BELT - INSPECT
H
VIEW O
F
CONNECTOR ON PC BOARD
LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED
HIS DOCUME
N
T CONTAINS P
R
OPRIETARY INFORMATIO
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
RITTEN PERMISSIO
N
D MAY NOT BE UPLICATED,
D
COMMUNICATED
PROPRIETARY & CONFIDENTIAL:TTO OT
0 VOLTS DETECTED FROM "L" TERMINAL ON
LONG 2, SHORT 6
HER PA
R
TIES O USE
R
D
FOR ANY P
U
RPOSE WITHOUT THE E PRESS
X
W
N
OF LIN
C
OLN GLOBAL, INC.
ALTERNATOR FOR 1 SECOND
MANUFACTURIN
NLESS OTHERWISE SPE
N 2 PLACE DECIMALS IS .02 in. ( 0.5 mm)
ON
N ALL ANGLES IS .5 OF A DEGREE
MATERIAL TOLERANCE ( ") TO A REE
G
TOLERANCE PER E2056
SCALE:
NONE
IF PRINTED
CONTROL:
CLEVELAN
D
FAULTY ALTERNATOR - CHECK
U
C
IFIE TOLERA CE:
D
N
EQUIPMENT TYPE
SUBJECT:
:
_1__
1
C
LASSIC 300
MACHIN SCHEMATIC
D
KUBOTA
PAGE
DOCUMENT
OF ___
O
INCORRECT BATTERY - INSPECT
LONG 2, SHORT 7 OVER 18 VOLTS DETECTED FROM ALTERNATOR
DR
NGINEER:
APPROVED:
A
WN BY:
Maglietta
D. BE DE
3
PLA
CE
DECIMALS IS .002
in.
(
0.05 mm)
DOCUMENT
REVIS ON:
FAULTY ALTERNATOR - CHECK
O
@
A2
S
IZE
N
UMBER:
I
E
LESS THAN 4 VOLTS TO RPM SENSOR AND/OR
LONG 2, SHORT 8
E
N
R
"
G
t
UNITS:
WITH PUBLISHED STANDARDS.
REFERE
NCE:
FAULTY ECU - CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU
APPROVAL
DATE:
ACTUATOR SENSED BY ECU
MATERIAL
DISPOSITION:
PROJECT
NUMBER:
L13351
NA
1
1/
1
6/2007
A
-
CRM37569
INC
H
L13097
DO NOT SCALE THIS
DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-22
G-22
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - WIRE FEED MODULE OPTION - (L9259)
WIRE FEED MODULE - WIRING DIAGRAM
ELECTRICAL SYMBOLS PER
E
1537
LEAD CO
L
OR COD
E
CONTROL
1
B
OARD
J1
Y
1
FLASHING
LEADS
R-RED
B-BLAC
K
MO
J2
L
EX CONNECTORS
J3
5
U-BLUE
G-GR EN
E
W
2
218
219
W-WHITE
N-BROWN
J1
1
J4
503
602
509
610
Y-YELLOW
3
1
6
1
4
8
1
4
3
6
2
P1
SHUNT
FIELD
TO
RHEOSTA
4
CONNECTOR CAVITY NUMBERING
SEQUENCE VIEWE FROM
OMPONENT SI OF BOARD.
T
D
5
634
667
2
1
2
3
4
5
6
7
8
9
10
5
C
DE
2
6
+
CONNECTS T
ENGINE WELDER
RECEPTACLE J5
O
115V
DC
N
N
.A
.
L
C
EA
D
S
31, 32
OMPONENTS VIEWE
A
ND 602 DO NOT GO INSI
D FROM EA
D
E
WIRE FEE
D
MODULE BOX.
7
.B
.
R
R
600
8
-
4
9
621
633
75A
76
1
5
9
3
7
4
8
2
6
GND
31
10
11
12
115V
AC
12
10 11
32
P5
P5
N
.A.
77
CONNECT
SEQUENCE VIEWED FROM
LEAD SIDE OF NNECTOR
OR CAVITY NUMBERING
GND
31
75
10
GND
31
1
2
3
4
5
6
7
8
9
C
O
J2
P2
CC/CV S
W
ITC
H
S1
510 602
SHOWN IN CV MODE
32
501
1
2
3
4
5
6
32
C
V
CONTROL
609
610A
510
501
503A
602
609
610A
510
501
503A
509
77A
R501
10K
75
610A
503A
503A
631
630
76A
503
501
609
J4
P4
602
J6
R
EMOTE CONNECTOR
P6
W
610A
Y
1
2
3
4
5
6
7
8
31
J
115 VA
C
75
76
77
2
75
76
77
2
1
2
3
4
5
6
A
32
GND
2A
GROUND B
C
600
608
610
CONTACTOR
D
E
4A
77B
76B
75A
4
4
R
EMOTE
F
75A
75A
P7
G
J7
510
AMPHENOL 1
J3
P3
77
4A
2
76B
76
2A
4
77B
POS
NEG
219
+
300 AMP
SHUNT
218
-
LOCAL/REMOTE
SHOWN IN LOCAL
S
W
ITC
M
H
S2
ODE
621
667
76A
77A
633
608
609
WELDER
CR4
666
634
+
+
+
250
25W
TO NE
BRUSH HOLDER
G
CC -
CC +
CV -
CR3
C501
C502
C503
CONTACTOR
631
630
622
CONTACTOR
30000 MF
D
EACH
75 LT
V
O
A
L9259
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.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-23
G-23
ELECTRICAL DIAGRAMS
SCHEMATIC - WIRE FEED MODULE OPTION - (G2562)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-24
G-24
ELECTRICAL DIAGRAMS
SCHEMATIC - IDLER (CODES 10545, 10546, 10657, 10658, 10911, 10927) - (L10826)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-25
SCHEMATIC - IDLER (CODES 11110 THRU 11475 PERKINS ENGINE ONLY) - (G4828)
G-25
ELECTRICAL DIAGRAMS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
G-26
G-26
ELECTRICAL DIAGRAMS
SCHEMATIC - CURRENT SENSOR PC BD (KUBOTA ENGINE ONLY) - (S25973)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
CLASSIC® 300D & 300G
Download from Www.Somanuals.com. All Manuals Search And Download.
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