RETURN TO MAIN MENU
IM842-B
®
CLASSIC 300D PERKINS April, 2005
For Machines with Code Numbers 11110, 11111, 11248,11249,11280, 11281
Safety Depends on You
Lincoln arc welding 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
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
OPERATOR’S MANUAL
Copyright © 2005 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: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
6. Eloigner les matériaux inflammables ou les recouvrir afin de
manuel aussi bien que les précautions de sûreté générales suiv-
prévenir tout risque d’incendie dû aux étincelles.
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
Sûreté Pour Soudage A L’Arc
la masse. Un court-circuit accidental peut provoquer un
1. Protegez-vous contre la secousse électrique:
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
8. S’assurer que la masse est connectée le plus prés possible
quand la machine à souder est en marche. Eviter toujours
de la zone de travail qu’il est pratique de le faire. Si on place
tout contact entre les parties sous tension et la peau nue
la masse sur la charpente de la construction ou d’autres
ou les vétements mouillés. Porter des gants secs et sans
endroits éloignés de la zone de travail, on augmente le risque
trous pour isoler les mains.
de voir passer le courant de soudage par les chaines de lev-
b. Faire trés attention de bien s’isoler de la masse quand on
age, câbles de grue, ou autres circuits. Cela peut provoquer
soude dans des endroits humides, ou sur un plancher
des risques d’incendie ou d’echauffement des chaines et des
metallique ou des grilles metalliques, principalement dans
câbles jusqu’� ce qu’ils se rompent.
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
9. Assurer une ventilation suffisante dans la zone de soudage.
c. Maintenir le porte-électrode, la pince de masse, le câble
Ceci est particuliérement important pour le soudage de tôles
de soudage et la machine à souder en bon et sûr état
galvanisées plombées, ou cadmiées ou tout autre métal qui
defonctionnement.
produit des fumeés toxiques.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
10. Ne pas souder en présence de vapeurs de chlore provenant
e. Ne jamais toucher simultanément les parties sous tension
d’opérations de dégraissage, nettoyage ou pistolage. La
des porte-électrodes connectés à deux machines à souder
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
parce que la tension entre les deux pinces peut être le
du solvant pour produire du phosgéne (gas fortement toxique)
total de la tension à vide des deux machines.
ou autres produits irritants.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
11. Pour obtenir de plus amples renseignements sur la sûreté,
pour le porte-électrode s’applicuent aussi au pistolet de
voir le code “Code for safety in welding and cutting� CSA
soudage.
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
TRANSFORMATEUR ET À
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc. 1. Relier à la terre le chassis du poste conformement au code de
b. Porter des vêtements convenables afin de protéger la l’électricité et aux recommendations du fabricant. Le dispositif
peau de soudeur et des aides contre le rayonnement de de montage ou la piece à souder doit être branché à une
l‘arc. bonne mise à la terre.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables. 2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres 3. Avant de faires des travaux à l’interieur de poste, la debranch-
de l’huile, tels que les gants en cuir, chemise épaisse, pan- er à l’interrupteur à la boite de fusibles.
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
� For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
� For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links� and then
“Product Registration�. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
General Description ...............................................................................................A-2
Design Features ....................................................................................................A-2
Pre-Operation Installation ......................................................................................A-3
Safety Precautions ..........................................................................................A-3
Exhaust Spark Arrester ...................................................................................A-3
Location/Ventilation.........................................................................................A-3
Machine Grounding.........................................................................................A-3
Lift Bail ............................................................................................................A-3
Trailers ............................................................................................................A-3
Vehicle Mounting.............................................................................................A-4
Polarity Control and Cable Sizes ....................................................................A-4
Pre-Operation Service ...........................................................................................A-4
Oil....................................................................................................................A-4
Fuel .................................................................................................................A-4
Cooling System ...............................................................................................A-4
Battery Charging .............................................................................................A-5
Operation .........................................................................................................Section B
Engine Operation...................................................................................................B-1
Starting The Perkins 404C-22 Engine.............................................................B-1
High Altitude Operation ...................................................................................B-1
Stopping the engine, Engine Break-In......................................................B-1,B-2
Welder Operation...................................................................................................B-2
Duty Cycle.......................................................................................................B-2
Control of Welding Current..............................................................................B-2
Idler Operation ................................................................................................B-3
Auxiliary Power, Fuel Consumption Data........................................................B-3
Accessories .....................................................................................................Section C
Optional Features (Field Installed)..................................................................C-1,C-2
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
General Instructions ..............................................................................................D-1
Cooling System .....................................................................................................D-1
Bearings ................................................................................................................D-1
Commutator and Brushes .....................................................................................D-1
Idler Maintenance..................................................................................................D-2
Nameplates ...........................................................................................................D-2
Purging Air from Fuel System................................................................................D-2
Engine Service Chart ............................................................................................D-3
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
Welder Troubleshooting ........................................................................................E-2
Electronic Idler Troubleshooting Guide...........................................................E-3,E-4
Engine Troubleshooting Guide .....................................................................E-5, E-6
Diagrams ..........................................................................................................Section F
Wiring Diagram ......................................................................................................F-1
Dimension Print......................................................................................................F-2
Parts List ..................................................................................................................P507
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - CLASSIC 300D PERKINS
INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
4 Cylinder 135.6 cu. in 12VDC battery Fuel: 15 gal.
4 Cycle (2.2 ltrs) (Group 45, 650 57 L.
Naturally Aspirated High Idle 1800 cold crank amps)
Water-Cooled Low Idle 1400 Bore x Stroke 2.0 KW Starter Oil: 11.2 Qts.
Perkins Diesel Engine Full Load 1725 55 A. Alternator 10.6 L.
404C-22 Cast Iron Cylinder, 3.43� x 3.64� w/ built in reg.
Block/Crankcase Coolant: 9.5 Qts.
32.7HP @1800 RPM (For Codes 11111
and Below) 9.0 L.
65 A. Alternator
w/ built in reg.
(For Codes 11248
and Above)
RATED OUTPUT @ 104°F(40°C) - WELDER
DESCRIPTION RATED DC OUTPUT * Duty DC CURRENT RANGE
VOLTS @ RATED AMPS CYCLE Fine Adjustments in each Range
40-350 Amps
220-Max.
300 Amp DC Welder 30V @ 250A 100% 160-240
All Copper Windings 32V @ 300A 60% 120-190
Pure DC Power Generator 99V DC Max. OCV @ 1800RPM 80-130
Min.-90
RATED OUTPUT @ 104°F(40°C) - GENERATOR
Auxiliary Power (1)
3,000 Watts Continuous, 60 Hz AC
26 Amps @ 115V
13 Amps @ 230V
PHYSICAL DIMENSIONS (2)
MODEL HEIGHT WIDTH DEPTH WEIGHT
K1643-3 CSA
w/o Wire Feed Module 1354 lbs.
(Codes 11110, 11248, 45.5 in. 24.00 in. 65.0 in. (616 kg)
11280) (1156 mm) (610 mm) (1651 mm
K1643-4 CSA
w/ Wire Feed Module 1389lbs.
(Codes 11111, 11249, (630 kg)
11281)
* 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 PERKINS
A-2 A-2
INSTALLATION
GENERAL DESCRIPTION All Copper Windings - For long life and dependable
operation.
The Classic® 300D Perkins is a heavy duty, engine
Engine Idler - The Classic 300D Perkins is equipped
driven, DC arc welding power source, capable of pro-
with an electronic automatic engine idler. It automati-
viding constant current output for stick welding or DC
cally increases and decreases engine speed when
TIG welding. This welder is wound with all copper
starting and stopping welding or using auxiliary
coils, rated at 300 amps/32 Volts, and provides other
power. A built-in time delay permits changing elec-
Classic features such as improved door latches and
trodes before the engine slows to its low idle speed.
stainless hinges. With the addition of the optional
The “Idler� control switch on the panel locks the idler
K623-1 Wire Feed Module â„? , the Classic 300D
in high idle position when desired.
Perkins will provide constant voltage output for run-
ning the LN-7, LN-23P, or LN-25 wire feeders. (The Auxiliary Power - 3.0 KVA of nominal 115/230V,
Wire Feed Module is factory installed on the K1643- 60Hz, AC. Output voltage is maintained within ± 10%
4). The optional K924-5 Remote Control Kit, provides at all loads up to rated capacity. (See Optional
a remote control rheostat for remote fine current and Features Section C for Power Plug Kit.)
open circuit voltage adjustment. See Section C for
description. GFCI Receptacle - One UL approved 115V ground
fault circuit interrupter duplex type receptacle is stan-
dard.
The Classic 300D Perkins has an Electronic Engine
Welder Enclosure - The complete welder is rubber
Protection System. In the event of sudden low oil
mounted on a rugged steel “C� channel base.
pressure or high coolant temperature, the engine
immediately shuts down. The Classic 300D Perkins
The output terminals are placed at the side of the
has a current range of 40-350 DC amps with output
machines so that they are protected by the door. The
ratings as follows:
output terminals are labeled (+) and (-).
Cranking System - A 12 volt electric starter is stan-
RATED OUTPUT DUTY CYCLE dard.
250A @ 30V 100%
Air Cleaner - Heavy duty two stage dry type.
300A @ 32V 60%
Muffler - A muffler and stainless steel exhaust outlet
elbow are standard.
These units are also capable of providing 3 KVA of Engine Hour Meter - A meter to record hours of oper-
115/230 volts of 60 cycle AC auxiliary power. ation.
The Classic 300D Perkins uses the Perkins 404C-22 Engine Protection - The system shuts the engine
industrial water-cooled diesel engine. down in the event of sudden low oil pressure or high
coolant temperature. A warning light on the control
DESIGN FEATURES panel will indicate such a fault. To reset the engine for
restarting, turn the ignition switch off then on.
Control Panel
Oil Drain Valve - A ball valve, hose and clamp are
Both the engine and the welder controls are located
standard.
on one recessed panel at the exciter end of the
machine. The welder controls consist of a five step
Remote Control - The Remote / Local Switch and
“Current Range Selector� switch and a “Fine Current
Receptacle are 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
weather starting.
The control panel also contains an engine tempera-
ture gauge, a battery charging ammeter, an oil pres-
sure gauge, one three prong grounding type recepta-
cles, one GFCI receptacle for auxiliary power and
three circuit breakers for protection.
CLASSIC 300D PERKINS
A-3 A-3
INSTALLATION
PRE-OPERATION INSTALLATION CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SUR-
WARNING
FACES.
Do not attempt to use this equipment until you Where there is a combustible surface directly under sta-
have thoroughly read the engine manufacturer’s tionary or fixed electrical equipment, the surface shall
manual supplied with your welder. It includes be covered with a steel plate at least .06�(1.6mm) thick,
important safety precautions, detailed engine which shall extend not more than 5.90�(150mm) beyond
starting, operating and maintenance instructions, the equipment on all sides.
and parts lists.
--------------------------------------------------------------------------------
------------------------------------------------------------------------
MACHINE GROUNDING
ELECTRIC SHOCK can kill.
� Do not touch electrically live parts or According to the United States National Electrical
electrode with skin or wet clothing. Code, the frame of this portable generator is not
� Insulate yourself from work and
required to be grounded and is permitted to serve as
ground
the grounding means for cord connected equipment
� Always wear dry insulating gloves.
plugged into its receptacle.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
� Use in open, well ventilated areas or Some state, local, or other codes or unusual operating
vent exhaust outside. circumstances may require the machine frame to be
grounded. It is recommended that you determine the
extent to which such requirements may apply to your
------------------------------------------------------------------------
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
provided on the welding generator frame foot. In gen-
guards off.
� Stop engine before servicing. eral, if the machine is to be grounded, it should be
� Keep away from moving parts. 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 insulat-
See additional warning information at the
ed joints, or to the metal framework of a building
front of this operator’s manual. which has been effectively grounded. The U.S.
-----------------------------------------------------------
National Code lists a number of alternate means of
grounding electrical equipment.
EXHAUST SPARK ARRESTER
LIFT BAIL
Some federal, state or local laws may require that
engines be equipped with exhaust spark arresters A lift bail is provided for lifting with a hoist.
when they are operated in certain locations where
WARNING
unarrested sparks may present a fire hazard. The
standard muffler included with this welder does not � Lift only with equipment of adequate
qualify as a spark arrester. When required by local lifting capacity.
regulations, a suitable spark arrester must be installed � Be sure machine is stable when lifting.
and properly maintained. � Do not lift this machine using lift bail if
it is equipped with a heavy accessory
such as trailer or gas cylinder.
CAUTION
FALLING � Do not lift machine if lift bail is
Use of an incorrect arrester may lead to engine damage
EQUIPMENT can damaged.
or performance loss. Contact the engine manufacturer
cause injury. � Do not operate machine while
for specific recommendations.
suspended from lift bail.
------------------------------------------------------------------------
LOCATION / VENTILATION ----------------------------------------------------------------------------
TRAILER (SEE OPTIONAL FEATURES)
Always operate the welder with the doors closed.
If the user adapts a non-Lincoln trailer, he must assume
Leaving the doors open changes the designed air flow
responsibility that the method of attachment and usage
and may cause overheating.
does not result in a safety hazard nor damage the weld-
ing equipment. Some of the factors to be considered are
The welder should be located to provide an unrestrict-
as follows:
ed flow of clean, cool air. Also, locate the welder so
1. Design capacity of trailer vs. weight of Lincoln equip-
that engine exhaust fumes are properly vented to an
ment and likely additional attachments.
outside area.
CLASSIC 300D PERKINS
A-4 A-4
INSTALLATION
2. Proper support of, and attachment to, the base of PRE-OPERATION SERVICE
the welding equipment so there will be no undue
CAUTION
stress to the framework.
3. Proper placement of the equipment on the trailer to READ the engine operating and maintenance instruc-
ensure stability side to side and front to back when tions supplied with this machine.
being moved and when standing by itself while
being operated or serviced.
WARNING
4. Typical conditions of use, i.e., travel speed, rough- � Stop engine while fueling.
ness of surface on which the trailer will be operat-
� Do not smoke when fueling.
ed; environmental conditions, likely maintenance.
� Keep sparks and flame away
from tank.
5. Conformance with federal, state and local laws. (1)
� Do not leave unattended while
(1) Consult your federal, state and local laws regarding specific
fueling.
requirements for use on public highways.
� Wipe up spilled fuel and allow
VEHICLE MOUNTING
DIESEL FUEL fumes to clear before starting
WARNING can engine.
cause fire � Do not overfill tank, fuel expan-
Improperly mounted concentrated loads may
sion may cause overflow.
cause unstable vehicle handling and tires or other
DIESEL FUEL ONLY
components to fail.
------------------------------------------------------------------------
� Only transport this Equipment on serviceable
vehicles which are rated and designed for such
OIL
loads.
� Distribute, balance and secure loads so vehicle
This unit is supplied from the factory with the engine
is stable under conditions of use.
crankcase filled with a high quality SAE 10W/30 oil.
� Do not exceed maximum rated loads for compo-
This oil should be acceptable for most typical ambient
nents such as suspension, axles and tires.
temperatures. Consult the engine operation manual
� Use appropriate nuts bolts and lockwashers to
for specific engine manufacturer’s recommendations.
attach the equipment base to the metal bed or
Upon receipt of the welder, check the engine dipstick
frame of vehicle.
to be sure the oil is at the “full� mark. DO NOT overfill.
� Follow vehicle manufacturer’s instructions.
------------------------------------------------------------------------
FUEL
POLARITY CONTROL AND CABLE SIZES
Fill the fuel tank with the grade of fuel recommended
in the Engine Operator’s manual. Make sure the fuel
With the engine off, route the electrode and work
valve on the water separator is in the open position.
cables through the strain relief bracket on the base
and connect to the studs located below the fuel tank
mounting rail. (See size recommendations below.)
COOLING SYSTEM
For positive polarity, connect the electrode cable to
the terminal marked �+�. For Negative polarity, con-
nect the electrode cable to the �-� stud. These con- The radiator has been filled at the factory with a 50-50
nections should be checked periodically and tightened mixture of ethylene glycol antifreeze and water.
if necessary. Check the radiator level and add a 50-50 solution as
needed (see engine manual or antifreeze container for
When welding at a considerable distance from the alternate antifreeze recommendations).
welder, be sure you use ample sized welding cables.
RECOMMENDED COPPER CABLE SIZES
Cables Sizes for Combined Length
of Electrode Plus Work Cable
Amps Duty Cycle Up to 200ft.(61m) 200 to 250ft.
(61 to 76m)
250 100% 1 1/0
300 60% 1/0 2/0
CLASSIC 300D PERKINS
A-5 A-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:
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 automatical-
ly 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 PERKINS
B-1 B-1
OPERATION
ENGINE OPERATION 7. Allow the engine to run at high idle speed for sev-
eral minutes to warm the engine. Stop the engine
WARNING and recheck the oil level, after allowing sufficient
time for the oil to drain into the pan. If the level is
Do not attempt to use this equipment until you
down, fill it to the full mark again. The engine con-
have thoroughly read the engine manufacturer’s
trols were properly set at the factory and should
manual supplied with your welder. It includes
important safety precautions, detailed engine require no adjusting when received.
starting, operating and maintenance instructions,
and parts lists. COLD WEATHER STARTING:
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
With a fully charged battery and the proper weight oil,
� Do not touch electrically live parts or
the engine should start satisfactorily even down to
electrode with skin or wet clothing.
about -15°F (-26°C), it maybe desirable to install cold-
� Insulate yourself from work and
ground starting aides.
� Always wear dry insulating gloves.
------------------------------------------------------------------------ Note: Extreme cold weather staring may require
ENGINE EXHAUST can kill.
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
� Do not operate with doors open or starting fluids be used!
guards off.
------------------------------------------------------------------------
� Stop engine before servicing.
HIGH ALTITUDE OPERATION:
� 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
See additional warning information at the
at an altitude above this, the fuel consumption and
front of this operator’s manual.
exhaust emissions may be excessive.
-----------------------------------------------------------
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
STOPPING THE ENGINE
cause overheating.
1. Turn the “IGNITION� switch to “OFF�
STARTING THE CLASSIC 300D PERKINS
At the end of each day’s welding, check the crankcase
404C-22 DIESEL ENGINE
oil level, drain accumulated dirt and water from the
water separator located on the fuel rail. Refill the fuel
1. Turn the “IDLER� switch to “HIGH�.
tank to minimize moisture condensation in the tank.
2. Turn the “IGNITION� switch to “ON�.
Also, running out of fuel tends to draw dirt into the fuel
3. Press the Glow Plug button for 20 to 30 seconds.
system.
(maximum 60 seconds).
4. Press the Start button. When the engine starts
When hauling the welder between job sites, close the
running, release both buttons. If the engine fails to
fuel feed valve on the separator located on the fuel
start in 20 seconds, wait 30 seconds and repeat
rail.
the above procedure.
5. Observe the oil pressure. If no pressure shows
If the fuel supply is cut off or runs out while the fuel
within 30 seconds, stop the engine and consult
pump is operating, air may be entrapped in the fuel
the engine operating manual. To stop the engine,
distribution system. If this happens, bleeding of the
turn the “IGNITION� switch to “OFF�.
fuel system may be necessary. Use qualified person-
6. If the engine protection warning light comes on
nel to do this per the instructions in the MAINTE-
during cranking or after start up, the “IGNITION�
NANCE section of this manual.
switch must be turned “OFF� to reset the engine
protection system.
CLASSIC 300D PERKINS
B-2 B-2
OPERATION
DUTY CYCLE
ENGINE BREAK-IN
The NEMA output rating of the Classic 300D Perkins is 300
Lincoln Electric selects high quality, heavy-duty industrial
amperes at 32 arc volts on a 60% duty cycle (consult
engines for the portable welding machines we offer.
Specifications in this manual for alternate ratings). Duty
While it is normal to see a small amount of crankcase oil
cycle is based on a ten minute period; thus, the welder can
consumption during initial operation, excessive oil use,
be loaded at rated output for six minutes out of every ten
wet stacking (oil or tar like substance at the exhaust
minute period.
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
CAUTION
for extended periods of time are especially susceptible to
the conditions described above. To accomplish success-
DO NOT TURN THE “CURRENT RANGE SELECTOR�
ful engine break-in, most diesel-powered equipment
WHILE WELDING because the current may arc between
needs only to be run at a reasonably heavy load within
the contacts and damage the switch.
the rating of the welder for some period of time during
-------------------------------------------------------------------------------
the engine’s early life. However, if the welder is subject-
The “Current Range Selector� provides five overlapping cur-
ed to extensive light loading, occasional moderate to
rent ranges. The “Fine Current Adjustment� adjusts the cur-
heavy loading of the engine may sometimes be neces-
rent from minimum to maximum within each range. Open
sary. Caution must be observed in correctly loading a
circuit voltage is also controlled by the “Fine Current
diesel/generator unit.
Adjustment� permitting control of the arc characteristics.
1. Connect the welder output studs to a suitable resis-
A high open circuit voltage setting provides the soft “butter-
tive load bank. Note that any attempt to short the
ing� arc with best resistance to pop-outs preferred for most
output studs by connecting the welding leads togeth-
welding. To get this characteristic, set the “Current Range
er, direct shorting of the output studs, or connecting
Selector� to the lowest setting that still provides the current
the output leads to a length of steel will result in cat-
you need and set the “Fine Current Adjustment� near maxi-
astrophic damage to the generator and voids the
mum.
warranty.
2. Set the welder controls for an output current and
For example: to obtain 175 amps and a soft arc, set the
voltage within the welder rating and duty cycle. Note
“Current Range Selector� to the 190-120 position and then
that any attempt to exceed the welder rating or duty
adjust the “Fine Current Adjustment� for 175 amps.
cycle for any period of time will result in catastrophic
damage to the generator and voids the warranty.
When a forceful “digging� arc is required, usually for vertical
3. Periodically shut off the engine and check the
and overhead welding, use a higher “Current Range
crankcase oil level.
Selector� setting and lower open circuit voltage.
WELDER OPERATION For example: to obtain 175 amps and a forceful arc, set the
“Current Range Selector� to the 240-160 position and the
“Fine Current Adjustment� setting to get 175 amps.
WARNING
ELECTRIC SHOCK can kill. Some arc instability may be experienced with EXX10 elec-
� Do not touch electrically live parts or trodes when trying to operate with long arc techniques at
electrode with skin or wet clothing.
settings at the lower end of the open circuit voltage range.
� Insulate yourself from work and ground.
CAUTION
FUMES & GASES can be dangerous.
� Keep your head out of the fumes.
DO NOT attempt to set the “Current Range Selector� between
� Use ventilation or exhaust to remove
the five points designated on the nameplate.
fumes from breathing zone.
--------------------------------------------------------------------------------
WELDING SPARKS can cause fire or
These switches have a spring loaded cam which almost
explosion.
eliminates the possibility of setting this switch between the
� Keep flammable material away.
designated points.
ARC RAYS can burn.
� Wear eye, ear, and body protection.
CLASSIC 300D PERKINS
B-3 B-3
OPERATION
IDLER OPERATION AUXILIARY POWER
Start the engine with the “Idler� switch in the “High� The AC auxiliary power, supplied as a standard, has a
position. Allow it to run at high idle speed for several rating of 3.0 KVA of 115/230 VAC (60 hertz).
minutes to warm the engine. See Specifications for
operating speeds. With the 3.0 KVA, 115/230 VAC auxiliary power, one
115V GFCI and one 230V duplex, grounding type
The idler is controlled by the “Idler� toggle switch on receptacles are provided. The circuit is protected with
the welder control panel. The switch has two posi- circuit breakers.
tions as follows:
The rating of 3.0 KVA permits a maximum continuous
1. In the “High� position, the idler solenoid current of 13 amps to be drawn from the 230 volt
deactivates, and the engine goes to high idle duplex receptacle. Or a total of 20 amps can be drawn
speed. The speed is controlled by the governor. 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: An optional power plug kit is available. When this kit is
specified, the customer is supplied with a plug for
a. When welding or drawing power for lights or tools each receptacle.
(approximately 100 watts minimum) from the
receptacles, the idler solenoid deactivates 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.
c. If the welding or power load is not re-started
before the end of the time delay, the idler sole-
noid activates and reduces the engine to low idle
speed.
CLASSIC 300D PERKINS WITH PERKINS 104-22 DIESEL ENGINE
TYPICAL FUEL CONSUMPTION DATA
Low Idle (1375 RPM)-No Load @ 45 Volts 0.28 gal/hr ( 1.06 ltrs/hr)
High Idle (1800 RPM)-No Load @ 96.6 Volts 0.42 gal/hr ( 1.59 ltrs/hr)
3000 Watts 0.59 gal/hr ( 2.23 ltrs/hr)
250 Amps @ 30 Volts 1.03 gal/hr ( 3.90 ltrs/hr)
300 Amps @ 32 Volts 1.37 gal/hr ( 5.19 ltrs/hr)
CLASSIC 300D PERKINS
C-1 C-1
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
compact case is designed for easy carrying, complete
WARNING with a handle. High frequency bypass is built in.
Additionally, the K936-3 control cable is required if
Pipe Thawing with an arc welder can cause fire,
remote control is used. If remote control is not used
explosion, damage to electric wiring or to the arc
the K936-4 control cable is required.
welder if done improperly. The use of an arc
welder for pipe thawing is not approved by the
PTA-26V TIG Torch K1783-9
CSA, nor is it recommended or supported by
Air cooled 200 amp torch equipped with valve for gas
Lincoln Electric.
flow control. 25Ft. length.
------------------------------------------------------------------------
Magnum Parts Kit For PTA-26V TIG Torch KP509
Power Plug Kit K802D
A power plug kit for the auxiliary power receptacles is
Control Cable K936-4 (required for TIG Module)
available. (Provides a plug for each receptacle.)
Control cable for connecting the K930-2 TIG Module.
Spark Arrestor Kit K903-1
Arc Start Switch K814 (required for TIG Module)
Includes a heavy gage steel, approved spark arrestor,
Comes with a 25ft.(7.6m) cable.
clamp and adapter for mounting to the muffler exhaust
Attaches to the TIG torch for convenient finger control.
pipe.
Contactor Kit K938-1 (required for TIG Module)
TRAILER K953-1
Provide “Cold� tungsten Tip when welding with the
Two-wheeled trailer with optional fender and light package.
TIG Module.
For highway use, consult applicable federal, state, and local
laws regarding possible additional requirements. There is a
Control Cable Extension K937-45
choice of 2 hitches, a fender & a light package.
Allows the TIG Module to be operated at distances up
to 200 ft. from the power source.Available in 45 ft.
Ball Hitch K958-1
(13.7m).
Lunette Eye Hitch K958-2
Fender & Light Kit K959-1
Water Valve Kit K844-1
Cable Rack K965-1
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 PERKINS
C-2 C-2
ACCESSORIES
WIRE FEEDER OPTIONS Magnum Spool Gun K487-25
Hand held semiautomatic wire feeder requires SG
Wire Feed Module K623-1
Control Module. 25 ft. length.
Provides constant voltage (CV) output with improved
SG Control Module K488 (For Magnum Spool Gun)
arc stability for Innershield welding. Excellent for MIG
welding. Recommended wire feeders are the LN-7,
The interface between the power source and the
LN-23P and LN-25. (Factory installed on the K1643-
spool gun. Provides control of wire speed and gas
2).
flow.
Input Cable K691-10 ( For SG Control Module)
LN-25 Wire Feeder K449
For Lincoln engine drives with 14-pin MS-type con-
Portable CC/CV unit for flux-cored and MIG welding.
nection, separate 115V NEMA receptacle and output
Includes Gas Solenoid & Internal Contactor. Requires
stud connections. 10 ft. length.
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 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.
CLASSIC 300D PERKINS
D-1 D-1
MAINTENANCE
SAFETY PRECAUTIONS 4. Follow the engine service schedule in this manual
and the detailed maintenance and troubleshooting
WARNING in the engine manufacturer’s manual.
Have qualified personnel do the maintenance
COOLING SYSTEM
work. Turn the engine off before working inside
the machine. In some cases, it may be neces-
The Classic 300D Perkins is equipped with a pressure
sary to remove safety guards to perform
radiator. Keep the radiator cap tight to prevent loss of
required maintenance. Remove guards only
coolant. Clean and flush the cooling system periodi-
when necessary and replace them when the
cally to prevent clogging the passage and overheating
maintenance requiring their removal is com-
the engine. When antifreeze is needed, always use
plete. Always use the greatest care when work-
the permanent type.
ing near moving parts.
BEARINGS
Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
This welder is equipped with a double-shielded ball
following the instructions, take the machine to bearing having sufficient grease to last indefinitely
the nearest Lincoln Field Service Shop. under normal service. Where the welder is used con-
----------------------------------------------------------------------- stantly or in excessively dirty locations, it may be nec-
ELECTRIC SHOCK can kill. essary to add one half ounce of grease per year. A
� Do not touch electrically live parts or pad of grease one inch wide, one inch long, and one
electrode with skin or wet clothing.
inch high weighs approximately one half ounce. Over-
� Insulate yourself from work and
greasing is far worse than insufficient greasing.
ground
� Always wear dry insulating gloves.
When greasing the bearings, keep all dirt out of the
area. Wipe the fittings completely clean and use clean
------------------------------------------------------------------------
equipment. More bearing failures are caused by dirt
ENGINE EXHAUST can kill.
� Use in open, well ventilated areas or introduced during greasing than from insufficient
vent exhaust outside. grease.
COMMUTATOR AND BRUSHES
------------------------------------------------------------------------
MOVING PARTS can injure.
WARNING
� Do not operate with doors open or
guards off.
Uncovered rotating equipment can be dangerous.
� Stop engine before servicing.
Use care so your hands, hair, clothing or tools do
� Keep away from moving parts.
not catch in the rotating parts. Protect yourself
------------------------------------------------------------------------
See additional warning information at from particles that may be thrown out by the rotat-
ing armature when stoning the commutator.
front of this operator’s 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 Periodically inspect the commutator, slip rings, and
least once every two months. In particularly dirty brushes by removing the covers. DO NOT remove or
locations, this cleaning may be necessary once a replace these covers while the machine is running.
week. Use low pressure air to avoid driving dirt into Commutators and slip rings require little attention.
the insulation. However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
2. “Current Range Selector� contacts should not be using fine sandpaper or a commutator stone. Never
greased. To keep the contacts clean, rotate the cur- use emery cloth or paper for this purpose.
rent control through its entire range frequently.
Good practice is to turn the handle from maximum
to minimum setting twice each morning before start-
ing to weld.
3. Put a drop of oil on the “Current Range Selector�
shaft at least once every month.
CLASSIC 300D PERKINS
D-2 D-2
MAINTENANCE
Replace brushes when they wear within 1/4� of the
PURGING AIR FROM FUEL SYSTEM
pigtail. A complete set of replacement brushes should
(PERKINS 404C-22 ENGINE)
be kept on hand. Lincoln brushes have a curved face
to fit the commutator. Have an experienced mainte-
WARNING
nance man seat these brushes by lightly stoning the
commutator as the armature rotates at full speed until
Keep fuel clear of open flames or arcs, allow
contact is made across the full face of the brushes.
engine to cool before working on the fuel system.
After stoning, blow out the dust with low pressure air.
Wipe up any spilled fuel and do not start engine
To seat slip ring brushes, position the brushes in until fumes clear.
place. Then slide one end of a piece of fine sandpaper ------------------------------------------------------------------------
between slip rings and brushes with the coarse side If the engine is running rough and you suspect air has
against the brushes. With slight additional finger pres- been trapped in the fuel system, (e.g. the engine was
sure on top of the brushes, pull the sandpaper around allowed to run out of fuel) perform the following steps
the circumference of the rings - in direction of rotation using qualified personnel:
only - until brushes seat properly. In addition, stone
slip ring with a fine stone. Brushes must be seated 1. Loosen by two or three turns, the vent screw
100%. (Figure D.1) on the fuel inlet connection.
Arcing or excessive exciter brush wear indicates a
possible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.
Vent Screw
IDLER MAINTENANCE
CAUTION
Priming
Before doing electrical work on the idler printed
Lever
circuit board, disconnect the battery.
------------------------------------------------------------------------ FIGURE D.1
When installing a new battery or using a jumper bat-
tery to start the engine, be sure the battery polarity is 2. Operate the electric fuel pump by turning the
connected properly. The correct polarity is negative “Ignition� switch “ON� until fuel, free of air, flows
ground. Damage to the engine alternator and the from the vent point. Tighten the vent screw.
printed circuit board can result from incorrect connec-
tion. 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
battery.
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 replace-
ment item number.
CLASSIC 300D PERKINS
D-3 D-3
MAINTENANCE
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 TYPE OR QUANTITY
I Coolant level
I 50/50 Water/Ethylene Glycol
Concentration of antifreeze
R Coolant (NOTE 3) 9.5qrts., 9.0L
I Engine oil level (NOTE 1)
R Engine oil (NOTE 1 & 3) 11.2qrts, 10.6L (including filter)
R
R R Engine oil filter Perkins #140517050
C Drain water separator & fuel strainer
R Fuel filter canister Perkins #2656613
I Tension of alternator drive belt
I Alternator drive belt wear
Perkins #080109107
R Alternator drive belt
C Air filter (earlier check may be req’d.)
R Air filter element Donaldson #P821575
R Renew the engine breather
I Tighten cylinder head
I Valve clearances Intake .008", exhaust .008"
I Electrical systems
I All nuts and bolts for tightness
I Injector performance Contact Perkins
I Leaks or engine damage
I Battery
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. S25953
CLASSIC 300D PERKINS
E-1 E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)�. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE� lists
the obvious external possibilities that may contribute
to the machine symptom.
WARNING
Have qualified personnel do the troubleshooting
work. Turn the engine off before working inside
the machine. In some cases, it may be neces-
sary to remove safety guards to perform
required maintenance. Remove guards only
when necessary and replace them when the
maintenance requiring their removal is com-
plete. Always use the greatest care when work-
ing near moving parts.
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.
------------------------------------------------------------
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CLASSIC 300D PERKINS
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Machine fails to hold the output 1. Rough or dirty commutator.
(heat) consistently.
2. Brushes may be worn down to
Limit.
3. Field circuit may have variable
resistance connection or inter-
mittent open circuit due to
loose connection or broken
wire.
4. Electrode lead or work lead
connection may be poor.
5. Wrong grade of brushes may
have been installed on gener-
ator.
6. Field rheostat may be making
poor contact and overheating.
Welder starts but fails to generate 1. Generator or exciter brushes
current. may be loose or missing.
2. Exciter may not be operating.
If all recommended possible areas
3. Field circuit of generator or of misadjustment have been
exciter may be open. checked and the problem persists,
Exciter may have lost excita- Contact your local Lincoln
4.
Authorized Field Service Facility.
tion.
5. Series field and armature cir-
cuit may be open-circuited.
Welding arc is loud and spatters 1. Current setting may be too
excessively. high.
2. Polarity may be wrong.
Welding current too great or too 1. Exciter output low causing low
small compared to indication on output compared to dial indica-
the dial. tion.
2. Operating speed too low or too
high.
Arc continuously pops out. 1. “Current Range Selector�
switch may be set at an inter-
mediate position.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CLASSIC 300D PERKINS
E-3 E-3
TROUBLESHOOTING
ELECTRONIC IDLER TROUBLESHOOTING GUIDE
With Idler Control Switch in the Auto Position,
Engine Will Not Return to Low Idle in Approximately 15 Seconds
After Welding and Auxiliary Loads are Removed
Set Idler Control Switch
to the Auto Position
Check for Continuity through Idler
Control Switch
Open Closed
Measure DC Voltage on Replace Idler
Idler Solenoid Coil Control Switch
0 VDC 12 VDC
Check Continuity of Check for Jamming
Reed Switch in Weld Circuit of the Idler Solenoid
Mechanism
Open Closed
1. Check Wiring in Replace Reed
Idler Solenoid Switch
Circuit
2. Replace Idler
P.C. Board
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CLASSIC 300D PERKINS
E-4 E-4
TROUBLESHOOTING
ELECTRONIC IDLER TROUBLESHOOTING GUIDE
With Idler Control Switch in the AUTO Position,
Engine Will Not Pick Up Speed When:
The Arc is Struck The Auxiliary Power Load is Turned ON
Reed Switch in Weld Circuit Power Load Too Small
Defective -- Will Not Close Try Load Above 150 Watts
To Check: Short the Red Lead Engine Does Not Pick Up Speed
on P.C. Board to Welder Frame.
1. Check for Jamming of the Idler
Solenoid Mechanism, or broken return
spring.
2. Check for Continuity of Current
Transformer (Toroid). Replace as
Engine Picks Up Speed Engine Does Not Pick Up Required.
Speed
1. Check for Break in 3. Check Idler Circuit Wiring and Repair
Red Lead and Repair 1. Check for Jamming of as Required.
the Idler Solenoid
2. Replace Reed Switch Mechanism, or broken 4. Replace Idler P.C. Board.
in Weld Circuit. return spring.
2. Check Idler Circuit
Wiring and Repair as
Required.
3. Replace Idler P.C.
Board.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CLASSIC 300D PERKINS
E-5 E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Engine does not start. 1. Lack of fuel.
2. Air mixed in the fuel system.
3. Clogged fuel filter.
4. Irregular and faulty fuel supply
(Injector pump trouble).
5. Glow plug not heated.
6. Clogged air cleaner.
7. No compression.
8. Engine protection light is ON.
Engine does not turn over. 1. Faulty Ignition switch and or
Injector pump solenoid.
2. Insufficient charging or com-
plete discharge of the battery.
If all recommended possible areas
3. Improper viscosity of the lubri- of misadjustment have been
cating oil. checked and the problem persists,
Contact your local Lincoln
Irregular running of the engine. 1. Air mixed in the fuel system. Authorized Field Service Facility.
2. Uneven fuel injection (Faulty
fuel injector pump).
3. Clogged fuel filter.
4. Defective governor.
5. Engine itself defective.
Engine stops during operation and 1. Lack of fuel in the fuel tank.
the Engine Protection light does
not turn on. 2. Clogged fuel filter.
3. Air mixed in the fuel system.
4. Faulty function of the engine.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CLASSIC 300D PERKINS
E-6 E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Engine stops during operation and 1. Overheat of the Engine.
the Engine Protection light does turn
on. Lack of Coolant Supply coolant.
Inspect leakage and correct.
Loose or slipping fan belt Remove
oil, dust, etc. and tighten.
Damaged fan belt. Replace.
Clogged radiator Flush the radia-
tor.
Clogged radiator fin. Clean.
Dust or scale clogged in the cooling
water passage. Flush the system.
Faulty function of the thermostat.
Inspect or replace thermostat.
Lack of lubricating oil. Add oil.
Overloading Decrease the load.
Faulty Idler/Engine Protection
Printed Circuit Board. Replace.
2. Loss of Engine Oil Pressure.
Lack of engine oil Supply oil up to
the specified level.
Fault in the Oil Pressure Switch
Replace the switch.
Oil leakage from the lubricating
system Inspect and retighten.
Clogged oil filter Replace with new
one.
Oil too light Drain and refill with
proper grade.
Faulty Idler/Engine Protection
P.C. Board. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CLASSIC 300D PERKINS
E-7 E-7
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
White or Blue Smoke. 1. Excess engine oil.
2. Too low viscosity of the
engine oil.
3. Faulty injection timing.
Dark Grey Smoke. 1. Unsuitable fuel.
2. Excess injection.
3. Faulty function of the engine.
4. Overloading.
5. Clogged air cleaner.
Faulty Charging. 1. Loose fan belt.
2. Faulty wiring. If all recommended possible areas
of misadjustment have been
3. Faulty battery. checked and the problem persists,
Contact your local Lincoln
4. Worn out alternator brush. Authorized Field Service Facility.
Starter Motor does not run. 1. Loose or damaged wiring.
2. Drained voltage from battery.
3. Damaged starter motor
(including solenoid).
Engine Protection Light not com- 1. Broken Light Bulb.
ing on.
2. Faulty light wiring.
3. Faulty Engine Control Unit.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CLASSIC 300D PERKINS
CLASSIC 300D PERKINS WIRING DIAGRAM FOR CODES 11110. 11111
F-1
LEAD COLOR CODE
CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR.
44
58
212D
212C
59
61
54
93
57
B-BLACK OR R-RED OR
LEADS CONNECTED TO ENGINE IDLER/ENGINE P.C. BOARD, SEE DETAIL
GRAY PINK
1 2 3 4 5 6 7 8 9 10 G-GREEN U-BLUE
NEUTRAL BONDED TO FRAME.
*
J1 P10 N-BROWN W-WHITE
NEUTRE RACCORDE AU BATI. 121110 9 8 7 6 5 4 3 2 1 Y-YELLOW
J5
IDLER/ENGINE PROTECTION P.C. BD. 1
400D Y
2
400E W
TO CURRENT
J2 3
600B
48 U
4 TRANSFORMER
610
B1 B2 B3 B4 B5 B6 N
SLIP RINGS
ALTERNATOR
610
-
IDLER
55
60A 610A
+ +
SOLENOID SLIP RING
602B
GLOW B
844 212E NEAREST
W
PLUGS
602
AC
*55 600C AC
844A TO IRON
R
*57
115 VOLT GFCI
PUMP J8 P8 W R
600
230 VOLT
RECEPTACLE
212E SOLENOID 41 G
1
41
-
RECEPTACLE
GND-C 2
600A
*212C 400F 21
7A X
ENGINE 3
42
HOT LINE HOT LOAD
*58 Y
*212D
53
4
HOUR
GLOW 15A
*61
IGNITION 42
602A
58H FUEL 5
METER
PLUG START ENGINE FUSE
PUMP
SWITCH 6 W
RHEOSTAT
CB4
+- WHITE LINE
FAILURE WHITE LOAD
10A LAMP 215
56 *844 214 REMOTE CONTROL
IDLER
60C
212A
*93
52
51C 6A
SWITCH SWITCH AND UY
51A 43 TEMPERATURE 810
WATER NW
RECEPTACLE
SWITCH/SENDER
SI ALT. AUX
GND-E
TEMPERATURE
50A *44 POWER SHUNT
GAUGE W
G 11A WINDINGS FIELD
G CB3
CB2
CB1
15A
41 15A
+ 20A
-
SERIES FIELD
60 820 SELECTOR
AMMETER 212B GND-T SWITCH -+
GND-N 200 *54
STARTING
90-MIN
G WK
GND-M
11B
MOTOR 130-80
I
S GROUND
S OIL PRESSURE GND-S +-
190-120
B SCREW
50 SWITCH/SENDER
OIL 240-160
NEAR FUSE 220-MAX
PRESSURE G
+
TO IDLER / ENGINE
GAUGE 11C
*59 INTERPOLE COILS
EXC PROTECTION P.C.Bd.
+ DIODE
51 ALTERNATOR AND
WELDING GENERATOR
51G CURRENT TRANSFORMER
MOV
*844A REED
GND-B
DIAGRAMS
*60A BRUSH POSITION SHOWN AS
SWITCH
GND-A
VIEWED FROM CONTROL PANEL
POSITIVE
NEGATIVE
GROUND SCREW NEAR
GROUND GROUND
CLASSIC 300D PERKINS
TO BASE TO ENGINE (CC+) & (CV+ WITH W.F.M.)
ENGINE GAUGES (CC-)
K924-5 REMOTE CONTROL (OPTIONAL) WIRE FEED MODULE (OPTIONAL)
ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
PLUG FOR REMOTE CONTROL
CONNECT "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
POTENTIOMETER
INLINE CONNECTORS
X
Y PLUG P5
W.F.M.
CONTROL
PANEL
G B W #8 LEAD WIRE FEED
CONNECT TO POS. & NEG. POS.
MODULE
NEG.
OUTPUT TERMINALS
RESISTORS #2 HEAVY LEAD
NEGATIVE CV
608
OUTPUT TERMINAL
609
PANEL #2 HEAVY LEAD
REMOTE CONTOL CONNECT TO CASE CONNECT TO NEG. 250 AMP THERMOSTAT ASSEMBLY
POTENTIOMETER BOX BRUSH HOLDER
MACHINE MUST NOT BE RUNNING
WHEN MAKING THESE CONNECTIONS.
A
M20499
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-1
CLASSIC 300D PERKINS WIRING DIAGRAM FOR CODES 11248, 11249, 11280, 11281
F-2
LEAD COLOR CODE
CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR.
44
58
212D
212C
59
61
54
93
57
B-BLACK OR R-RED OR
LEADS CONNECTED TO ENGINE IDLER/ENGINE P.C. BOARD, SEE DETAIL
ON OLDER BOARDS, GRAY PINK
1 2 3 4 5 6 7 8 9 10 J31 WAS J1, G-GREEN U-BLUE
NEUTRAL BONDED TO FRAME.
*
J31 P10 N-BROWN
J32 WAS J2. W-WHITE
NEUTRE RACCORDE AU BATI. 121110 9 8 7 6 5 4 3 2 1 Y-YELLOW
J5
IDLER/ENGINE PROTECTION P.C. BD. 1
400D Y
2
400E W
TO CURRENT
J32 3
600B
48 U
4 TRANSFORMER
610
B1 B2 B3 B4 N
SLIP RINGS
ALTERNATOR
610
-
IDLER
55
60A 610A
+ +
SOLENOID SLIP RING
602B
GLOW B
844 212E NEAREST
W
PLUGS
602
AC
*55 600C AC
844A TO IRON
R
*57
115 VOLT GFCI
PUMP J8 P8 W R
600
230 VOLT
RECEPTACLE
212E SOLENOID 41 G
1
41
-
RECEPTACLE
GND-C 2
600A
*212C 400F 21
7A X
ENGINE 3
42
HOT LINE HOT LOAD
*58 Y
*212D
53
4
HOUR
GLOW 15A
*61
IGNITION 42
602A
58H FUEL 5
METER
PLUG START ENGINE FUSE
PUMP
SWITCH 6 W
RHEOSTAT
CB4
+- WHITE LINE
FAILURE WHITE LOAD
10A LAMP 215
56 *844 214 REMOTE CONTROL
IDLER
60C
212A
*93
52
51C 6A
SWITCH SWITCH AND UY
51A 43 TEMPERATURE 810
WATER NW
RECEPTACLE
SWITCH/SENDER
SI ALT. AUX
GND-E
TEMPERATURE
50A *44 POWER SHUNT
GAUGE W
G 11A WINDINGS FIELD
G CB3
CB2
CB1
15A
41 15A
+ 20A
-
SERIES FIELD
60 820 SELECTOR
AMMETER 212B GND-T SWITCH -+
GND-N 200 *54
STARTING
90-MIN
G WK
GND-M
11B
MOTOR 130-80
I
S GROUND
S OIL PRESSURE GND-S +-
190-120
B SCREW
50 SWITCH/SENDER
OIL 240-160
NEAR FUSE 220-MAX
PRESSURE G
+
TO IDLER / ENGINE
D+
GAUGE 11C
*59 INTERPOLE COILS
PROTECTION P.C.Bd. DIODE
51
AND
WELDING GENERATOR
B+ ALTERNATOR
CURRENT TRANSFORMER
MOV
*844A REED
GND-B
*60A
DIAGRAMS
BRUSH POSITION SHOWN AS
SWITCH
GND-A
VIEWED FROM CONTROL PANEL
POSITIVE
NEGATIVE
GROUND SCREW NEAR
GROUND GROUND
CLASSIC 300D PERKINS
TO BASE TO ENGINE (CC+) & (CV+ WITH W.F.M.)
ENGINE GAUGES (CC-)
K924-5 REMOTE CONTROL (OPTIONAL) WIRE FEED MODULE (OPTIONAL)
ON MACHINE, REMOVE PLUG "P10" FROM CONNECTOR "J5".
PLUG FOR REMOTE CONTROL
CONNECT "P5" ON W.F.M. TO CONNECTOR "J5" ON MACHINE.
POTENTIOMETER
INLINE CONNECTORS
X
Y PLUG P5
W.F.M.
CONTROL
PANEL
G B W #8 LEAD WIRE FEED
CONNECT TO POS. & NEG. POS.
MODULE
NEG.
OUTPUT TERMINALS
RESISTORS #2 HEAVY LEAD
NEGATIVE CV
608
OUTPUT TERMINAL
609
PANEL #2 HEAVY LEAD
REMOTE CONTOL CONNECT TO CASE CONNECT TO NEG. 250 AMP THERMOSTAT ASSEMBLY
POTENTIOMETER BOX BRUSH HOLDER
MACHINE MUST NOT BE RUNNING
WHEN 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 specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2
F-3
A
A
24.00
A
A
A
CONTROL PANEL
NOTES:
N.A. CENTER OF GRAVITY WITH
OIL AND WATER IN ENGINE, N.A.
BUT NO FUEL. A L
A
F 40.94
N.B. O.56 TRAILER MOUNTING
N.C.
C.
HOLES. A
A
37.12
N.C. DIMENSION TO TOP OF
EXHAUST ELBOW OR G
RAINCAP.
A
A
A
A
A
A
N.B. O .56 SKID
A A
O .56 SKID A A 4.00
4.00 A
A
MOUNTING HOLE 18.50
MOUNTING A A
A A
23.00 C
HOLE A
A A
A
K 20.62
A
A
D
A
A A
J H
DIAGRAMS
A
A
B
CLASSIC 300D PERKINS
45.5
12.82 41.66
65.00 57.70 8.70 3.25
27.94
CLASSIC 300D PERKINS
S10766-8
C
WELDER A B C D F G H J K L
PART NO.
S10766
F-3
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
|