Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 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....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ 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: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contr...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TABLE OF CONTENTS
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1Safety Precautions..............
Page 8 - INSTALLATION; INPUT - GASOLINE ENGINE
TECHNICAL SPECIFICATIONS – CLASSIC 300G (K1754-1) CLASSIC 300G A-1 INSTALLATION A-1 DC CURRENT RANGE Fine Adjustment in each Range 40-350 Amps DUTY CYCLE 100% 60% RATED DC OUTPUT* VOLTS @ RATED AMPS 30V @ 250A NEMA Rating 32V @ 300A (1) 115V will operate either 60 Hz. or 50/60 Hz. power tools, light...
Page 9 - P R E - O P E R AT I O N I N S TA L L AT I O N; EXHAUST SPARK ARRESTER; LIFT BAIL; SAFETY PRECAUTIONS
P R E - O P E R AT I O N I N S TA L L AT I O N EXHAUST SPARK ARRESTER Some federal, state or local laws may require thatengines be equipped with exhaust spark arresterswhen they are operated in certain locations whereunarrested sparks may present a fire hazard. Thestandard muffler included with this...
Page 10 - PRE-OPERATION SERVICE; OIL; CAUTION; POLARITY CONTROL AND CABLE SIZES; • Do not leave unattended while; GASOLINE FUEL ONLY; GASOLINE
PRE-OPERATION SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. OIL This unit is supplied from the factory with the enginecrankcase filled with a high quality SAE 10W/30 oil.This oil should be acceptable for most typical ambienttemperatures.C o n s u l t t ...
Page 12 - OPERATION; See additional warning information at the
B-1 OPERATION B-1 SAFETY PRECAUTIONS Operate the welder with the doors closed. Leaving thedoors open changes the designed air flow and can causeoverheating. GENERAL DESCRIPTION The Classic® 300G is a heavy duty, engine driven, DCarc welding power source, capable of providing constantcurrent output f...
Page 13 - WELDER OPERATION
• When hauling the welder between job sites, close the fuel feed valve beneath the fuel tank. • If the fuel supply is cut off or runs out while the fuel pump is operating, air may be entrapped in the fueldistribution system. If this happens, bleeding of thefuel system may be necessary. Refer to the ...
Page 14 - AUXILIARY POWER
B-3 OPERATION B-3 CLASSIC 300G AUXILIARY POWER The AC auxiliary power, supplied as a standard, has arating of 3.0 kVA of 115/230 VAC (60 hertz). With the 3.0 kVA, 115/230 VAC auxiliary power, one115V duplex and one 230V duplex, grounding typereceptacle are provided. The circuit is protected withcirc...
Page 15 - ACCESSORIES; OPTIONAL EQUIPMENT; Control Cable Extension -
C-1 ACCESSORIES C-1 CLASSIC 300G OPTIONAL EQUIPMENT (Field Installed) Accessory Set (K704) - Includes 35 ft. (10.7m) elec- trode and 30 ft. (9.1m) work cables, headshield, workclamp and electrode holder. Pipe Thawing with an arc welder can cause fire,explosion, damage to electric wiring or to the ar...
Page 16 - MAINTENANCE
D-1 MAINTENANCE D-1 SAFETY PRECAUTIONS GENERAL INSTRUCTIONS • Blow out the welder and controls with an air hose atleast once every two months. In particularly dirtylocations, this cleaning may be necessary once aweek. Use low pressure air to avoid driving dirt intothe insulation. • ”Current Range Se...
Page 17 - IDLER CONTROL MAINTENANCE; negative; NAMEPLATES
D-2 MAINTENANCE D-2 Replace brushes when they wear within 1/4” of thepigtail. A complete set of replacement brushes shouldbe kept on hand. Lincoln brushes have a curved faceto fit the commutator. Have an experienced mainte-nance man seat these brushes by lightly stoning thecommutator as the armature...
Page 18 - ENGINE SERVICE
D-3 D-3 CLASSIC 300G 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 I Coolant level I Conc 50/50 Water/Ethylene Glycol e nt...
Page 19 - TROUBLESHOOTING; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING CLASSIC 300G E-1 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. CAUTION ELECTRIC SHOCK can kil...
Page 20 - Local Lincoln Authorized Field Service Facility; PROBLEMS
E-2 TROUBLESHOOTING CLASSIC 300G E-2 Observe all Safety Guidelines detailed throughout this manual 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...
Page 21 - NOT
E-3 TROUBLESHOOTING E-3 CLASSIC 300G Observe all Safety Guidelines detailed throughout this manual 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...
Page 22 - ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE
E-4 TROUBLESHOOTING CLASSIC 300G E-4 ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE Engine Will Not Return to Low Idle in Approximately 10 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...
Page 23 - ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE; Auxiliary Load; The Arc is Struck; Both
E-5 TROUBLESHOOTING CLASSIC 300G E-5 ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE With Idler Control Switch in the AUTO Position,Engine Will Not Pick Up Speed When: Auxiliary Load 1. Load too small. Try load above 150 Watts. 2. Check for loose or disconnected wire runningfrom black lead out of exc...
Page 25 - Does
E-7 TROUBLESHOOTING CLASSIC 300G E-7 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. CAUTION Observe all Safety Gui...
Page 27 - DIAGRAMS; CL
F-1 DIAGRAMS F-1 CLASSIC 300G NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Departmen...
Page 29 - WIRING / CONNECTION DIAGRAM
F-3 DIAGRAMS F-3 CLASSIC 300G S26097 A RESISTORS Y X B G W F G ORANGE WHITE JUMPER WHITE JUMPER PIN CABLE CONNECTION TABLE C D E LEAD COLOR RED BLUE CV "WIRE" CONTROL POT CCW BLUE RED ORANGE REMOTE CONTROL BOX CONNECT TO CASE K2464-1 REMOTE CONTROL WIRING / CONNECTION DIAGRAM CC "STICK C...
Page 30 - DIMENSION PRINT
F-4 DIAGRAMS F-4 CLASSIC 300G PART NO. WELDER A B C D E F G H S10766-9 J K L CLASSIC 300G S10766 1/03 METRIC cm (ENGLISH in.) 170.0 (66.91) 146.6 (57.70) 22.1 (8.70) 58.4 (23.00) 67.0 (26.38) 34.3 (13.50) 105.8 (41.66) 8.26 (3.25) 115.6 (45.5) A CONTROL PANEL F G B H D E C O HOLE O MOUNTING HOLE N.A...
Page 31 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...