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
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 flame-resist...
Page 4 - iii; Refer to
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 instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la...
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-1General Description ............
Page 8 - INSTALLATION; TEChNICAL SPECIFICATIONS - CLASSIC® 300D PERKINS; INPuT - DIESEL ENGINE; PhYSICAL DIMENSIONS
A-1 INSTALLATION CLASSIC® 300D PERKINS A-1 TEChNICAL SPECIFICATIONS - CLASSIC® 300D PERKINS Make/Model Description Speed (RPM) Displacement Starting Capacities System 4 Cylinder 135 cu. in 12VDC battery Fuel: 15 gal. 4 Cycle (2.2 ltrs) (Group 24, 650 57 L. Perkins Naturally Aspirated High Idle 1800 ...
Page 9 - GENERAL DESCRIPTION; DESIGN FEATuRES
A-2 INSTALLATION CLASSIC® 300D PERKINS A-2 GENERAL DESCRIPTION The Classic® 300D Perkins is a heavy duty, engine driven,DC arc welding power source, capable of providing constantcurrent output for stick welding or DC TIG welding. Thiswelder is wound with all copper coils, rated at 300 amps/32V o l t...
Page 10 - P R E - O P E R AT I O N I N S TA L L AT I O N
A-3 INSTALLATION CLASSIC® 300D PERKINS A-3 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 haz...
Page 12 - CLASSIC® 300D PERKINS; bATTERY ChARGING; NEGATIVE GROuND; To prevent ExPLOSION when:; c) using a booster - connect the positive lead to; To prevent ELECTRICAL DAMAGE when:; • To prevent bATTERY buCKLING, tighten nuts on
A-5 INSTALLATION CLASSIC® 300D PERKINS A-5 bATTERY ChARGING The Classic® 300D Perkins is equipped with a wetcharged battery. The charging current is automatical-ly regulated when the battery is low (after starting theengine) to a trickle current when the battery is fullycharged. When replacing, jump...
Page 13 - OPERATION; ENGINE OPERATION; See additional warning information at the
b-1 OPERATION b-1 ENGINE OPERATION Operate the welder with the doors closed. Leavingthe doors open changes the designed air flow and cancause overheating. STARTING ThE CLASSIC® 300D PERKINS404D-22 DIESEL ENGINE 1. Turn the “IDLER” switch to “HIGH”. 2. Turn the “IGNITION” switch to “ON”. 3. Press the...
Page 14 - WELDER OPERATION; DuTY CYCLE
b-2 OPERATION b-2 CLASSIC® 300D PERKINS ENGINE bREAK-IN Lincoln Electric selects high quality, heavy-duty industrialengines for the portable welding machines we offer.While it is normal to see a small amount of crankcase oilconsumption during initial operation, excessive oil use,wet stacking (oil or...
Page 15 - AuxILIARY POWER; CLASSIC® 300D PERKINS WITh PERKINS 104D-22 DIESEL ENGINE
b-3 OPERATION b-3 AuxILIARY POWER If a GFCI Module is tripped, See the MAINTENANCEsection for detailed information on testing and reset-ting the GFCI Module. 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 powe...
Page 16 - ACCESSORIES; OPTIONAL FEATuRES
C-1 ACCESSORIES C-1 CLASSIC® 300D PERKINS OPTIONAL FEATuRES (Field Installed) GENERAL OPTIONS Pipe Thawing with an arc welder can cause fire,explosion, damage to electric wiring or to the arcw e l d e r i f d o n e i m p r o p e r l y . T h e u s e o f a n a r cwelder for pipe thawing is not approve...
Page 17 - WIRE FEEDER OPTIONS; Remote Voltage Control Kit for LN-25
C-2 ACCESSORIES C-2 WIRE FEEDER OPTIONS Wire Feed Module K623-1 Provides constant voltage (CV) output with improvedarc stability for Innershield welding. Excellent for MIGwelding. Recommended wire feeders are the LN-7,LN-23P and LN-25. (Factory installed on the K1643-2). LN-25 Wire Feeder K449 Porta...
Page 18 - MAINTENANCE; SAFETY PRECAuTIONS; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n a t
D-1 MAINTENANCE D-1 SAFETY PRECAuTIONS GENERAL INSTRuCTIONS 1. 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. 2. “Current Range ...
Page 19 - IDLER MAINTENANCE; negative; NAMEPLATES; CAuTION; Vent Screw
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 22 - TROubLEShOOTING; hOW TO uSE TROubLEShOOTING GuIDE
E-1 TROubLEShOOTING CLASSIC® 300D PERKINS 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 have qualifie...
Page 23 - Local Lincoln Authorized Field Service Facility; PRObLEMS
CLASSIC® 300D PERKINS E-2 TROubLEShOOTING 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 troubl...
Page 24 - ELECTRONIC IDLER TROubLEShOOTING GuIDE
E-3 TROubLEShOOTING CLASSIC® 300D PERKINS E-3 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 Co...
Page 26 - does
E-5 TROubLEShOOTING CLASSIC® 300D PERKINS E-5 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 S...
Page 29 - DIAGRAMS
F-1 DIAGRAMS F-1 CLASSIC® 300D PERKINS N O T E : T h is d ia g ra m i s f o r re fe re n c e o n ly . It m a y n o t b e a c c u ra te f o r a ll m a c h in e s c o v e re d b y t h is m a n u a l. T h e s p e c if ic d ia g ra m f o r a p a rt ic u la r c o d e i s p a s te d i n s id e t h e m a c...
Page 32 - NOTES