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RETURN TO MAIN INDEX
SVM194-A
October, 2009
®
CLASSIC 300 D & 300 G
For use with machine code number: 10545, 10546, 10657, 10658,10911, 10927,11110
11111, 11112, 11113, 11243, 11244, 11248, 11249,
11280, 11281, 11411, 11412, 11413, 11414, 11472,
11473, 11474, 11475
Classic® 300G: 10659, 10912, 11135
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful op
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or 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
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ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. 7.a. Use only compressed gas cylinders explosion. containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and from starting a fire. Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mate
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iv iv SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté specifiques qui parraissent dans ce la masse. Un court-circuit accidental peut provoquer un manuel aussi bien que les précautions de sûreté générales suiv- échauffement et un risque dʼinc
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v v SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln El
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vi vi SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturerʼs recommen- dations. If interference occurs, it may be necessary to take additional precautions such as filter
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I I - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section Aʼs Classic® 300D Perkins 104-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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A1.1 A1.1 TABLE OF CONTENTS - INSTALLATION SECTION Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.2 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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A1.2 A1.2 INSTALLATION TECHNICAL SPECIFICATIONS - CLASSIC® 300D INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System Perkins 4 cylinder High Idle 1800 135.6 cu. in 12VDC batteries Fuel: 15 gal. 104-22 Diesel 4 Cycle Low Idle 1350 (2.2 L) (2) & Starter 57 L Engine 32.7 HP @ Full Load 1725 (Water Cooled) 1800 RPM Bore x Stroke Oil: 8.7 Qts. 8.2 L 3.875” x 5.00” (98.4 mm x 127.0mm) Coolant: 7.9 gal. 7.5 L RATED OUTPUT - WELDER (1) WELDING OUTPUT* OPEN CIR
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A1.3 A1.3 INSTALLATION DESIGN FEATURES GENERAL DESCRIPTION Control Panel ® The Classic 300 D is a heavy duty, engine driven, DC arc welding power source, capable of providing con- Both the engine and the welder controls are located on stant current output for stick welding or DC TIG weld- one recessed panel at the exciter end of the machine. ing. This welder is wound with all copper coils, rated at The welder controls consist of a five step “Current 300 amps/32 Volts, and provides other Classic®
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A1.4 A1.4 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 have thoroughly read the engine manufacturerʼs stationary or fixed electrical equipment, the surface manual supplied with your welder. It includes shall be covered with a steel plate at least .06”(1.6mm) important safety precautions, detailed engine starting, operating and maintenance instruc
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A1.5 A1.5 INSTALLATION RECOMMENDED COPPER CABLE SIZES TRAILER (See Optional Features) Cables Sizes for Combined Length If the user adapts a non-Lincoln trailer, he must of Electrode Plus Work Cable assume responsibility that the method of attachment Amps Duty Cycle Up to 200ft.(61m) 200 to 250ft. and usage does not result in a safety hazard nor dam- (61 to 76m) age the welding equipment. Some of the factors to be 250 100% 1 1/0 considered are as follows: 300 60% 1/0 2/0 1. Design capacity of tra
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A1.6 A1.6 INSTALLATION ENGINE BREAK-IN Battery Charging WARNING Lincoln Electric selects high quality, heavy-duty indus- GASES FROM BATTERY can explode. trial engines for the portable welding machines we • Keep sparks, flame and cigarettes offer. While it is normal to see a small amount of away. crankcase oil consumption during initial operation, excessive oil use, wetstacking (oil or tar like substance at the exhaust port), or excessive smoke is not normal. BATTERY ACID can burn eyes and skin.
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B1.1 B1.1 TABLE OF CONTENTS - OPERATION SECTION Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.2 Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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B1.2 B1.2 OPERATION 7. Allow the engine to run at high idle speed for sev- ENGINE OPERATION eral minutes to warm the engine. Stop the engine and recheck the oil level, after allowing sufficient WARNING 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 manufacturerʼs manual supplied with your welder. It includes trols were properly set at the factory and shoul
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B1.3 B1.3 OPERATION When a forceful “digging” arc is required, usually for WELDER OPERATION vertical and overhead welding, use a higher “Current Range Selector” setting and lower open circuit voltage. WARNING For example: to obtain 175 amps and a forceful arc, ELECTRIC SHOCK can kill. set the “Current Range Selector” to the 240-160 posi- • Do not touch electrically live parts or tion and the “Fine Current Adjustment” setting to get electrode with skin or wet clothing. 175 amps. • Insulate yourse
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B1.4 B1.4 OPERATION AUXILIARY POWER The AC auxiliary power, supplied as a standard, has a rating of 3.0 kVA of 115/230 VAC (60 hertz). With the 3.0 kVA, 115/230 VAC auxiliary power, one 115V duplex and one 230V duplex, grounding type receptacle are provided. The circuit is protected with circuit breakers. The rating of 3.0 kVA permits a maximum continuous current of 13 amps to be drawn from the 230 volt duplex receptacle. Or a total of 26 amps can be drawn from the 115 volt duplex receptacle. Th
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C1.1 C1.1 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1.2 Wire Feed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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C1.2 C1.2 ACCESSORIES OPTIONAL FEATURES (Field Installed) Remote Control Kit (K924-4) - Contains switch, receptacle, remote control rheostat, and 100 ft (30.5m) GENERAL OPTIONS cable for adjusting the OCV at the welding site.(For Codes below 10911.) WARNING Remote Control Kit (K924-5) - Contains remote con- trol rheostat and 100 ft. (30.5 m) cable for adjusting the OCV at the welding site. (For Codes 10911 and Pipe Thawing with an arc welder can cause fire, above.) explosion, damage to electric
