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IM659-B
®
December, 2004
CLASSIC 300G
For Machines with Code Numbers 10659,10912,11135
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.
R
NRTL/C
OPERATOR
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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 Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 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. Us
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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 hos
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� 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
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vi TABLE OF CONTENTS vi Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions.................................................................................................A-2 Pre-Operation Installation...................................................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – CLASSIC 300G (K1754-1) INPUT - GASOLINE ENGINE Make/Model Description Speed (RPM) Displacement Ignition Capacities cu. in. (Ltrs.) System High Idle 1800 Delco Voyager Fuel: 15 gal. 4 Cylinder High Energy 57 Ltrs. GM 4 Cycle 3.0 Liter Water-Cooled Full Load 1800 Distributor Type Oil: 4.5 Qts. Gasoline Engine 4.3 Ltrs. Classic 300G Cast Iron Cylinder 183.0(3.0) Electronic (K1754-1) Block/Crankcase Low Idle 1360 Cooling
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A-2 A-2 INSTALLATION SAFETY PRECAUTIONS CAUTION WARNING Do not attempt to use this equipment until you DO NOT MOUNT OVER COMBUSTIBLE SUR- have thoroughly read the engine manufacturer’s FACES. manual supplied with your welder. It includes Where there is a combustible surface directly under important safety precautions, detailed engine stationary or fixed electrical equipment, the surface starting, operating and maintenance instructions, shall be covered with a steel plate at least and parts li
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A-3 A-3 INSTALLATION When welding at a considerable distance from the TRAILER (See ACCESSORY Section) welder, be sure you use ample size welding cables. If the user adapts a non-Lincoln trailer, he must RECOMMENDED COPPER CABLE SIZES assume responsibility that the method of attachment Cables Sizes for Combined Length and usage does not result in a safety hazard nor dam- of Electrode Plus Work Cable age the welding equipment. Some of the factors to be Up to 200 ft. 200 to 250 ft. considered
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A-4 A-4 INSTALLATION BATTERY CHARGING WARNING GASES FROM BATTERY can explode. � Keep sparks, flame and cigarettes away. BATTERY ACID can burn eyes and skin. � Wear gloves and eye protection and be careful when boosting, charging or working near battery. To prevent EXPLOSION when: � Installing a new battery - disconnect the nega- tive cable from the old battery first and connect the negative cable to the new battery last. � Connecting a battery charger remove the battery from the welder by d
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B-1 B-1 OPERATION SAFETY PRECAUTIONS CAUTION DO NOT MOUNT OVER COMBUSTIBLE SURFACES. WARNING Where there is a combustible surface directly under Do not attempt to use this equipment until you stationary or fixed electrical equipment, the surface have thoroughly read the engine manufacturer’s shall be covered with a steel plate at least manual supplied with your welder. It includes .06”(1.6mm) thick, which shall extend not more than important safety precautions, detailed engine starting, operatin
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B-2 B-2 OPERATION Air Cleaner - Heavy duty two stage dry type. � When hauling the welder between job sites, close the fuel feed valve beneath the fuel tank. Muffler-A Muffler and stainless steel exhaust outlet elbow are standard. � If the fuel supply is cut off or runs out while the fuel pump is operating, air may be entrapped in the fuel Engine Hour Meter - A meter to record hours of oper- distribution system. If this happens, bleeding of the ation. fuel system may be necessary. Refer to the in
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B-3 B-3 OPERATION CONTROL OF WELDING CURRENT 2. In the “Auto” / position, the engine operates as follows: CAUTION � When welding or drawing power for lights or tools DO NOT TURN THE “CURRENT RANGE SELEC- (approximately 100-150 watts minimum) from the TOR” WHILE WELDING because the current may receptacles, the engine operates at high idle speed. arc between the contacts and damage the switch. ------------------------------------------------------------------------ � When weldi
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C-1 C-1 ACCESSORIES OPTIONAL EQUIPMENT (Field Installed) Accessory Set (K704) - Includes 35 ft. (10.7m) elec- Wire Feed Module (K623-1) - Provides constant trode and 30 ft. (9.1m) work cables, headshield, work voltage (CV) output with improved arc stability for clamp and electrode holder. Innershield welding. Excellent for MIG welding. Recommended wire feeders are the LN-7, LN-23P and LN-25. WARNING GFCI Receptacle Kit (K1690-1) - Includes one UL approved 115V ground fault circuit interrupter
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D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS � When necessary, remove the sediment bowl, if so equipped, from beneath the fuel tank and clean out WARNING any accumulated dirt and water. Have qualified personnel do the maintenance � Follow the engine service schedule in this manual work. Turn the engine off before working inside and the detailed maintenance and troubleshooting in the machine. In some cases, it may be neces- the engine manufacturer’s manual. sary to remove safety guards to perform requ
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D-2 D-2 MAINTENANCE Replace brushes when they wear within 1/4” of the PURGING AIR FROM FUEL SYSTEM ( GM pigtail. A complete set of replacement brushes should 3.0L ENGINE) be kept on hand. Lincoln brushes have a curved face to fit the commutator. Have an experienced mainte- nance man seat these brushes by lightly stoning the WARNING 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
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D-3 D-3 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 Concentration of antifreeze 50/50 Water/Ethylene Glycol I Radiator for contamination or blockage R Coolant (NOTE 3) 9.9qrts, 9.4L I Engine oil level ( NOTE 1 ) RR Engine oil ( NOTE 1 & 3 ) 4.5qts, 4.3L ( including filter ) R
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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. _______________________________________________________________
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E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSES COURSE OF ACTION PROBLEMS Machine fails to hold the heat con- 1. Rough or dirty commutator. stantly. 2. Brushes may be worn down to limit. 3. Field circuit may have variable resistance connection or intermit- tent open circuit due to loose, or broken wire. 4. Electrode lead or work lead con- nection may be poor. 5. Wrong grade of brushes may have been instal
