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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’S MANUAL
Copyright © 2004 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
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
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
the arc rays.
3.b. Insulate yourself from work and ground using dry insulation.
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
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases.When welding, keep
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
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
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
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
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SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
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.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
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
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SAFETY
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:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
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
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
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
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Mar. ‘93
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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!
Thank 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.
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TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Safety Precautions.................................................................................................A-2
Pre-Operation Installation......................................................................................A-2
Exhaust Spark Arrester...................................................................................A-2
Location/Ventilation.........................................................................................A-2
Machine Grounding.........................................................................................A-2
Lift Bail ............................................................................................................A-2
Trailers ............................................................................................................A-2
Polarity Control and Cable Sizes ....................................................................A-3
Pre-Operation Service ...........................................................................................A-3
Oil....................................................................................................................A-3
Fuel .................................................................................................................A-3
Cooling System...............................................................................................A-3
Battery Charging .............................................................................................A-4
Operation .........................................................................................................Section B
General Description...............................................................................................B-1
Design Features ....................................................................................................B-1
Starting The GM 3.0L Engine..........................................................................B-2
Stopping the engine ........................................................................................B-2
Welder Operation...................................................................................................B-2
Duty Cycle.......................................................................................................B-2
Control of Welding Current..............................................................................B-3
Idler Operation ................................................................................................B-3
Auxiliary Power ...............................................................................................B-3
Throttle Body Deicing......................................................................................B-3
Accessories.....................................................................................................Section C
Optional Equipment (Field Installed) .....................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
General Instructions..............................................................................................D-1
Cooling System.....................................................................................................D-1
Bearings................................................................................................................D-1
Commutator and Brushes .....................................................................................D-1
Idler Control Maintenance.....................................................................................D-2
Nameplates...........................................................................................................D-2
Purging Air from Fuel System................................................................................D-2
Engine Maintenance .............................................................................................D-2
Engine Service Chart ............................................................................................D-3
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
Troubleshooting..............................................................................................E-2,E-3
Electronic Idler Troubleshooting Guide...........................................................E-4,E-5
Troubleshooting .....................................................................................E-5, E-6,E-7
Diagrams ..........................................................................................................Section F
Wiring Diagram (Classic 300G).......................................................................F-1,F-2
Dimension Print......................................................................................................F-3
Parts List ......................................................................................................P379 Series
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – CLASSIC 300G (K1754-1)
INPUT - GASOLINE ENGINE
Make/Model
Description
Speed (RPM)
High Idle 1800
Full Load 1800
Displacement
cu. in. (Ltrs.)
Ignition
System
Capacities
Delco Voyager
High Energy
Fuel: 15 gal.
57 Ltrs.
4 Cylinder
GM
3.0 Liter
4 Cycle
Water-Cooled
Gasoline Engine
Cast Iron Cylinder
Block/Crankcase
53.0 HP @
1800 RPM
Distributor Type
Electronic
Oil: 4.5 Qts.
4.3 Ltrs.
Classic 300G
(K1754-1)
183.0(3.0)
Low Idle 1360
Cooling 9.9 Qts.
9.4 Ltrs.
RATED OUTPUT - WELDER
DESCRIPTION
RATED DC OUTPUT*
DUTY CYCLE
DC CURRENT RANGE
Fine Adjustment in each Range
VOLTS @ RATED AMPS
300 Amp DC Welder
All Copper Windings
Pure DC Power
Generator
30V @ 250A
100%
40-350 Amps
NEMA Rating
32V @ 300A
60%
OUTPUT - GENERATOR
1
Auxiliary Power
3000 Watts, 60 Hz. AC
(26 Amps @ 115V), (13 Amps @ 230V)
ENGINE OPERATING LOAD
FUEL CONSUMPTION
.89 gal/hr (3.37 ltrs/hr)
1.32 gal/hr (5.00 ltrs/hr)
1.42 gal/hr (5.32 ltrs/hr)
1.24 gal/hr (4.70 ltrs/hr)
1.27 gal/hr (4.82 ltrs/hr)
1.33 gal/hr (5.04 ltrs/hr)
1.47 gal/hr (5.57 ltrs/hr)
1.66 gal/hr (6.27 ltrs/hr)
1.83 gal/hr (6.91 ltrs/hr)
2.15 gal/hr (8.12 ltrs/hr)
Low Idle (1360 RPM)-No Load
High Idle (1800 RPM)-No Load
AC Auxiliary-115 Volts-26 Amps
50 Amps @ 22 Volts @ 60% Duty Cycle
100 Amps @ 24 Volts @ 60 % Duty Cycle
150 Amps @ 26 Volts @ 60% Duty Cycle
200 Amps @ 28 Volts @ 60 % Duty Cycle
250 Amps @ 30 Volts @ 60 % Duty Cycle
300 Amps @ 32 Volts @ 60 % Duty Cycle
250 Amps @ 30 Volts @ 100 % Duty Cycle
PHYSICAL DIMENSIONS
HEIGHT
WIDTH
DEPTH
WEIGHT
40.94** in.
1039.9 mm
24.00 in.
609.6 mm
66.91in.
1700 mm
1330 lbs. (603kg.)
**Top of enclosure, add 8.0” (203.2mm) for exhaust
(1) 115V will operate either 60 Hz. or 50/60 Hz. power tools, lights etc.
* Based on a 10 min. period.
CLASSIC 300G
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A-2
A-2
INSTALLATION
SAFETY PRECAUTIONS
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SUR-
FACES.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, the surface
shall be covered with a steel plate at least
.06”(1.6mm) thick, which shall extend not more than
5.90”(150mm) beyond the equipment on all sides.
------------------------------------------------------------------------
MACHINE GROUNDING
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
According to the United States National Electrical
Code, the frame of this portable generator is not
required to be grounded and is permitted to serve as
the grounding means for cord connected equipment
plugged into its receptacle.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
Some state, local, or other codes or unusual operating
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
machine grounding stud marked with the symbol
is provided on the welding generator frame foot. In
general, if the machine is to be grounded, it should be
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 insulated
joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National Code
lists a number of alternate means of grounding electri-
cal equipment.
-----------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
the front of this operator’s manual.
-----------------------------------------------------------
PRE-OPERATION INSTALLATION
EXHAUST SPARK ARRESTER
Some federal, state or local laws may require that
engines be equipped with exhaust spark arresters
when they are operated in certain locations where
unarrested sparks may present a fire hazard. The
standard muffler included with this welder does not
qualify as a spark arrester. When required by local
regulations, a suitable spark arrester must be installed
and properly maintained.
LIFT BAIL
A lift bail is provided for lifting with a hoist.
WARNING
• Lift only with equipment of
adequate lifting capacity.
• Be sure machine is stable
when lifting.
CAUTION
Use of an incorrect arrester may lead to engine dam-
age or performance loss. Contact the engine manu-
facturer for specific recommendations.
• Do not lift this machine using
lift bail if it is equipped with a
heavy accessory such as trail-
er or gas cylinder.
------------------------------------------------------------------------
FALLING
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bail.
• Do not lift machine if lift bail is
LOCATION / VENTILATION
Always operate the welder with the doors closed.
Leaving the doors open changes the designed air flow
and may cause overheating.
The welder should be located to provide an unrestrict-
ed flow of clean, cool air. Also, locate the welder so
that engine exhaust fumes are properly vented to an
outside area.
CLASSIC 300G
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A-3
A-3
INSTALLATION
When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
TRAILER (See ACCESSORY Section)
If the user adapts a non-Lincoln trailer, he must
assume responsibility that the method of attachment
and usage does not result in a safety hazard nor dam-
age the welding equipment. Some of the factors to be
considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
3. Proper placement of the equipment on the trailer to
ensure stability side to side and front to back when
being moved and when standing by itself while being
operated or serviced.
4. Typical conditions of use, i.e., travel speed, rough-
ness of surface on which the trailer will be operated;
environmental conditions, likely maintenance.
RECOMMENDED COPPER CABLE SIZES
Cables Sizes for Combined Length
of Electrode Plus Work Cable
Up to 200 ft.
200 to 250 ft.
200 to76.2 m
Amps
250
Duty Cycle
100%
60.96 m
1
1/0
2/0
300
60%
1/0
PRE-OPERATION SERVICE
CAUTION
READ the engine operating and maintenance instruc-
tions supplied with this machine.
WARNING
(1)
5. Conformance with federal, state and local laws.
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
(1)
Consult applicable federal, state and local laws regarding specific
requirements for use on public highways.
• Do not leave unattended while
fueling.
WARNING
• Wipe up spilled fuel and allow
fumes to clear before starting
engine.
• Do not overfill tank, fuel expan-
sion may cause overflow.
VEHICLE MOUNTING
GASOLINE
can cause fire
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
or explosion.
GASOLINE FUEL ONLY
• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.
• Distribute, balance and secure loads so vehicle
is stable under conditions of use.
• Do not exceed maximum rated loads for compo-
nents such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of
vehicle.
• Follow vehicle manufacturer’s instructions.
------------------------------------------------------------------------
------------------------------------------------------------------------
OIL
This unit is supplied from the factory with the engine
crankcase filled with a high quality SAE 10W/30 oil.
This oil should be acceptable for most typical ambient
temperatures.
Consult the engine operation manual for specific
engine manufacturer’s recommendations. Upon receipt
of the welder, check the engine dipstick to be sure the
oil is at the “full” mark. DO NOT overfill.
FUEL
POLARITY CONTROL AND CABLE SIZES
With the engine off, route the electrode and work
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.)
For Positive polarity, connect the electrode cable to
the terminal marked “+”. For Negative polarity, con-
nect the electrode cable to the “-” stud. These con-
nections should be checked periodically and tightened
if necessary.
Fill the fuel tank with the grade of fuel recommended in
the Engine Operator’s manual. Make sure the fuel
valves on the sediment bowl and the water separator
are in the open positions.
COOLING SYSTEM
The radiator has been filled at the factory with a 50-50
mixture of ethylene glycol antifreeze and water. Check
the radiator level and add a 50-50 solution as needed
(see engine manual or antifreeze container for alter-
nate antifreeze recommendations)
CLASSIC 300G
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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 disconnecting the negative
cable first, then the positive cable and battery
clamp. When reinstalling, connect the negative
cable last.
• 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:
•
•
Installing a new battery.
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 300G is equipped with a wet charged bat-
tery. The charging current is automatically 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 300G
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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
stationary or fixed electrical equipment, the surface
shall be covered with a steel plate at least
.06”(1.6mm) thick, which shall extend not more than
5.90”(150mm) beyond the equipment on all sides.
------------------------------------------------------------------------
The Classic 300G uses the GM 3.0L industrial water-
cooled gasoline engine.
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
RATED OUTPUT
DUTY CYCLE
250A @ 30V
300A @ 32V
100%
60%
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
DESIGN FEATURES
Control Panel
----------------------------------------------------
Both the engine and the welder controls are located on
one recessed panel at the exciter end of the machine.
The welder controls consist of a five step “Current Range
Selector” switch and a “Fine Current Adjustment” rheo-
stat. 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.
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at the
front of this operator’s manual.
The control panel also contains an engine temperature
gauge, a battery charging ammeter, an oil pressure
gauge, two three prong grounding type receptacles and
four circuit breakers for auxiliary power.
Operate the welder with the doors closed. Leaving the
doors open changes the designed air flow and can cause
overheating.
All Copper Windings - For long life and dependable
operation.
GENERAL DESCRIPTION
®
Engine Idler Control - The Classic 300G is equipped
with an electronic automatic engine idle control. It auto-
matically increases and decreases engine speed when
starting and stopping welding or using auxiliary
power. A built-in time delay permits changing electrodes
before the engine slows to its low idle speed. The “Idler”
control switch on the panel locks the idler in high idle
position when desired.
The Classic 300G is a heavy duty, engine driven, DC
arc welding power source, capable of providing constant
current output for stick welding or DC TIG welding. This
welder is wound with all copper coils, rated at 300
amps/32 Volts, and provides other Classic features such
as improved door latches and stainless hinges. With the
™
addition of the optional K623-1 Wire Feed Module the
Classic 300G will provide constant voltage output for run-
ning the LN-7, LN-23P, or LN-25 wire feeders. The
optional K924-4 Remote Control Kit (field installed) pro-
vides a switch, or K924-5 Remote Control Kits provide a
receptacle and a remote control rheostat for remote fine
current and open circuit voltage adjustment.
Auxiliary Power - 3.0 kVA of nominal 115/230V, 60Hz,
AC. Output voltage is maintained within 10% at all
loads up to rated capacity. (See Optional Features for
Power Plug Kit.)
Welder Enclosure - The complete welder is rubber
The Classic 300G has an electronic Engine Protection
system. In the event of sudden low oil pressure or high
coolant temperature, the engine immediately shuts down.
The Classic 300G has a current range of 40-350 DC
amps with output ratings as follows:
mounted on a rugged steel “C” channel base.
The output terminals are placed at the side of the
machines so that they are protected by the door. The
output terminals are labeled (+) and (-).
These units are also capable of providing 3 kVA of
115/230 volts of 60 cycle AC auxiliary power.
Cranking System - A 12 volt electric starter is standard.
CLASSIC 300G
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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
distribution system. If this happens, bleeding of the
fuel system may be necessary. Refer to the instruc-
tions in the MAINTENANCE section of this manual.
Engine Hour Meter - A meter to record hours of oper-
ation.
Engine Protection - The system shuts the engine
down in the event of sudden low oil pressure or high
coolant temperature. A warning light on the control
panel will indicate such a fault. To reset the engine for
restarting, turn the ignition switch off then on.
REFER TO THE ENGINE
Operation and maintenance manual for additional
information on the engine supplied with this welder.
High Idle RPM (OCV) Adjustment- A potentiometer
is mounted on the output rail that allows the operator to WELDER OPERATION
adjust the high idle engine speed between 1700 and
1800 RPM’S in 20 RPM increments. This is to allow
further adjustment of the OCV. Total OCV adjustment
range is about 10 Volts.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
STARTING THE CLASSIC 300G GM 3.0L
GASOLINE ENGINE
electrode with skin or wet clothing.
• Insulate yourself from work and ground.
1. Turn the “IDLER” switch to “HIGH”.(Optional )
2. Turn the “IGNITION” switch to “ON”.
3. Press the Start button. When the engine starts run-
ning, release button. If the engine fails to start in 20
seconds, wait 30 seconds and repeat the above
procedure.
4. Observe the oil pressure. If no pressure shows with-
in 30 seconds, stop the engine and consult the
engine operating manual. To stop the engine, turn
the “IGNITION” switch to “OFF”.
FUMES & GASES can be dangerous.
• Keep your head out of the fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
5. Allow the engine to run at high idle speed for sev-
eral minutes to warm up. If idle control switch is left
in “Auto” position, engine will run at 1600 RPM until
engine coolant temperature reaches 130 F.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
DUTY CYCLE
WARNING
Under NO conditions should ether or other starting
fluids be used!
The NEMA output rating of the Classic 300G is 300
amperes at 32 arc volts on a 60% duty cycle (consult
Specifications in this manual for alternate ratings).
Duty cycle is based on a ten minute period; thus, the
welder can be loaded at rated output for six minutes
out of every ten minute period.
-------------------------------------------------------------------------
STOPPING THE ENGINE
• Turn the “IGNITION” switch to “OFF”
• At the end of each day’s welding, check the
crankcase oil level, drain accumulated dirt and water
from the sediment bowl under the fuel tank and refill
the fuel tank to minimize moisture condensation in the
tank. Also, running out of fuel tends to draw dirt into
the fuel system.
CLASSIC 300G
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B-3
B-3
OPERATION
CONTROL OF WELDING CURRENT
2. In the “Auto”
operates as follows:
/
position, the engine
CAUTION
• When welding or drawing power for lights or tools
(approximately 100-150 watts minimum) from the
receptacles, the engine operates at high idle speed.
DO NOT TURN THE “CURRENT RANGE SELEC-
TOR” WHILE WELDING because the current may
arc between the contacts and damage the switch.
------------------------------------------------------------------------
• When welding ceases or the power load is turned off,
a preset time delay of about 10 seconds starts. This
time delay cannot be adjusted.
The “Current Range Selector” provides five overlap-
ping current ranges. The “Fine Current Adjustment”
adjusts the current from minimum to maximum within
each range. Open circuit voltage is also controlled by
the “Fine Current Adjustment” permitting control of the
arc characteristics.
• If the welding or power load is not re-started before
the end of the time delay the throttle body controller
reduces the engine to low idle speed.
AUXILIARY POWER
A high open circuit voltage setting provides the soft
“buttering” arc with best resistance to pop-outs pre-
ferred for most welding. To get this characteristic, set
the “Current Range Selector” to the lowest setting that
still provides the current you need and set the “Fine
Current Adjustment” near maximum. For example: to
obtain 175 amps and a soft arc, set the “Current
Range Selector” to the 190-120 position and then
adjust the “Fine Current Adjustment” for 175 amps.
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. The 115 volt
duplex receptacle has a configuration which permits
20 amps to be drawn from either half. The total com-
bined load of all receptacles is not to exceed 3.0 kVA.
When a forceful “digging” arc is required, usually for
vertical and overhead welding, use a higher “Current
Range Selector” setting and lower open circuit volt-
age. 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.
An optional power plug kit is available. When this kit is
specified, the customer is supplied with a plug for
each receptacle.
Some arc instability may be experienced with EXX10
electrodes when trying to operate with long arc tech-
niques at settings at the lower end of the open circuit
voltage range.
THROTTLE BODY DEICING SYSTEM
CAUTION
The welder has been designed to allow continuous
year-round operation. Engine coolant is channeled
through the Throttle Bottle Injector (TBI) housing to
prevent the build up of ice on the TBI throat around
the throttle plate. The electronic controller is pro-
grammed to automatically compensate for the build up
of ice on the throttle plate. There will be no noticeable
change in the operation of the welder should icing
develop. On start-up, there is a possibility for the
engine to overspeed ( to a maximum of 2000 RPM )
for up to 10 seconds after throttle body icing condi-
tions have occurred.The electronic governor will cor-
rect itself for the new operating conditions and normal
operation will resume.
DO NOT attempt to set the “Current Range Selector”
between the five points designated on the nameplate.
------------------------------------------------------------------------
These switches have a spring loaded cam which
almost eliminates the possibility of setting this switch
between the designated points.
IDLER CONTROL OPERATION
The idle is controlled by the “Idler” toggle switch on
the welder control panel. The switch has two positions
as follows:
1. In the “High”
position, and the engine goes
to high idle speed. The speed is controlled by the gov-
ernor.
CLASSIC 300G
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C-1
C-1
ACCESSORIES
OPTIONAL EQUIPMENT (Field Installed)
Accessory Set (K704) - Includes 35 ft. (10.7m) elec-
trode and 30 ft. (9.1m) work cables, headshield, work
clamp and electrode holder.
Wire Feed Module (K623-1) - Provides constant
voltage (CV) output with improved arc stability for
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 duplex
type receptacle and installation instructions. Replaces
the factory installed 115V duplex receptacle. Each
receptacle of the GFCI duplex is rated at 20 amps.
Maximum total current from the GFCI duplex is limited
to 20 amps.
Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly. The use of an arc
welder for pipe thawing is not approved by the
CSA, nor is it recommended or supported by
Lincoln Electric.
------------------------------------------------------------------------
Power Plug Kit (K802D) - A 20 amp power plug kit
for the auxiliary power receptacles is available.
(Provides a plug for each receptacle.)
TIG Module - Portable, high frequency unit with gas
valve for TIG welding. Rated at 300 amps / 60% duty
cycle. (Request Publication E3.205).
Order K930-2
Remote Control Kit (K924-4) - Contains switch,
receptacle, remote control rheostat, and 100 ft
(30.5m) cable for adjusting the OCV at the welding
site.
Control Cable - Connects TIG Module to the Classic
300G.
Order K936-4
Arc Start Switch - Provides on/off control at the TIG
Trailer (K953-1) - Two-wheeled trailer with optional
fender and light package. For highway use, consult
applicable federal, state, and local laws regarding
possible additional requirements. Their is a choice of
2 hitches, a fender & a light package. Order:
K953-1 Trailer
Module.
Order K814
Contactor Kit - For use with TIG Module.
Order K938-1
K958-1 Ball Hitch
Control Cable Extension - Allows the TIG Module to
be operated at distances up to 200 ft. from the power
source. Availiable length: 45 ft. (13.7m).
Order K937-45
K958-2 Lunette Eye Hitch
K959-1 Fender & Light Kit.
K965-1 Cable Storage Rack
Water Valve Kit - For use with a water-cooled TIG
Torch. Installs inside of TIG Module.
Order K844-1
Remote Control Kit (K924-5) - Contains a remote
control rheostat, and 100 ft. (30.5m) cable for adjust-
ing the OCV at the welding site.
K2261-1 OIL DRAIN KIT - Includes ball valve, hose
and clamp.
Remote Control Kit (K2464-1) - Contains a remote
control rheostat (for adjusting the CC “STICK” OCV),
remote control potentiometer (for adjusting the CV
“WIRE” OCV), and 100ft.(30.5m) cable.
CLASSIC 300G
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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
any accumulated dirt and water.
WARNING
Have qualified personnel do the maintenance
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.
• Follow the engine service schedule in this manual
and the detailed maintenance and troubleshooting in
the engine manufacturer’s manual.
COOLING SYSTEM
The Classic 300G is equipped with a pressure radia-
tor. Keep the radiator cap tight to prevent loss of
coolant. Clean and flush the cooling system periodi-
cally to prevent clogging the passage and overheating
the engine. When antifreeze is needed, always use
the permanent type. Capacity = 9.9 qts (9.4 Ltrs.).
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.
-----------------------------------------------------------------------
ELECTRIC SHOCK can kill.
BEARINGS
This welder is equipped with a double-shielded ball
bearing having sufficient grease to last indefinitely
under normal service. Where the welder is used con-
stantly or in excessively dirty locations, it may be nec-
essary to add one half ounce of grease per year. A
pad of grease one inch wide, one inch long, and one
inch high weighs approximately one half ounce. Over-
greasing is far worse than insufficient greasing.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
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
introduced during greasing than from insufficient
grease.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
COMMUTATOR AND BRUSHES
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
WARNING
front of this operator’s manual.
Uncovered rotating equipment can be dangerous.
Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself
from particles that may be thrown out by the rotat-
-----------------------------------------------------------
ing armature when stoning the commutator.
GENERAL INSTRUCTIONS
------------------------------------------------------------------------
Shifting of the commutator brushes may result in:
- Change in machine output
• Blow out the welder and controls with an air hose at
least once every two months. In particularly dirty
locations, this cleaning may be necessary once a
week. Use low pressure air to avoid driving dirt into
the insulation.
- Commutator damage
- Excessive brush wear
Periodically inspect the commutator, slip rings, and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
• ”Current Range Selector” contacts should not be
greased. To keep the contacts clean, rotate the cur-
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.
• Put a drop of oil on the “Current Range Selector”
shaft at least once every month.
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D-2
D-2
MAINTENANCE
Replace brushes when they wear within 1/4” of the
pigtail. A complete set of replacement brushes should
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
commutator as the armature rotates at full speed until
contact is made across the full face of the brushes.
After stoning, blow out the dust with low pressure air.
PURGING AIR FROM FUEL SYSTEM ( GM
3.0L ENGINE)
WARNING
Keep fuel clear of open flames or arcs, allow
engine to cool before working on the fuel system.
Wipe up any spilled fuel and do not start engine
until fumes clear.
------------------------------------------------------------------------
The fuel system operates as follows, The fuel pump
will operate for a maximum of 3 seconds when the
ignition switch is turned “ON”. The pump will restart
once the start button is pushed and continue when the
engine starts. To purge the system of air if fuel lines
have been removed, the ignition switch can be tog-
gled “ON” and “OFF” (at 3 second intervals) until fuel
flows through the fuel return line in the neck of the
tank.
To seat slip ring brushes, position the brushes in
place. Then slide one end of a piece of fine sandpaper
between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres-
sure on top of the brushes, pull the sandpaper around
the circumference of the rings - in direction of rotation
only - until brushes seat properly. In addition, stone
slip ring with a fine stone. Brushes must be seated
100%.
Arcing or excessive exciter brush wear indicates a
possible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.
The GM 3.0L engine does not require the system to
be bled. If the engine runs out of fuel and the tank is
refilled, the engine will restart within a few seconds if
the engine is properly tuned.
IDLER CONTROL MAINTENANCE
ENGINE MAINTENANCE
CAUTION
Before doing electrical work, disconnect the bat-
tery.
Refer to the engine operation and maintenance man-
ual for additional information on the engine.
------------------------------------------------------------------------
When installing a new battery or using a jumper bat-
tery to start the engine, be sure the battery polarity is
connected properly. The correct polarity is negative
ground. Damage to the engine alternator and the TBI
controller can result from incorrect connection.
• Proper operation of the idle control requires good
grounding of the TBI controller, and battery.
• If desired, the welder can be used without automatic
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 replacement
item number.
CLASSIC 300G
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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
Coolant level
Concentration of antifreeze
Radiator for contamination or blockage
Coolant (NOTE 3)
TYPE OR QUANTITY
50/50 Water/Ethylene Glycol
9.9qrts, 9.4L
I
I
I
I
R
Engine oil level ( NOTE 1 )
Engine oil ( NOTE 1 & 3 )
Engine oil filter
Drain fuel bowl
Fuel filter canister
Tension of Alternator/ Fan belt
Alternator/ Fan belt wear
Alternator Belt
R
R
C
R
R
4.5qts, 4.3L ( including filter )
AC PF25
C
R
PSI# 32500292
I
I
R
R
I
Good Year 11AV0955
Good Year 11AV1220
Fan Belt
Tighten cylinder head
Spark Plugs (Gap = 0.040)
Electrical systems
All nuts and bolts for tightness
Air filter (earlier check may be req’d)
Air filter element
R
I
4 - AC R46TS
I
4
I
C
C
R
Donaldson#P181050 Nelson #70206N
BCI GROUP 45
Leaks or engine damage
Battery
I
I = Inspect
Notes (1) Consult Engine Operators Manual for oil Recommendations.
C = Clean
R = Replace
(2) Consult engine operators manual for additional maintenance schedule information.
(3) Fill slowly! Ensure correct quantity is used.
2/01
(4) Clean the air filter if the engine is operating in very dusty conditions.
Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.
These preventative maintenance periods apply to average conditions of operation.
If necessary, use shorter periods.
S20919-3
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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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
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-
TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such as output
terminals or internal wiring.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or vent exhaust
outside.
MOVING PARTS can injure.
• Do not operate with doors open or guards off.
• Stop engine before servicing.
• Keep away from moving parts.
• Remove guards only when necessary and replace when work
requiring removal is complete.
• Only qualified personnel should install, use or service this
equipment.
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 300G
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E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSES
RECOMMENDED
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 installed on generator.
6. Field rheostat may be making
poor contact and overheating.
Welder starts but fails to generate
current.
1. Generator or exciter brushes may
be loose or missing.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
2. Exciter may not be operating.
3. Field circuit of generator or
exciter may be open.
4. Exciter may have lost excitation.
5. Series field and armature circuit
may be open-circuited.
Welding arc is loud and spatters
excessively.
1. Current setting may be too high.
2. Polarity may be wrong.
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 300G
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E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSES
RECOMMENDED
COURSE OF ACTION
PROBLEMS
1. Exciter output low causing low
output compared to dial indica-
tion.
Welding current too great or too
small compared to indication on the
dial.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
2. Operating speed too low or high.
Arc continuously pops out.
FLASHING THE FIELDS:
1. “Current Range Selector” switch
may be set at an intermediate
position.
1. Stop the engine welder and disconnect the positive battery terminal.
2. Remove the cover from the exciter.
3. Turn the “Fine Current Adjustment” (rheostat) to “100” on the dial.
4. Using a 12 volt automotive battery, connect its negative terminal to the negative brushholder. The negative
brushholder is the one nearest to the rotor lamination. See the wiring diagram. With the engine NOT running,
touch the positive battery terminal to the positive brushholder. Remove the battery from the circuit.
5. Replace the exciter cover.
6. Reconnect the positive battery cable.
7. Start the welder and the generator voltage should build up.
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 300G
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E-4
E-4
TROUBLESHOOTING
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
Remove Molex connector
from current sensing board.
Replace Idler
Control Switch.
Operation Same
Check wiring between TBI controller and current sensing board.
Machine Idlers
1. Check for current in wires looping through
current sensor.
2. Replace current sensor.
Have TBI controller inspected at authorized service shop.
Not O.K.
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 300G
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E-5
E-5
TROUBLESHOOTING
ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE
With Idler Control Switch in the AUTO Position,Engine Will Not Pick Up Speed When:
The Arc is Struck
Both
Auxiliary Load
Check for loose or disconnected 1. Check Idler circuit wiring. Possible
1. Load too small. Try load
above 150 Watts.
2. Check for loose or
wire running between weld
selector switch and output stud.
problems are wires from Current
Sensing Board reversed at idler
switch or wires connected incorrectly
at Current Sensor Molex plug.
disconnected wire running
from black lead out of exciter
to CB2 circuit breaker.
2. Replace current Sensing 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 300G
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E-6
E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
1. Faulty Ignition switch
Engine does not start
2. Insufficient charging or complete
discharge of the battery Charge.
3. Lack of fuel or air mixed in the
fuel system.
2. Clogged fuel filter.
4. Irregular and faulty fuel supply
(Injector pump trouble)
5. Moisture or carbon on spark
plugs.
6. Improper viscosity of the lubri-
cating oil.
7. Clogged air cleaner.
8. No compression.
9. Engine protection light is ON.
Irregular running of the Engine.
1. Air mixed in the fuel system.
2. Uneven fuel injection (Faulty fuel
injector pump).
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
3. Clogged fuel filter.
4. Defective governor.
5. Engine itself defective.
Engine stops running During
Operation and the Engine
Protection Light Does Turn On.
(Solid Light)
1. Lack of fuel in the tank.
2. Clogged fuel filter.
3. Air mixed in the fuel system.
4. Lack of Engine Oil.
5. Fault in oil pressure switch.
6. Oil leakage from the lubricating
system.
7. Clogged oil filter.
8. Oil too light.
9. Faulty TBI controller.
10. 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 300G
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E-7
E-7
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
1.
Engine Stops During Operation and
the Engine Protection Light Does
Turn On. (Flashing)
Lack of Coolant.
2. Loose or slipping fan belt.
3. Damaged fan belt.
White or Blue Smoke.
Dark Smoke
1. Excess engine oil.
2. Too low viscosity of the engine
oil.
1. Excess injection.
2. Clogged air cleaner.
3. Faulty function of the engine.
1. Loose fan belt.
Faulty Charging
2. Faulty wiring.
3. Faulty battery.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
4. Worn out alternator brush.
Starter Motor does not run.
1. Loose or damaged wiring.
2. Low Battery voltage.
3. Damaged starter motor.
1. Poor grade of Gasoline.
2. Spark advance to far.
Engine Knocking.
Lack of Power.
1. Carbon deposits causing pre-
ignition.
2. Incorrect timing.
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 300G
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E-8
E-8
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
1. Dirty Air Filter.
Surging
2. Engine running at RPM limiter
(2000 RPM).
1. Ice build up on throttle plate.
Large Decrease in Speed.
Engine runs Irregularly.
1. Faulty coolant temperature
sender.
1. Faulty idler circuit.
Engine fails to pick up speed when
Arc is struck.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
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 300G
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F-1
F-1
DIAGRAMS
+
CLASSIC 300G
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F-2
F-2
DIAGRAMS
{
+
CLASSIC 300G
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F-3
F-3
DIAGRAMS
K2464-1 REMOTE CONTROL
WIRING / CONNECTION DIAGRAM
X
Y
G
B
W
CV "WIRE" CONTROL POT
CCW
RESISTORS
CC "STICK CONTROL
BLUE
ORANGE
RED
CABLE CONNECTION TABLE
LEAD COLOR
PIN
E
RED
F
ORANGE
BLUE
G
C
D
WHITE JUMPER
REMOTE CONTROL BOX
CONNECT TO CASE
WHITE JUMPER
A
S26097
CLASSIC 300G
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F-4
F-4
DIAGRAMS
CLASSIC 300G
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● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● Keep flammable materials away.
● Wear eye, ear and body protection.
WARNING
SpanisAh VISO DE
PRECAUCION
French
● No toque las partes o los electrodos ● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
● Isolez-vous du travail et de la terre.
German
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
● 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
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● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
Spanish
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux
tien.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
● Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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• 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
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