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Lincoln Electric CLASSIC 300G 10659 manual

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Table of contents for the manual

  • Page 1

    CLA SSIC ® 300G OPERA TOR’S MANUAL For Machines with Code Numbers 10659,10912,11135 IM659-B December, 2004 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[...]

  • Page 2

    FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC RA YS can burn. 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. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

  • Page 4

    FOR ELECTRICALL Y powered equipment. 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. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

  • Page 5

    iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

  • Page 6

    v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

  • Page 7

    vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions...........................................................[...]

  • Page 8

    TECHNICAL SPECIFICA TIONS – CLASSIC 300G (K1754-1) CLASSIC 300G A-1 INST ALLA TION A-1 DC CURRENT RANGE Fine Adjustment in each Range 40-350 Amps DUTY CYCLE 100% 60% RATED DC OUTPUT* VOLTS @ RATED AMPS 30V @ 250A NEMA Rating 32V @ 300A (1) 115V will operate either 60 Hz. or 50/60 Hz. power tools, lights etc. * Based on a 10 min. period. Make/Mode[...]

  • Page 9

    PRE-OPERA TION INST ALLA TION EXHAUST SP ARK 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[...]

  • Page 10

    PRE-OPERA TION SER VICE READ the engine operating and maintenance instruc- tions supplied with this machine. 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 manu[...]

  • Page 11

    BA TTER Y CHARGING 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 obser[...]

  • Page 12

    B-1 OPERA TION B-1 SAFETY PRECAUTIONS Operate the welder with the doors closed. Leaving the doors open changes the designed air flow and can cause overheating. GENERAL DESCRIPTION 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 we[...]

  • Page 13

    • When hauling the welder between job sites, close the fuel feed valve beneath the fuel tank. • If the fuel supply is cut off or runs out while the fuel pump is operating, air may be entrapped in the fuel distribution system. If this happens, bleeding of the fuel system may be necessary. Refer to the instruc- tions in the MAINTENANCE section of[...]

  • Page 14

    B-3 OPERA TION B-3 CLASSIC 300G 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[...]

  • Page 15

    C-1 ACCESSORIES C-1 CLASSIC 300G OPTIONAL EQUIPMENT (Field Installed) Accessory Set (K704) - Includes 35 ft. (10.7m) elec- trode and 30 ft. (9.1m) work cables, headshield, work clamp and electrode holder. 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 w[...]

  • Page 16

    D-1 MAINTENANCE D-1 SAFETY PRECAUTIONS GENERAL INSTRUCTIONS • 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. • ”Current Range Selector” contacts should not be greased[...]

  • Page 17

    D-2 MAINTENANCE D-2 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 mad[...]

  • Page 18

    D-3 D-3 CLASSIC 300G MAINTENANCE ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS F I RST SERV ICE - (50 HOURS) EVERY 100 HOURS OR 3 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 600 HOURS OR 12 MONTHS EN GINE SERVICE (NOTE 2) MAINTENANCE ITEM TYPE OR QUANTITY I Coolant l evel I Conc 50/50 Water/Ethylene Glycol e n tration of antifr eeze I Radiator for contam [...]

  • Page 19

    E-1 TROUBLESHOOTING CLASSIC 300G E-1 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION ELECTRIC SHOCK can kill. • Do not touch electrically live parts such a[...]

  • Page 20

    E-2 TROUBLESHOOTING CLASSIC 300G E-2 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS P[...]

  • Page 21

    E-3 TROUBLESHOOTING E-3 CLASSIC 300G Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION FLASHING T[...]

  • Page 22

    E-4 TROUBLESHOOTING CLASSIC 300G E-4 ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE Engine Will Not Return to Low Idle in Approximately 10 Seconds After Welding and Auxiliary Loads are Removed Set Idler Control Switch to the Auto Position Check for Continuity through Idler Control Switch Open Closed Remove Molex connector Replace Idler from current[...]

  • Page 23

    E-5 TROUBLESHOOTING CLASSIC 300G E-5 ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE With Idler Control Switch in the AUTO Position,Engine Will Not Pick Up Speed When: Auxiliary Load 1. Load too small. Try load above 150 Watts. 2. Check for loose or disconnected wire running from black lead out of exciter to CB2 circuit breaker. The Arc is Struck Ch[...]

  • Page 24

    E-6 TROUBLESHOOTING CLASSIC 300G E-6 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COUR[...]

  • Page 25

    E-7 TROUBLESHOOTING CLASSIC 300G E-7 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION Observe all Safety Guidelines detailed throughout this manual PROBLEMS ([...]

  • Page 26

    E-8 TROUBLESHOOTING E-8 CLASSIC 300G Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS ([...]

  • Page 27

    F-1 DIAGRAMS F-1 CLASSIC 300G NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number[...]

  • Page 28

    F-2 DIAGRAMS F-2 CLASSIC 300G NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number[...]

  • Page 29

    F-3 DIAGRAMS F-3 CLASSIC 300G S26097 A RESIST ORS Y X B G W F G ORANGE WHITE JUMPER WHITE JUMPER PIN CA BLE CONNEC TION TABLE C D E LEAD COLOR RED BLUE CV "WIRE" CONTROL POT CCW BLUE RED ORANGE REMOTE CONTROL BOX CONNECT TO CA SE K2 46 4 -1 REMOTE CONT ROL WIRI NG / CONNECT I ON DI AGRAM CC "STICK CONTROL[...]

  • Page 30

    F-4 DIAGRAMS F-4 CLASSIC 300G PART NO. WELDER A B C D E F G H S10766-9 J K L CLASSIC 300G S10766 1/03 METRIC cm (ENGLISH in.) 170.0 (66.91) 146.6 (57.70) 22.1 (8.70) 58.4 (23.00) 67.0 (26.38) 34.3 (13.50) 105.8 (41.66) 8.26 (3.25) 115.6 (45.5) A CONTROL PANEL F G B H D E C O HOLE O MOUNTING HOLE N.A. N.B. NOTES: OIL AND WATER IN ENGINE, BUT NO FUEL[...]

  • Page 31

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE PARA EL[...]

  • Page 32

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

  • Page 33

    • 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 • World's Leader in Welding and Cutting Products •[...]