Lincoln Electric CLASSIC 300 D PERKINS Operator'S Manual Download 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.

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1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes 
outdoors.

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1.c. Do  not  add the fuel near an open flame

welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz-
ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

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1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

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1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

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1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

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SAFETY

i

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

ELECTRIC AND 
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes 

localized Electric and Magnetic Fields (EMF). Welding 
current creates EMF fields around welding cables and 
welding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right 
side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines

Summary of Contents for CLASSIC 300 D PERKINS

Page 1: ...on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful Clev...

Page 2: ...KER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy...

Page 3: ...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 3 i When w...

Page 4: ...eas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situ...

Page 5: ...opri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pa...

Page 6: ...important when identifying the correct replacement parts CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumable...

Page 7: ...wer Fuel Consumption Data B 3 ________________________________________________________________________ Accessories Section C Optional Features Field Installed C 1 _____________________________________...

Page 8: ...TION RATED DC OUTPUT Duty DC CURRENT RANGE VOLTS RATED AMPS CYCLE Fine Adjustments in each Range 40 350 Amps 220 Max 300 Amp DC Welder 30V 250A 100 160 240 All Copper Windings 32V 300A 60 120 190 Pure...

Page 9: ...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 Id...

Page 10: ...ints 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 electrical equipment LIFT BAIL A lift bail is prov...

Page 11: ...regarding specific requirements for use on public highways POLARITY CONTROL AND CABLE SIZES With the engine off route the electrode and work cables through the strain relief bracket on the base and co...

Page 12: ...ing near battery To prevent EXPLOSION when a Installing a new battery disconnect thenega tive cable from the old battery first and connect the negative cable to the new battery last b Connecting a bat...

Page 13: ...ent Possible Concerns NONE Voltage spikes or high voltage regulation can cause the capac itative elements to fail Surge protection transient protection and additional loading is recom mended for 100 f...

Page 14: ...operator s manual WARNING 7 Allow the engine to run at high idle speed for sev eral minutes to warm the engine Stop the engine and recheck the oil level after allowing sufficient time for the oil to d...

Page 15: ...e loaded at rated output for six minutes out of every ten minute period CONTROL OF WELDING CURRENT DO NOT TURN THE CURRENT RANGE SELECTOR WHILE WELDING because the current may arc between the contacts...

Page 16: ...ecifications for operating speeds The idler is controlled by the Idler toggle switch on the welder control panel The switch has two posi tions as follows 1 In the High position the idler solenoid deac...

Page 17: ...PTA 26V TIG Torch 25 ft 2pc KP509 Parts Kit K930 2 TIG Module K936 4 Control Cable for TIG Module K937 45 TIG Module Control Cable Extension K814 Arc Start Switch K938 1 Contactor Kit WIRE FEEDER OPTI...

Page 18: ...1809 11810 This welder is equipped with a double synthetic sealed ball bearing having sufficient grease to last indefinitely under normal service COMMUTATOR AND BRUSHES Uncovered rotating equipment ca...

Page 19: ...nnected properly The correct polarity is negative ground Damage to the engine alternator and the printed circuit board can result from incorrect connec tion 1 Proper operation of the idler requires go...

Page 20: ...head Valve clearances Electrical systems All nuts and bolts for tightness Injector performance Leaks or engine damage Battery 50 50 Water Ethylene Glycol 9 5qt 9 0L 8 45qt 8L refill amount Perkins 140...

Page 21: ...eceptacle must not be tripped Reset if necessary Push the Reset button located on the GFCI This will assure normal GFCI operation Plug a night light with an ON OFF switch or other product such as a la...

Page 22: ...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...

Page 23: ...circuit may have variable resistance connection or inter mittent open circuit due to loose connection or broken wire 4 Electrode lead or work lead connection may be poor 5 Wrong grade of brushes may...

Page 24: ...h Open Closed Measure DC Voltage on Replace Idler Idler Solenoid Coil Control Switch 0 VDC 12 VDC Check Continuity of Check for Jamming Reed Switch in Weld Circuit of the Idler Solenoid Mechanism Open...

Page 25: ...ring 2 Check for Continuity of Current Transformer Toroid Replace as Required 3 Check Idler Circuit Wiring and Repair as Required 4 Replace Idler P C Board Engine Picks Up Speed 1 Check for Break in R...

Page 26: ...ir mixed in the fuel system 3 Clogged fuel filter 4 Irregular and faulty fuel supply Injector pump trouble 5 Glow plug not heated 6 Clogged air cleaner 7 No compression 8 Engine protection light is ON...

Page 27: ...and correct Loose or slipping fan belt Remove oil dust etc and tighten Damaged fan belt Replace Clogged radiator Flush the radia tor Clogged radiator fin Clean Dust or scale clogged in the cooling wa...

Page 28: ...viscosity of the engine oil 3 Faulty injection timing 1 Unsuitable fuel 2 Excess injection 3 Faulty function of the engine 4 Overloading 5 Clogged air cleaner 1 Loose fan belt 2 Faulty wiring 3 Faulty...

Page 29: ...y 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 writ...

Page 30: ...y 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 writ...

Page 31: ...BRUSH POSITION SHOWN AS VIEWED FROM CONTROL PANEL SELECTOR SWITCH 90 MIN 130 80 190 120 240 160 220 MAX WELDING GENERATOR LEAD COLOR CODE G GREEN N BROWN U BLUE W WHITE Y YELLOW B BLACK OR GRAY R RED...

Page 32: ...CLASSIC 300D PERKINS F 4 DIAGRAMS F 4...

Page 33: ...GRAVITY WITH O N B 56 TRAILER MOUNTING HOLES S10766 C PART NO WELDER A B C D F G H J K S10766 8 65 00 57 70 8 70 27 94 12 82 41 66 3 25 CLASSIC 300D PERKINS L 45 5 CONTROL PANEL N C DIMENSION TO TOP O...

Page 34: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 35: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 36: ...ill contact you by the next business day For Non U S Service Email globalservice lincolnelectric com Cleveland Ohio 44117 1199 U S A TEL 1 216 481 8100 For Service in U S and Canada Call 1 888 935 387...

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