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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 diag

ram 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.  G

ive the equipment code number..

L11866

CL

AS

SI

300G

   W

IR

IN

DI

AG

RA

M  FOR CODES 10912 AND 11135

C

CONT

ROL

 P

AN

EL

 C

OMP

ON

EN

TS

61

0A

60

0C

+

-

+

-

21

A

81

0

82

0

11

B

B

SL

IP RIN

GS

TO

 IR

ON

A

54

3

2

1

AL

TE

RN

AT

OR

AU

XI

LI

AR

Y

POW

ER

WI

NDIN

GS

CB

3

CB

1

11

5 V

OL

T

REC

EP

TAC

LE

23

0 V

OL

T

REC

EP

TAC

LE

21

A

NE

GA

TI

VE

SE

LE

CT

OR

SW

IT

CH

WE

LD

ER

LE

AD BL

OC

K

AC

AC

42

60

2A

GN

D-

E

U

CB

2

CB

4

     

FU

SE

15

A

1
2

3
4
5
6
7

8
9

10
11

1

3

4

5

6

60

0A

41

GE

NE

RA

TO

R

N

-W

+Y

G

G

B

60

0B

61

0

61

0

60

2B

+

84

AL

TE

RN

AT

OR

RO

TO

R

SL

IP RIN

G

NE

AR

ES

T

-

J5

P8

J8

POS

IT

IV

E

LE

AD C

OL

OR 

CO

DE

P1

0

+Y

-W

N

U

W

B

51

60

RHE

OS

TA

T

EX

C

+

70

(CC

-)

(CC+

) & 

(CV

WI

TH

 W.

F.

M.

)

S

B

Y

W

G

PL

UG

 F

OR

RE

M

OT

E C

ON

TR

OL

PO

TE

NT

IO

M

ETE

R

B

X

60

2

W

SW

IT

CH F

OR 

LO

CA

OR

IN L

OCA

PO

SI

TI

ON

.

X

Y

#2

 HE

AV

Y L

EAD

W

IR

E F

EED

 MODU

LE

 (O

PT

IO

NA

L)

W

IR

E

FEED

MODUL

E

W.

F.M.

CO

NT

RO

L

PA

NE

L

PO

S.

OU

TP

UT

 TE

RM

IN

AL

S

CON

NE

CT

 T

O POS

. &

 N

EG.

CO

NNE

CT

 T

NE

G.

BRU

SH H

OLD

ER

60

8

60

9

#2

 H

EA

VY L

EAD

#8

  L

EA

D

NE

GA

TI

VE

 C

V

OU

TP

UT

 TE

RM

IN

AL

PA

NE

L

MACH

IN

E MUST

 NOT

 BE R

UN

NI

NG

ON

 M

ACH

INE

, R

EM

OVE

 P

LU

G "P

10" 

FR

OM

 C

ONNE

CT

OR

 "J

5".

CO

NNE

CT

 P

LU

G "P

5" 

ON

 W.

F.

M.

 TO

 C

ONNE

CT

OR

 "J

5" 

ON

 M

ACH

INE

.

PL

UG

(P5

)

25

0 A

M

P

TH

ER

M

OS

TA

T

AS

SE

MB

LY

INLI

NE

CO

NN

ECT

OR

S

RE

M

OT

E C

ON

TR

OL

PO

TE

NT

IO

M

ETE

R B

OX

+

GR

OU

ND

TO

 B

AS

E

GR

OU

ND

TO

 E

NG

IN

E

4A

B

B

SH

OW

N A

VI

EW

ED 

FR

OM

 R

EAR.

CO

NN

ECT

TO

 C

AS

E

G

'

NEU

TRA

L B

ONDE

TO

 F

RA

M

E

NEU

TRE 

RAC

CO

RDE

 AU

 B

AT

I

(G

RO

UND SCR

EW

NE

AR F

US

E)

3 4 5 14

61

62

15 19

ZEN

ITH TH

ROTT

LE

BOD

Y

CO

NTROLLER

PE

R E1

53

7

B - 

BL

AC

OR

 G

RA

Y

G -

 G

RE

EN

R - 

RE

D O

PI

NK

U - 

BL

UE

W - 

W

HI

TE

Y - 

YE

LL

OW

71

72

82

81

76

74

73

83

99E

78

99

80

89

40

0F

CURR

EN

T

SE

NS

OR

3 2 1

4

21 22

+

-

-

WHITE CO

NN

ECTOR

BLA

CK

CO

NN

EC

TOR

11

9

8

5

4

3

1

17

13

C

.

0

1

+

96

99D

87A

WATE

R

TEMP. SE

NS

OR

A

B

AI

R

TEMP. SE

NS

OR

95

CB

5

AB

C

93

#

IN

JE

CTOR

THROTTLE PLATE

MOT

OR

A

B

92

91

90

97

97A

99B

99C

67

2

MA

P SE

NS

OR

12

CO

IL

DIS

TRIB

UT

OR

IDL

ER

SW

IT

CH

AL

TE

RN

AT

OR

IG

NI

TI

ON

SW

IT

CH

ST

AR

TE

R

MO

TO

R

EN

GI

NE

HO

UR M

ET

ER

EN

GI

NE

FAILU

RE

LAMP

ST

AR

T

WAT

ER

 T

EMP

.

GA

UG

E

S

A

B

94

FU

EL

 P

UMP

77

OI

L PR

ES

S.

GA

UG

E

S

CON

TROL P

ANEL

GROUND

 SCREW

69

45

R

G

87

99A

97B

97C

{

{

R

E

SISTOR

S

50

87B

G

AMME

TE

R

SENSOR

WATER TEMP. 

SENDER

SENSOR

OI

L PRESSURE SWIT

CH

 & SENSOR

SW

IT

CH

WK

G

PAR

TS

 SUP

PL

IE

D

 WITH 

EN

GI

NE

1

2

3

2

1

3

4

RP

M CO

NTROL

10 K

15

A

15

A

20

A

20

A

41

42

60

0

RE

MOT

E C

ONT

ROL

 S

HOW

N

K9

24-5 R

EM

OTE

 C

ON

TR

OL (O

PT

IO

NA

L)

W

HEN M

AKI

NG T

HESE CON

NECT

IONS.

*

NE

G.

2

12

11

21

6A

6A

67

B

11

A

11

Summary of Contents for CLASSIC 300 G

Page 1: ...houghtful 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 a...

Page 2: ...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...

Page 3: ...cal earth ground 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 coo...

Page 4: ...vent 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...

Page 5: ...appropri 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 paiss...

Page 6: ...ion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number __________...

Page 7: ...eration 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 Sec...

Page 8: ...WIDTH DEPTH WEIGHT 40 94 in 24 00 in 66 91in 1039 9 mm 609 6 mm 1700 mm 1330 lbs 603kg Top of enclosure add 8 0 203 2mm for exhaust OUTPUT GENERATOR Auxiliary Power 1 3000 Watts 60 Hz AC 26 Amps 115V...

Page 9: ...per 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 effectivel...

Page 10: ...chment 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...

Page 11: ...ION 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...

Page 12: ...cing Keep away from moving parts See additional warning information at the front of this operator s manual WARNING DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly...

Page 13: ...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...

Page 14: ...rcuit voltage is also controlled by the Fine Current Adjustment permitting control of the arc characteristics A high open circuit voltage setting provides the soft buttering arc with best resistance t...

Page 15: ...the OCV at the welding site 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 cabl...

Page 16: ...and use clean equipment More bearing failures are caused by dirt introduced during greasing than from insufficient grease COMMUTATOR AND BRUSHES Uncovered rotating equipment can be dangerous Use care...

Page 17: ...gine 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...

Page 18: ...ear 11AV0955 R Fan Belt Good Year 11AV1220 I Tighten cylinder head R Spark Plugs Gap 0 040 4 AC R46TS I Electrical systems I All nuts and bolts for tightness 4 C C Air filter earlier check may be req...

Page 19: ...lumn 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 Step 2 POSSIBLE CAUS...

Page 20: ...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 p...

Page 21: ...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 ci...

Page 22: ...e Idler from current sensing board Control Switch Operation Same Machine Idlers Check wiring between TBI controller and current sensing board 1 Check for current in wires looping through current senso...

Page 23: ...uck Check for loose or disconnected wire running between weld selector switch and output stud If for any reason you do not understand the test procedures or are unable to perform the tests repairs saf...

Page 24: ...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 p...

Page 25: ...e or Blue Smoke Dark Smoke Faulty Charging Starter Motor does not run Engine Knocking Lack of Power 1 Lack of Coolant 2 Loose or slipping fan belt 3 Damaged fan belt 1 Excess engine oil 2 Too low visc...

Page 26: ...e you proceed CAUTION PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTS S RECOMMENDED COURSE OF ACTION Surging Large Decrease in Speed Engine runs Irregularly Engine fails to pick up speed when Arc i...

Page 27: ...EAR CONNECT TO CASE G NEUTRAL BONDED TO FRAME NEUTRE RACCORDE AU BATI GROUND SCREW NEAR FUSE A 02 3 4 5 14 61 62 K924 4 REMOTE CONTROL OPTIONAL WITH MACHINE NOT RUNNING REMOVE PLUG P9 ON MACHINE FROM...

Page 28: ...LEAD 8 LEAD NEGATIVE CV OUTPUT TERMINAL PANEL MACHINE MUST NOT BE RUNNING ON MACHINE REMOVE PLUG P10 FROM CONNECTOR J5 CONNECT PLUG P5 ON W F M TO CONNECTOR J5 ON MACHINE PLUG P5 250 AMP THERMOSTAT AS...

Page 29: ...ORS Y X B G W F G ORANGE WHITE JUMPER WHITE JUMPER PIN CABLE CONNEC TION TABLE C D E LEAD COLOR RED BLUE CV WIRE CONTROL POT CCW BLUE RED ORANGE REMOTE CONTROL BOX CONNECT TO CASE K2464 1 REMOTE CONTR...

Page 30: ...8 4 1 6 6 8 2 6 3 2 5 1 1 5 6 4 5 5 A C O N T R O L P A N E L F G B H D E C O H O L E O M O U N T I N G H O L E N A N B N O T E S O I L A N D W A T E R I N E N G I N E B U T N O F U E L N A C E N T E...

Page 31: ...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 32: ...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 33: ...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 Pr...

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