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Lincoln Electric CLASSIC 300 HE, Operator'S Manual

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Lincoln Electric CLASSIC 300 HE Operator'S Manual Download Page 7

TABLE OF CONTENTS

Page

   Installation .......................................................................................................Section A

         Technical Specifications ........................................................................................A-1

         General Description...............................................................................................A-2

         Design Features ....................................................................................................A-2

         Pre-Operation Installation......................................................................................A-3

                Safety Precautions ..........................................................................................A-3

                Exhaust Spark Arrester ...................................................................................A-3

      Location/Ventilation.........................................................................................A-3

                Angle of Operation ..........................................................................................A-4

      Machine Grounding.........................................................................................A-4

      Lift Bail ............................................................................................................A-4

      Trailers ............................................................................................................A-4

                Vehicle Mounting.............................................................................................A-5

      Polarity Control and Cable Sizes ....................................................................A-5

         Pre-Operation Service ...........................................................................................A-5

      Oil, Fuel...........................................................................................................A-5

      Cooling System ...............................................................................................A-5

      Battery Charging .............................................................................................A-6

                Electrical Devices use with this Product..........................................................A-7

________________________________________________________________________

   Operation .........................................................................................................Section B

         Engine Operation...................................................................................................B-1

      Starting The Kubota D1503-M Engine............................................................B-1

                Cold Weather Starting.....................................................................................B-1

                High Altitude Operation...................................................................................B-1

      Stopping the engine, Engine Break-In.....................................................B-1, B-2

         Welder Operation...................................................................................................B-2

      Duty Cycle.......................................................................................................B-2

      Control of Welding Current..............................................................................B-2

      Idler Operation ................................................................................................B-3

       Auxiliary Power, Fuel Consumption Data........................................................B-3

________________________________________________________________________

   Accessories.....................................................................................................Section C

         Optional Features (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 Maintenance..................................................................................................D-2

Nameplates ...........................................................................................................D-2

         Purging Air from Fuel System................................................................................D-2

Engine Service Chart ............................................................................................D-3

         GFCI Module Testing and Restting Procedure .....................................................D-4

________________________________________________________________________

   Troubleshooting..............................................................................................Section E

         Safety Precautions.................................................................................................E-1

Welder Troubleshooting ........................................................................................E-2

Electronic Idler Troubleshooting Guide...........................................................E-3,E-4

Engine Troubleshooting Guide ...............................................................E-5 thru E-8

________________________________________________________________________

   Diagrams ..........................................................................................................Section F

         Wiring Diagrams ....................................................................................................F-1

         Dimension Print......................................................................................................F-2

________________________________________________________________________

   Parts List................................................................................................... P-734, Series

Summary of Contents for CLASSIC 300 HE

Page 1: ...hines having Code Numbers 11902 12684 Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operation 8 00 AM to 6 00 PM ET Mon thru Fri After hours Use Ask the Experts at lincolnelectric com A Lincoln Service Representative will contact you no later than the following business day For Service outside the USA Email globalservice lincolnelectric com Save for future reference Da...

Page 2: ...N A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual symptoms see your supervisor Perhaps the welding atmosphere and ventilation system should be checked WEAR CORRECT EYE EAR BODY PROTECTION PROTECT your eyes and face with welding helmet properly fitted...

Page 3: ... 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 1 e In some cases it ...

Page 4: ...rm to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 FUMES AND GASES CAN BE DANGEROUS 5 a Welding may produce fumes a...

Page 5: ...ent passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy MA 022690 9101 6 j Do not use a welding power source for pipe...

Page 6: ... inflammables 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 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 6 Eloigner les m...

Page 7: ...er Operation B 3 Auxiliary Power Fuel Consumption Data B 3 ________________________________________________________________________ Accessories Section C Optional Features 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 ...

Page 8: ...HT WIDTH DEPTH WEIGHT 45 5 in 2 24 3 in 62 8 in 1371lbs 1156 mm 616 mm 1594 mm 622kg RATED OUTPUT 104 F 40 C GENERATOR DESCRIPTION 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 DC Power Generator 90V DC Max OCV 1800RPM 80 130 Min 90 Auxiliary Power 1...

Page 9: ...il pressure gauge a fuel hour led indicator gauge temperature gauge For auxiliary power consists of one 20 amp 120VAC 5 20R duplex receptacle with GFCI protection and one 15 amp 240VAC 6 15R receptacle protected by 2 pole 15 Amp breaker All Copper Windings For long life and dependable operation Engine Idler The Classic 300HE is equipped with an electronic automatic engine idler It automatically in...

Page 10: ...ch and Receptacle are standard 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 suita...

Page 11: ...of alternate means of grounding electrical equipment LIFT BAIL A lift bail is provided for lifting with a hoist TRAILER See Optional Features If the user adapts a non Lincoln trailer the user 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...

Page 12: ...tions 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 When welding at a considerable distance from the welder be sure you use ample sized welding cables RECOMMENDED COPPER CABLE SIZES Cables Sizes for Combined Length of Electrode...

Page 13: ... near battery To prevent ExPLOSION when a Installing a new battery disconnect the negative cable from the old battery first and connect the negative cable to the new battery last b 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 c Using a booster con...

Page 14: ...t 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 fail safe operation DO NOT RUN THESE DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS These devices require large current inrush for starting Some synchronous motors may be frequency sensitive to attain m...

Page 15: ...l 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 See additional warning information at the front of this operator s manual WARNING COLD WEATHER STARTING With a fully charged battery and the proper weight oil the engine should start satisfactorily even down to abo...

Page 16: ...age range 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 ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground FUMES GASES can b...

Page 17: ...ltage is now correct at the receptacles for auxiliary power This must be done before a tripped GFCI can be reset properly See the MAINTENANCE section for detailed information on testing and resetting the GFCI CLASSIC 300HE WITH KUBOTA D1503 DIESEL ENGINE TYPICAL FUEL CONSUMPTION DATA Low Idle No Load High Idle No Load 3 000 Watts 150 Amps 26 Volts 200 Amps 28 Volts 250 Amps 30 Volts 300 Amps 32 Vo...

Page 18: ...ot approved by the CSA nor is it recommended or supported by Lincoln Electric FIELD INSTALLED OPTIONAL ACCESSORIES Follow these steps 1 Go to www lincolnelectric com 2 At the top of the screen in the Search field type E6 156 click on Search icon 3 On the results screen click on CLASSIC 300HE product information 4 On the results screen which shows CLASSIC 300HE sales literature document scroll down...

Page 19: ...thrown out by the rotat ing armature when stoning the commutator Shifting of the commutator brushes may result in Change in machine output 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 b...

Page 20: ... 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 IDLER MAINTENANCE Before doing electrical work disconnect the bat tery 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 ...

Page 21: ...D 3 D 3 CLASSIC 300HE MAINTENANCE ...

Page 22: ...his receptacle 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 lamp into the Duplex receptacle and turn the product ON Push the Test button located on the GFCI The night light or other product should go OFF Push the Reset button again The light or other produc...

Page 23: ...f you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility HOW TO USE TROUBLESHOOTING GUIDE 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 invalidat...

Page 24: ...OURSE OF ACTION Machine fails to hold the output heat consistently 1 Rough or dirty commutator 2 Brushes may be worn down to Limit 3 Field 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 have been installed on gener ator 6 Field rheostat may be maki...

Page 25: ...g current too great or too small compared to indication on the dial Arc continuously pops out 1 Generator or exciter brushes may be loose or missing 2 Exciter may not be operating 3 Field circuit of generator or exciter may be open 4 Exciter may have lost excita tion 5 Series field and armature cir cuit may be open circuited 1 Current setting may be too high 2 Polarity may be wrong 1 Exciter outpu...

Page 26: ... Auto Position Check for Continuity through Idler Control Switch Open Closed Check Voltage across Replace Idler Idler Control switch Control Switch 12 VDC 0 VDC Contact Kubota Replace current Engine Repair Sensing PCB Facility 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 fo...

Page 27: ...B Engine Repair Facility E 5 TROUBLESHOOTING CLASSIC 300HE E 5 ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE 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 Check for loose or disconnected wire running betwee...

Page 28: ...1 Lack of fuel 2 Air 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 1 Faulty Ignition switch and or Injector pump solenoid 2 Insufficient charging or com plete discharge of the battery 3 Improper viscosity of the lubri cating oil 1 Air mixed in the ...

Page 29: ...ENGINE IS NOT RUNNING LEAD TO WATER TEMPERATURE SWITCH MAY BE GROUNDED CHECK LONG 1 SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS LONG 2 SHORT 1 0 RPM IS DETECTED AND 12V IS DETECTED FAULTY RPM SENSOR CHECK FOR GOOD CONNECTION FROM L TERMINAL ON ALTERNATOR FAULTY ECU CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU LONG 2 SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT FAULTY ACTUATOR CHECK FOR PRO...

Page 30: ... 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 battery 4 Worn out alternator brush 1 Loose or damaged wiring 2 Drained voltage from battery 3 Damaged starter motor including solenoid 1 Faulty light indicator 2 Faulty light wiring 3 Faulty Engine...

Page 31: ...ot 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 for code 11902 ...

Page 32: ... 1 SENSOR SWITCH 5J SENSOR J3 J2 J1 1 4 1 4 1 1 2 3 4 5 A 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 for code 12684 ...

Page 33: ...7 12 62 75 4 00 4 00 23 00 8 70 41 66 3 35 57 80 56 SKID MOUNTING HOLE 56 SKID MOUNTING HOLE N B N B N A NOTES N A CENTER OF GRAVITY WITH OIL AND WATER IN ENGINE BUT NO FUEL N B Ø 56 TRAILER MOUNTING HOLES 20 62 18 50 40 75 45 50 26 00 13 50 CONTROL PANEL ...

Page 34: ...parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa moja da l Aislese del trabajo y de la tierra l Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension l Isolez vous du travail et de la terre l Berühren Sie keine stromführenden Teile oder Elektroden mit ...

Page 35: ... und Entlüftung des Arbeitsplatzes l Mantenha seu rosto da fumaça l Use ventilação e exhaustão para remover fumo da zona respiratória l Turn power off before servicing l Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio l Débranchez le courant avant l entre tien l Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten l Não o...

Page 36: ...stomer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufactur...

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