Lincoln Electric CLASSIC 300 D PERKINS Operator's Manual
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CLASSIC
300 D PERKINS
®
February 2013
For Machines with Code Numbers 11572, 11573, 11640, 11641, 11809, 11810, 11915, 12091, 12092
Safety Depends on You
Lincoln arc welding and cutting
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
OPERATOR'S MANUAL
Copyright © 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: 1.216.481.8100
For Service in U.S. and Canada: Call 1.888.935.3877
FAX: 1.216.486.1751
WEB SITE: lincolnelectric.com
For Non-U.S. Service: Email globalservice@lincolnelectric.com
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric CLASSIC 300 D PERKINS
Summary of Contents for Lincoln Electric CLASSIC 300 D PERKINS
- Page 1 CLASSIC 300 D PERKINS ® February 2013 For Machines with Code Numbers 11572, 11573, 11640, 11641, 11809, 11810, 11915, 12091, 12092 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...
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Page 2: California Proposition 65 Warnings
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. -
Page 3: Electric Shock Can Kill
SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”... - Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire.
- Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté...
- Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 7: Table Of Contents
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 Machine Grounding..................A-3 Lift Bail ......................A-3 Trailers ......................A-3 Vehicle Mounting.....................A-4 Polarity Control and Cable Sizes ..............A-4 Pre-Operation Service ...................A-4 Oil........................A-4 Fuel .........................A-4... -
Page 8: Installation
INSTALLATION TECHNICAL SPECIFICATIONS - CLASSIC ® 300D PERKINS INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting System Capacities Fuel: 4 Cylinder 135 cu. in 12VDC battery 15 gal.(57 L.) (Codes 11572, 4 Cycle (2.2 ltrs) (Group 24, 650 11573, 11640, 11641) Perkins Naturally Aspirated... -
Page 9: General Description
INSTALLATION GENERAL DESCRIPTION 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 The Classic ® 300D Perkins is a heavy duty, engine driven, idle position when desired. -
Page 10: Pre-Operation Installation
INSTALLATION PRE-OPERATION INSTALLATION CAUTION DO NOT MOUNT OVER COMBUSTIBLE SURFACES. WARNING Where there is a combustible surface directly under sta- Do not attempt to use this equipment until you tionary or fixed electrical equipment, the surface shall have thoroughly read the engine manufacturerʼs be covered with a steel plate at least .06”(1.6mm) thick, manual supplied with your welder. -
Page 11: Vehicle Mounting
INSTALLATION 2. Proper support of, and attachment to, the base of PRE-OPERATION SERVICE the welding equipment so there will be no undue CAUTION stress to the framework. 3. Proper placement of the equipment on the trailer to READ the engine operating and maintenance ensure stability side to side and front to back when instructions supplied with this machine. -
Page 12: Battery Charging
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: a) Installing a new battery - disconnect thenega- tive cable from the old battery first and connect the negative cable to the new battery last. -
Page 13: Electrical Devices Use With This Product
DO NOT USE THESE DEVICES WITH THIS PRODUCT. The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product. CLASSIC ® 300D PERKINS... -
Page 14: Operation
OPERATION ENGINE OPERATION Allow the engine to run at high idle speed for sev- eral minutes to warm the engine. Stop the engine WARNING and recheck the oil level, after allowing sufficient time for the oil to drain into the pan. If the level is Do not attempt to use this equipment until you down, fill it to the full mark again. -
Page 15: Welder Operation
The NEMA output rating of the Classic ® 300D Perkins is 300 Lincoln Electric selects high quality, heavy-duty industrial amperes at 32 arc volts on a 60% duty cycle (consult engines for the portable welding machines we offer. Specifications in this manual for alternate ratings). Duty While it is normal to see a small amount of crankcase oil cycle is based on a ten minute period;... -
Page 16: Idler Operation
OPERATION IDLER OPERATION AUXILIARY POWER Start the engine with the “Idler” switch in the “High” If a GFCI is tripped, See the MAINTENANCE section position. Allow it to run at high idle speed for several for detailed information on testing and resetting the minutes to warm the engine. -
Page 17: Accessories
CSA, nor is it recommended or supported by KP1697-068 - Drive Roll Kit .068 in (1.7 mm) Cored Lincoln Electric. Wire ------------------------------------------------------------------------ KP1697-5/64 - Drive Roll Kit 5/64 in (2.0 mm) -
Page 18: Maintenance
MAINTENANCE SAFETY PRECAUTIONS Follow the engine service schedule in this manual and the detailed maintenance and troubleshooting WARNING in the engine manufacturerʼs manual. Have qualified personnel do the maintenance COOLING SYSTEM work. Turn the engine off before working inside the machine. In some cases, it may be neces- The Classic ®... -
Page 19: Idler Maintenance
MAINTENANCE Replace brushes when they wear within 1/4” of the PURGING AIR FROM FUEL SYSTEM pigtail. A complete set of replacement brushes should (PERKINS 404D-22 ENGINE) be kept on hand. Lincoln brushes have a curved face to fit the commutator. Have an experienced mainte- WARNING nance man seat these brushes by lightly stoning the commutator as the armature rotates at full speed until... -
Page 20: Engine Service Chart
MAINTENANCE ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS FIRST SERVICE - (20 / 50 HOURS) EVERY 100 HOURS OR 3 MONTHS EVERY 250 HOURS OR 6 MONTHS EVERY 500 HOURS OR 12 MONTHS EVERY 1000 HOURS ENGINE SERVICE (NOTE 2) MAINTENANCE ITEM TYPE OR QUANTITY Coolant level... -
Page 21: Gfci Testing And Resetting Procedure
MAINTENANCE GFCI TESTING RESETTING PROCEDURE The GFCI should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI: • If the GFCI has tripped, first carefully remove any load and check it for damage. •... -
Page 22: 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. - Page 23 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Machine fails to hold the output Rough or dirty commutator. (heat) consistently. Brushes may be worn down to Limit. Field circuit may have variable resistance connection or inter- mittent open circuit due to loose connection or broken...
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Page 24: Electronic Idler Troubleshooting Guide
TROUBLESHOOTING ELECTRONIC IDLER TROUBLESHOOTING GUIDE With Idler Control Switch in the Auto Position, Engine Will Not Return to Low Idle in Approximately 15 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... - Page 25 TROUBLESHOOTING ELECTRONIC IDLER TROUBLESHOOTING GUIDE With Idler Control Switch in the AUTO Position, Engine Will Not Pick Up Speed When: The Arc is Struck The Auxiliary Power Load is Turned ON Reed Switch in Weld Circuit Power Load Too Small Defective -- Will Not Close Try Load Above 150 Watts To Check: Short the Red Lead Engine Does Not Pick Up Speed...
- Page 26 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Engine does not start. Lack of fuel. Air mixed in the fuel system. Clogged fuel filter. Irregular and faulty fuel supply (Injector pump trouble). Glow plug not heated.
- Page 27 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Engine stops during operation and 1. Overheat of the Engine. the Engine Protection light does turn Lack of Coolant Supply coolant. Inspect leakage and correct. Loose or slipping fan belt Remove oil, dust, etc.
- Page 28 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION White or Blue Smoke. Excess engine oil. Too low viscosity of the engine oil. Faulty injection timing. Dark Grey Smoke. Unsuitable fuel. Excess injection. Faulty function of the engine.
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Page 29: Diagrams
Enhanced Diagram DIAGRAMS CLASSIC 300D PERKINS ®... - Page 30 Enhanced Diagram DIAGRAMS CLASSIC 300D PERKINS ®...
- Page 31 Enhanced Diagram DIAGRAMS WHITE CLASSIC 300D PERKINS ®...
- Page 32 DIAGRAMS CLASSIC ® 300D PERKINS...
- Page 33 DIAGRAMS CLASSIC ® 300D PERKINS...
- Page 34 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
- Page 35 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
- Page 36 Need Help? Lincoln Electric “Rapid Response” Service! Call 1.888.935.3877 to talk to a Service Representative Hours of Operation: 8:00 A.M. to 6:00 P.M. (ET) Mon. thru Fri. After hours? Use “Ask the Experts” at lincolnelectric.com A Lincoln Service Representative will contact you by the next business day.