Lincoln Electric CLASSIC 300 HE Operator's Manual
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Lincoln Electric CLASSIC 300 HE Operator's Manual

For use with machines having code numbers: 11902, 12684
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Operator's Manual
CLASSIC
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10153-A
| Issue D ate Jul-17
© Lincoln Global, Inc. All Rights Reserved.
®
300 HE
For use with machines 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

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Summary of Contents for Lincoln Electric CLASSIC 300 HE

  • Page 1 Operator’s Manual CLASSIC ® 300 HE For use with machines having Code Numbers: 11902, 12684 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
  • Page 6 S FETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7.

  • 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 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...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - CLASSIC 300HE ® INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System 3 Cylinder 24.8HP (18.5kW) 91.47 cu. in 12VDC battery Fuel: Naturally Aspirated (1.56 ltrs) (Group 24, 650 Kubota Water-Cooled High Idle 1800 cold crank amps) 16 gal.(60.6 L.) Bore x Stroke...

  • Page 9: General Description

    INSTALLATION GENERAL DESCRIPTION an electronic automatic engine idler. It automatically increases and decreases engine speed when starting and stopping welding or using auxiliary power. A built- The Classic 300HE is a heavy duty, engine driven, ® in time delay permits changing electrodes before the DC arc welding power source, capable of providing engine slows to its low idle speed.

  • Page 10: Pre-Operation Installation

    INSTALLATION PRE-OPERATION INSTALLATION Welder Enclosure - The complete welder is rubber WARNING mounted on a rugged steel “C” channel base. The output terminals are placed at the side of the Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s machines so that they are protected by the door.

  • Page 11: Angle Of Operation

    INSTALLATION ANGLE OF OPERATION LIFT BAIL Engines are designed to run in the level condition which is A lift bail is provided for lifting with a hoist. where the optimum performance is achieved. The maximum angle of continuous operation is 20 degrees in all directions, WARNING 30 degrees Intermittent (less than 10 minutes continuous) in all directions.

  • Page 12: Vehicle Mounting

    INSTALLATION PRE-OPERATION SERVICE VEHICLE MOUNTING WARNING CAUTION Improperly mounted concentrated loads may READ the engine operating and maintenance cause unstable vehicle handling and tires or other instructions supplied with this machine. components to fail. WARNING • Only transport this Equipment on serviceable vehicles which are rated and designed for such •...

  • Page 13: 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 the negative cable from the old battery first and connect the negative cable to the new battery...

  • Page 14: 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 300HE ®...

  • Page 15: Operation

    30 seconds, stop the engine and consult the engine operating manual. To stop the engine, turn the “IGNI- TION” switch to “OFF”. Lincoln Electric selects high quality, heavy-duty indus- 6. If the engine protection warning light comes on during trial engines for the portable welding machines we cranking or after start up, the “IGNITION”...

  • Page 16: Welder Operation

    OPERATION DUTY CYCLE Larger machines with a capacity of 350 amperes and higher, which are operated at low or no-load condi- The NEMA output rating of the Classic 300HE is 300 tions for extended periods of time are especially sus- ® amperes at 32 arc volts on a 60% duty cycle (consult ceptible to the conditions described above.

  • Page 17: Idler Operation

    OPERATION IDLER OPERATION The AC auxiliary power, supplied as a standard, has a rating of 3.0 kVA of 120/240 VAC (60 hertz). Start the engine with the “Idler” switch in the “High” position. Allow it to run at high idle speed for several With the 3.0 KVA, 120/240 VAC auxiliary power, one minutes to warm the engine.

  • Page 18: Accessories

    The use of an arc welder for pipe thawing is not approved by the CSA, nor is it recommended or supported by Lincoln Electric. ------------------------------------------------------------------------ FIELD INSTALLED OPTIONAL ACCESSORIES Follow these steps: 1.

  • Page 19: Maintenance

    MAINTENANCE SAFETY PRECAUTION Follow the engine service schedule in this manual WARNING and the detailed maintenance and troubleshooting in the engine manufacturer’s 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 300HE is equipped with a pressure radi- ®...

  • Page 20: Idler Maintenance

    MAINTENANCE Replace brushes when they wear within 1/4”(3.5mm) 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 experi- enced maintenance person seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact is made across the full face of the brushes.
  • Page 21 MAINTENANCE CLASSIC 300HE ®...
  • Page 22 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 23: 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 24 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- If all recommended possible areas of mittent open circuit due to...
  • Page 25 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION Welder starts but fails to generate Generator or exciter brushes current. may be loose or missing. Exciter may not be operating. Field circuit of generator or exciter may be open.

  • Page 26: 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 27 TROUBLESHOOTING ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE With Idler Control Switch in the AUTO Position, Engine Will Not Pick Up Speed When: The Arc is Struck Both Auxiliary Load 1. Check Idler circuit wiring. Possible 1. Load too small. Try load Check for loose or disconnected Problems are wires from Current Sensing above 100 Watts.
  • Page 28 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 29 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual LIGHT CODE FAILURE DETECTED POSSIBLE CAUSE - CORRECTIVE MEASURE LONG 1, SHORT 1 RPM IS OVER 115% OF RATED RPM (2070 RPM) ACTUATOR IS STUCK - REMOVE ACTUATOR AND VERIFY PLUNGER PULLS IN WHEN ENERGIZED LONG 1, SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND LOW OIL - CHECK OIL LEVEL ON DIPSTICK...
  • Page 30 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.

  • Page 31: Diagrams

    DIAGRAMS for code 11902 CLASSIC 300HE ®...
  • Page 32 DIAGRAMS for code 12684 CLASSIC® 300HE...
  • Page 33 DIAGRAMS CLASSIC 300HE ®...
  • Page 34 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 35 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 36 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

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