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Operator's Manual
CLASSIC
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IM966
| Issue D ate Aug-08
© Lincoln Global, Inc. All Rights Reserved.
®
300D KUBOTA
For use with machines having Code Numbers:
11499, 11500
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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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric 11499
Summary of Contents for Lincoln Electric 11499
- Page 1 Operator’s Manual ® CLASSIC 300D KUBOTA For use with machines having Code Numbers: 11499, 11500 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.
- 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 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...
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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-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 KUBOTA INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System 4 Cylinder 4 Cycle 148.53 cu. in 12VDC battery Fuel: 15 gal. Naturally Aspirated (2.43 ltrs) (Group 24, 650 57 L Kubota Water-Cooled High Idle 1800... -
Page 9: General Description
INSTALLATION Engine Idler - The Classic® 300D is equipped with GENERAL DESCRIPTION an electronic automatic engine idler. It automatically increases and decreases engine speed when start- The CLASSIC® ® 300D KUBOTA is a heavy duty, ing and stopping welding or using auxiliary engine driven, DC arc welding power source, capable power. -
Page 10: Pre-Operation Installation
INSTALLATION PRE-OPERATION INSTALLATION CAUTION WARNING DO NOT MOUNT OVER COMBUSTIBLE SURFACES. Where there is a combustible surface directly under sta- Do not attempt to use this equipment until you have tionary or fixed electrical equipment, the surface shall thoroughly read the engine manufacturerʼs manual sup- be covered with a steel plate at least .06”(1.6mm) thick, plied with your welder. -
Page 11: Trailers
INSTALLATION TRAILER (See Optional Features) RECOMMENDED COPPER CABLE SIZES Cables Sizes for Combined Length of Electrode Plus Work Cable If the user adapts a non-Lincoln trailer, the user must assume responsibility that the method of attachment Amps Duty Cycle Up to 200ft.(61m) 200 to 250ft. (61 to 76m) and usage does not result in a safety hazard nor dam- 100%... -
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 the negative cable from the old battery first and connect the negative cable to the new battery... -
Page 13: Operation
To stop the engine, turn the “IGNI- TION” switch to “OFF”. 6. If the engine protection warning light comes on during Lincoln Electric selects high quality, heavy-duty indus- cranking or after start up, the “IGNITION” switch must trial engines for the portable welding machines we be turned “OFF”... -
Page 14: 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® 300D tions for extended periods of time are especially sus- KUBOTA is 300 amperes at 32 arc volts on a 60% ceptible to the conditions described above. -
Page 15: Idler Operation
OPERATION IDLER OPERATION The AC auxiliary power, supplied as a standard, has a rating of 3.0 kVA of 115/230 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, 115/230 VAC auxiliary power, one minutes to warm the engine. -
Page 16: Accessories
The use of an arc welder for pipe thawing is not approved by the TIG OPTIONS CSA, nor is it recommended or supported by Lincoln Electric. TIG Module (K930-2) - Provides high frequency and ------------------------------------------------------------------------ shielding gas control for AC and DC GTAW (TIG) welding applications. -
Page 17: Wire Feed Options
ACCESSORIES WIRE FEED OPTIONS Magnum Spool Gun (K487-25)-Hand held semiauto- Wire Feed Module (K623-1) - Provides constant matic wire feeder requires SG Control Module. 25 ft. voltage (CV) output with improved arc stability for (7.6m)length. Innershield welding. Excellent for MIG welding. Recommended wire feeders are the LN-7, LN-23P SG Control Module (K488) (For Magnum Spool and LN-25. -
Page 18: Maintenance
MAINTENANCE MAINTENANCE Follow the engine service schedule in this manual and the detailed maintenance and troubleshooting in WARNING 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”(3.5mm) P U R G I N G A I R F R O M F U E L S Y S T E M of the pigtail. A complete set of replacement brushes (KUBOTA V2403M ENGINE) should be kept on hand. -
Page 20: Engine Service Chart
MAINTENANCE ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS FIRST SERVICE (50 HOURS) EVERY 100 HOURS OR 3 MONTHS EVERY 150 HOURS OR 4 MONTHS EVERY 30O HOURS OR 9 MONTHS EVERY 400 HOURS OR 12 MONTHS EVERY 500 HOURS OR 15 MONTHS EVERY 600 HOURS OR 18 MONTHS ENGINE SERVICE (NOTE 2) MAINTENANCE ITEM... -
Page 21: Gfci Receptacle Testing And Restting Procedure
MAINTENANCE GFCI RECEPTACLE TESTING AND RESET- TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage. - Page 22 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.
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Page 23: Troubleshooting
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... -
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 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 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 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 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 KUBOTA... - Page 30 DIAGRAMS CLASSIC® 300D KUBOTA...
- Page 31 DIAGRAMS CLASSIC® 300D KUBOTA...
- Page 32 NOTES CLASSIC® 300D KUBOTA...
- Page 33 NOTES CLASSIC® 300D KUBOTA...
- 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...
- 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- ●...
- 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.