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Emerson EM6000 Cordless Telephone User Manual

1. saan 0 ONY dris MOTBA Ta ama n e 9 SENI dS and 31LLOHHL 8 dau 4 30104 WHOlVNHBITV N 9 9 M 4 3918 6 0b a 3040098 SYLNSN 3000 OL ET HATIOHLNOO SY NMOHS STOSNAS 5878 Era AG08 SLN3NOdNO9 TANVd TOHLNOD E LIOSHL HLIN3Z J 6590 2009 303 WYY VYIA 9NIHIM 9006 5155 12 yo1oannoo 9 1 CLASSIC 300G LINCOLN E N LL DIAGRAMS F 2 Jequunu epoo eu 104 uoWiyedsq ejqiGej eui j sjeued eunsoj oue y euo uo episui pejsed si epoo sejnomed siy Aq je 10 eq jou e2u9JeJ8J JO S SIUL LON 99811 SNOLLO3NNOO ASSHL 9NDIVIN ONINNN 38 LON 1 3NIHOVIN 1V1SOWH3HL 052 31 2 5 93N 01 LOANNOD 809 QV31 2 311dON TaNvd TWNIAYAL NALNO o AALLVORN aan O S WINH3L 1NdLNO 333 04 O NO
2. Cut Ll gt LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR SRM OBHOX HD OHBRBEE lt K MA CUCRITEOSSXSUEIL HS ET REL BE SUCR Rr de EL AMENER 0 SAAD HA HHR ele BEHE ET gl illai aui Qui al gll Gail guet LINCOLN 5 World s Leader in Welding and Cutting Products Sales 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
3. DESIGN FEATURES Control Panel Both the engine and the welder controls are located on one recessed panel at the exciter end of the machine The welder controls consist of a five step Current Range Selector switch and a Fine Current Adjustment rheo stat The welder is equipped with a Start button an Ignition switch an Idler control switch and a Glow Plug button for easier cold weather starting The control panel also contains an engine temperature gauge a battery charging ammeter an oil pressure gauge two three prong grounding type receptacles and four circuit breakers for auxiliary power All Copper Windings For long life and dependable operation Engine Idler Control The Classic 300G is equipped with an electronic automatic engine idle control It auto matically increases and decreases engine speed when starting and stopping welding or using auxiliary power 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 idle position when desired Auxiliary Power 3 0 kVA of nominal 115 230V 60Hz AC Output voltage is maintained within 10 at all loads up to rated capacity See Optional Features for Power Plug Kit Welder Enclosure The complete welder is rubber mounted on a rugged steel channel base The output terminals are placed at the side of the machines so that they a
4. IM659 B CLASSIC 3006 For Machines with Code Numbers 10659 10912 11135 Safety Depends on You Lincoln arc welding 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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Q NRTL C OPERATOR S MANUAL LI NCOLN Copyright 2004 Lincoln Global Inc World s Leader Welding and Cutting Products Sales 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 l WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING
5. 39 NOVI 8 3002 40109 av31 15913434 21081409 35901 QNnouo Qunouo 3595 GNNOHO TOHLNOD 3313918 YILIN YNOH 3NION3 SNIONSHLIM Gilddns sid HOLON 6 89 HOLOBNNOD z xong 6L 3019300 Sb 3 HATIOHLNO ANY 2160 3300 WVYOVIC 9008 2155719 CLASSIC 300G LINCOLN 8 F 3 D IAGRAMS F 3 K2464 1 REMOTE CONTROL WIRING CONNECTION DIAGRAM RESISTORS CC STICK CON ITROL WHITE JUMPER A S26097 CLASSIC 300G LINCOLN DIAGRAMS p F 4 99 018 9 4 a v ON Led 968 8501 310H ONIINNON ais 99 PSL gf 6776 0729 Ul HSI19N3 0 26 07971 ONILN 16 99 00 1 9008 0155710 6 99 015 91913 J 10H NOW 135 00712010 TANVd 10 1 09 NOISN3WIQ S8310H ONILNNON 8 99 701 00747 1304 ON Lng JNION3 NI H31VM 110 ALIAVHO 40 8 0 SALON CLASSIC 300G LINCOLN 8 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese BIR Do not touch electrically live parts or electrode with skin or wet clothing Insulate y
6. 60 Duty Cycle 1 66 gal hr 6 27 Itrs hr 300 Amps 32 Volts 60 Duty Cycle 1 83 gal hr 6 91 Itrs hr 250 Amps 30 Volts 100 Duty Cycle 2 15 gal hr 8 12 Itrs hr PHYSICAL DIMENSIONS HEIGHT WEIGHT 40 94 in 1039 9 mm 1700 mm 1330 Ibs 603kg 609 6 mm Top of enclosure add 8 0 203 2mm for exhaust 1 115V will operate either 60 Hz or 50 60 Hz power tools lights etc Based on a 10 min period CLASSIC 300G LINCOLN A 2 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing nsulate yourself from work ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside XN IN 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 PRE OPERATION INSTALLATION EXHAUST SPARK ARRESTER Some federal state or local laws may require that engines be equipped with exhaust spark arrester
7. 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 cable Wire Feed Module K623 1 Provides constant voltage CV output with improved arc stability for Innershield welding Excellent for MIG welding Recommended wire feeders are the LN 7 LN 23P and LN 25 GFCI Receptacle Kit K1690 1 Includes one UL approved 115V ground fault circuit interrupter duplex type receptacle and installation instructions Replaces the factory installed 115V duplex receptacle Each receptacle of the GFCI duplex is rated at 20 amps Maximum total current from the GFCI duplex is limited to 20 amps TIG Module Portable high frequency unit with gas valve for TIG welding Rated at 300 amps 60 duty cycle Request Publication E3 205 Order K930 2 Control Cable Connects TIG Module to the Classic 300G Order K936 4 Arc Start Switch Provides on off control at the TIG Module Order K814 Contactor Kit For use with TIG Module Order K938 1 Control Cable Extension Allows the TIG Module to be operated at distances up to 200 ft from the power source Availiable length 45 ft 13 7m Order K937 45 Water Valve Kit For use with a water cooled TIG Torch Installs inside of TIG Module Order K844 1 K2261 1 OIL DRAIN KIT Includes ball valve hose and clamp CLASSIC 300G LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUT
8. 2 Welder Operation iii B 2 CY d m ees B 2 Control of Welding Current enne B 3 Idler Operations B 3 Auxiliary POWer iii B 3 Throttle Body Deicing circio s nat sages E AOA B 3 1 5 ws Section C Optional Equipment Field C 1 Maintenance 1 Section D Safety PreCaulions e EE D 1 General Instructions issu D 1 Cooling M D 1 Et D 1 Commutator and Brushes is deine hein i EUR D 1 Idler Control Maintenance is D 2 Nameplates T D 2 Purging Air from Fuel System D 2 Engine Maintenance 2 2 ck ised EEEE ends D 2 Engine Service Chart D 3 Troubleshooting Section E Safety tien heii ed Aiea EX YU RENE Mena E 1 Troubleshooting 99 E 2 E 3 Electronic Idler Troubleshooting 2 E 4 E 5 5 6 7 Section F Wiring Diagram Classic 300 anii itcr vie er ie F 1 F 2 Dimension eene eene rennen naeh F 3 Parts List recie c pad
9. Alternator Fanbelt jAltermator Fanbeltwear R AlterntorBelt Year 11AV0955 R Fan Belt 004 Year 11AV1220 i ugnen eylnderhead m EE Es 2 Donaldson P181050 Nelson 70206N Leaks or engine damage J Battery 6 1 Inspect C Clean R Replace Spark Plugs Gap 0 040 4 AC R46TS ej IE LES Good Year 11AV0955 0 HE Good Year 11AV1220 ___________ RR 4 AC R46TS ES E ej _ S Donaldson P181050 Nelson 70206N Notes 1 Consult Engine Operators Manual for oil Recommendations 2 Consult engine operators manual for additional maintenance schedule information 3 Fill slowly Ensure correct quantity is used 4 Clean the air filter if the engine is operating in very dusty conditions Above operations to be carried out by trained personnel with reference to the workshop manual where necessary These preventative maintenance periods apply to average conditions of operation If necessary use shorter periods S20919 3 CLASSIC 300G LINCOLN ET TROUBLESHOOTING E 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 factor
10. HO 1W901HO4 HOLIMS M GVA 2 TWNINYAL 17820 SHOLSIS3H 2 70 Inqon __ iS ON 9 SINNINH3L LNdLNO g 0333 804 J SAN 9 5040119905 GATIVLSNI TINON 0334 4 Q3TIVISNI SHL MOT38 Q3 SI LI 31 HOLIMS 335 JOMINOO LONH HLOL 94 1021400 31990 NVI SHOLIINNOI X oma USLSWOUNALOd OPERA y o mong ION1NOO 3103 9 66 OL EE EL 35 NO 497 OLO3NNOO OL W AM NO Sdu 193NNO2 T HOLONNOO WOH Obd SNIHOVI NO HOLIMS 19143034 TWNOILdO SINGOW 9333 31M IVNOILdO 103109 SLOWSY 7726 WM HUM 19 09 55 quom 3825 YOSNAS TOHLNOO 9 8 SNA MAYIS DIAGRAMS SONIGNIM o HAMOd SN YOLVNYSLTV 1V1SOZHH YALIN YNOH ANIONS v9 T9 D o HLIM 7 Gariddns SLHVd e 5 93199193954 8 31914304 voo9 LION 0 Z LION SL y NOWI OL m 4
11. Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with 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 2 a Electric current flowing through any conductor causes localized Ele
12. Sf YOLOINNOO OL W JM NO Sdh ONIA 199409 457 HOLO3NNOO WO 014 ON ld 3AOW3H NO IVNOILLdO SINGOW Q33 93 8 SOd 01 LOANNOD SHOLIANNO9 __ XO8 YSLSWOLLNSLOd 1031409 SLOWSY 30193 357201 199 05 YALAWOLLNALOd OHLNO9 SLOWSY 0 103109 SLOWSY 9 756 WEM HUM 10 8 99 29 AILISOd 9 qo 309435 8 SNA YVAN MYS ANNOYS 8 SONIONIM W3MOd n 9 2 5 1 201 1 e YOLVNYSLTV 4 NMOHS 1031409 SLOWSY wi a vo 30 901 803 HOLIMS HOLMS VL HE n 30193138 sa 1VISO3HH 9 2 YW p e 30143934 t lt Y009 LIOA 085 lt ov OL 8209 9009 dS 019 i S NIY dS WOlOH HOLVNHALTV Y JJ e tH MA vy 93719193934 A 31IHM Y 8 M ama n 9 N3349 M 1040904 01 939408 WHLNAN SY NMOHS SIN3NOdWOO TOHLNOO
13. battery from the circuit 5 Replace the exciter cover 6 Reconnect the positive battery cable 7 Start the welder and the generator voltage should build up CAUTION 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 CLASSIC 300G LINCOLN E 4 TROUBLESHOOTING E 4 ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE Engine Will Not Return to Low Idle in Approximately 10 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 Remove Molex connector Replace 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 sensor 2 Replace current sensor Have TBI controller inspected at authorized service shop Not O K A CAUTION 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 CLASSIC 300G LINCOLN 5 E 5 TROUBLESHOOTING E 5 ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE With Idler Control Switch in the AUTO Positi
14. for sev eral minutes to warm up If idle control switch is left in Auto position engine will run at 1600 RPM until engine coolant temperature reaches 130 F A WARNING Under NO conditions should ether or other starting fluids be used STOPPING THE ENGINE Turn the IGNITION switch to OFF At the end of each day s welding check the crankcase oil level drain accumulated dirt and water from the sediment bowl under the fuel tank and refill the fuel tank to minimize moisture condensation in the tank Also running out of fuel tends to draw dirt into the fuel system When hauling the welder between job sites close the fuel feed valve beneath the fuel tank f the fuel supply is cut off or runs out while the fuel pump is operating air may be entrapped in the fuel distribution system If this happens bleeding of the fuel system may be necessary Refer to the instruc tions in the MAINTENANCE section of this manual REFER TO THE ENGINE Operation and maintenance manual for additional information on the engine supplied with this welder WELDER OPERATION A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground FUMES amp GASES can be dangerous Keep your head out of the fumes 9 Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosi
15. problem persists Contact your local Lincoln Authorized Field Service Facility Worn out alternator brush Starter Motor does not run Loose or damaged wiring Low Battery voltage Damaged starter motor Engine Knocking Poor grade of Gasoline Spark advance to far Lack of Power Carbon deposits causing pre ignition Incorrect timing CAUTION 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 CLASSIC 300G LINCOLN 5 E 8 TROUBLESHOOTING E 8 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION i 1 Dirty Air Filter 2 Engine running at RPM limiter 2000 RPM Large Decrease in Speed Ice build up on throttle plate Engine runs Irregularly Faulty coolant temperature sender Engine fails to pick up speed when Faulty idler circuit Arc is struck If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility A CAUTION 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 troublesho
16. respirat ria 9 fsUPBHEILTASESUCFEU CARE 24758 else e SUAS MAS sis PARAH 7 Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas e XL7TTL2A 9 AVCWRUD PSB RET BRAY FE e HE BIS AGS XA Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas NRIVOAN ERUALEEE Ro e 20 Sel Sepe Asal HAS WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O it ie BIR Chinese Qai dul jua Sarin e os uui ARI ge cal sd ue Aie Ao pha J gail e Ads cuts gall l Jai y e
17. ATTERY BUCKLING tighten nuts on battery clamp until snug The Classic 300G is equipped with a wet charged bat tery The charging current is automatically regulated when the battery is low after starting the engine to a trickle current when the battery is fully charged When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed This system is NEGATIVE GROUND CLASSIC 300G LINCOLN 8 B 1 OPERATION B 1 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside 3 MOVING PARTS can injure Do not operate with doors open or guards off MTM Stop engine before servicing Keep away from moving parts See additional warning information at the front of this operator s manual Operate the welder with the doors closed Leaving the doors open changes the designed air flow and can cause overheating GENERAL DESCRIPTION The Classic 300G is a heavy d
18. IONS A WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the machine In some cases it may be neces sary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is com plete Always use the greatest care when work ing near moving parts Do not put your hands near the engine cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves e ENGINE EXHAUST can kill 3 Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure Do not operate with doors open or guards off A Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual GENERAL INSTRUCTIONS Blow out the welder and controls with an air hose at least once every two months In particularly dirty locations this cleaning may be necessary once a week Use low pressure air to avoid driving dirt into the insulation Current Range Selector contacts should not be greased To keep the contacts clean rotate the cur rent control through its
19. as 3 Clogged fuel filter of misadjustment have been checked and the problem persists 4 Defective governor Contact your local Lincoln 5 Engine itself defective Authorized Field Service Facility Engine stops running During Operation and the Engine Protection Light Does Turn On 2 Clogged fuel filter Solid Light Lack of fuel in the tank Air mixed in the fuel system Lack of Engine Oil Fault in oil pressure switch Oil leakage from the lubricating system Clogged oil filter Oil too light Faulty TBI controller 10 Faulty function of the engine A CAUTION 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 CLASSIC 300G LINCOLN 8 E 7 TROUBLESHOOTING E 7 Observe all Safety Guidelines detailed throughout this manual Engine Stops During Operation and 1 Lack of Coolant the Engine Protection Light Does Tum On Flashing 2 Loose or slipping fan belt 3 Damaged fan belt White or Blue Smoke 1 Excess engine oil 2 Too low viscosity of the engine Dark Smoke Excess injection Clogged air cleaner Faulty function of the engine Faulty Charging Loose fan belt Faulty wiring Faulty battery i If all recommended possible areas of misadjustment have been checked and the
20. be grounded It is recommended that you determine the extent to which such requirements may apply to your particular situation and follow them explicitly A machine grounding stud marked with the symbol is provided on the welding generator frame foot In general if the machine is to be grounded it should be connected with a 8 or larger copper 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 effectively grounded The U S National Code lists a number of alternate means of grounding electri cal equipment LIFT BAIL A lift bail is provided for lifting with a hoist A WARNING Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trail er or gas cylinder Do not lift machine if lift bail is damaged Do not operate machine while suspended from lift bail FALLING EQUIPMENT can cause injury CLASSIC 300G LINCOLN 8 A 3 TRAILER See ACCESSORY Section If the user adapts a non Lincoln trailer he 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 trailer vs weight of Linc
21. clear The fuel system operates as follows The fuel pump will operate for a maximum of 3 seconds when the ignition switch is turned ON The pump will restart once the start button is pushed and continue when the engine starts To purge the system of air if fuel lines have been removed the ignition switch can be tog gled ON and OFF at 3 second intervals until fuel flows through the fuel return line in the neck of the tank The GM 3 0L engine does not require the system to be bled If the engine runs out of fuel and the tank is refilled the engine will restart within a few seconds if the engine is properly tuned ENGINE MAINTENANCE Refer to the engine operation and maintenance man ual for additional information on the engine CLASSIC 300G LINCOLN D 3 MAINTENANCE D 3 ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS FIRST SERVICE 50 HOURS EVERY 100 HOURS OR 3 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 600 HOURS OR 12 MONTHS ENGINE SERVICE NOTE 2 MAINTENANCE ITEM TYPE OR QUANTITY jCoedatlevel G Concentration of antifreeze S0 50 Water Ethylene Glycol Radiator for contamination or blockage R Coolant NOTE3 99qrts 94L jEngmeoillvel NOTE1 o HB Engine oil NOTE 1 amp 3 4 5qts 4 3L including filter Engine oil filter AC PF25 jDrinfuelbowl ____ R Fuelfilercanister PSI 32500292 of
22. ctric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety nes minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should a
23. en work requiring removal is complete Only qualified personnel should install use or service this equipment CAUTION 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 CLASSIC 300G LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSES COURSE OF ACTION PROBLEMS Machine fails to hold the heat con Rough or dirty commutator stantly Brushes may be worn down to limit Field circuit may have variable resistance connection or intermit tent open circuit due to loose or broken wire Electrode lead or work lead con nection may be poor Wrong grade of brushes may have been installed on generator Field rheostat may be making poor contact and overheating Welder starts but fails to generate Generator or exciter brushes may current be loose or missing If all recommended possible areas of misadjustment have been Exciter may not be operating checked and the problem persists Contact your local Lincoln Field circuit of generator or Authorized Field Service Facility exciter may be open Exciter may have lost excitation Series field and armature circuit may be open circuited Welding arc is loud and spatters Curre
24. entire range frequently Good practice is to turn the handle from maximum to minimum setting twice each morning before start ing to weld Put a drop of oil on the Current Range Selector shaft at least once every month When necessary remove the sediment bowl if so equipped from beneath the fuel tank and clean out any accumulated dirt and water Follow the engine service schedule in this manual and the detailed maintenance and troubleshooting in the engine manufacturer s manual COOLING SYSTEM The Classic 300G is equipped with a pressure radia tor Keep the radiator cap tight to prevent loss of coolant Clean and flush the cooling system periodi cally to prevent clogging the passage and overheating the engine When antifreeze is needed always use the permanent type Capacity 9 9 qts 9 4 Ltrs BEARINGS This welder is equipped with a double shielded ball bearing having sufficient grease to last indefinitely under normal service Where the welder is used con stantly or in excessively dirty locations it may be nec essary to add one half ounce of grease per year A pad of grease one inch wide one inch long and one inch high weighs approximately one half ounce Over greasing is far worse than insufficient greasing When greasing the bearings keep all dirt out of the area Wipe the fittings completely clean and use clean equipment More bearing failures are caused by dirt introduced during greasing than from insuff
25. g head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 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 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 2 FUMES AND GASES can be dangerou
26. he manufacturer 5 e Also see item 1 b Mar 95 SAFETY 7 WELDING SPARKS can gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent 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 lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may expl
27. icient grease COMMUTATOR AND BRUSHES WARNING Uncovered rotating equipment can be dangerous Use care so your hands hair clothing or tools do not catch in the rotating parts Protect yourself from particles that may be 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 black or appear uneven have them cleaned by an experienced maintenance man using fine sandpaper or a commutator stone Never use emery cloth or paper for this purpose CLASSIC 300G LINCOLN D 2 MAINTENANCE D 2 Replace brushes when they wear within 1 4 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 experienced mainte nance man 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 After stoning blow out the dust with low pressure air To seat slip ring brushes position the brushes in place Then slide one end of a piece of fine sandpaper between slip rings and brushes with the coarse side against the b
28. l recommended in the Engine Operators manual Make sure the fuel valves on the sediment bowl and the water separator are in the open positions COOLING SYSTEM The radiator has been filled at the factory with a 50 50 mixture of ethylene glycol antifreeze and water Check the radiator level and add a 50 50 solution as needed see engine manual or antifreeze container for alter nate antifreeze recommendations CLASSIC 300G LINCOLN 8 A4 INSTALLATION BATTERY CHARGING WARNING GASES FROM BATTERY can explode e Keep sparks flame and cigarettes 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 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 the welder by disconnecting the negative cable first then the positive cable and battery clamp When reinstalling connect the negative cable last Using a booster connect the positive lead to the battery first then connect the negative lead to the ground lead on the base To prevent ELECTRICAL DAMAGE when e Installing a new battery e Using a booster Use correct polarity Negative Ground To prevent BATTERY DISCHARGE if you have an ignition switch turn it off when engine is not running To prevent B
29. lectrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY PR CAUTIONS DE S RET 6 Eloigner les mat riaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder e
30. lso be on your right side X Connect the work cable to the workpiece as close as possible to the area being welded 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 8 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel weldin
31. n ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POUR contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projectio
32. ns quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables 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 paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Cart
33. nt setting may be too high excessively Polarity may be wrong CAUTION 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 CLASSIC 300G LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSES COURSE OF ACTION PROBLEMS Welding current too great or too 1 Exciter output low causing low small compared to indication on the output compared to dial indica dial tion If all recommended possible areas Operating speed too low or high of misadjustment have been checked and the problem persists Contact your local Lincoln Arc continuously pops out Current Range Selector switch Authorized Field Service Facility may be set at an intermediate position FLASHING THE FIELDS 1 Stop the engine welder and disconnect the positive battery terminal 2 Remove the cover from the exciter 3 Turn the Fine Current Adjustment rheostat to 100 on the dial 4 Using a 12 volt automotive battery connect its negative terminal to the negative brushholder The negative 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
34. ode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN CYLINDER may explode 22238 sr if damaged 7 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other e
35. oln equipment and likely additional attachments 2 Proper support of and attachment 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 being moved and when standing by itself while being operated or serviced 4 Typical conditions of use i e travel speed rough ness of surface on which the trailer will be operated environmental conditions likely maintenance 5 Conformance with federal state and local laws 1 1 Consult applicable federal state and local laws regarding specific requirements for use on public highways A WARNING VEHICLE MOUNTING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on serviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for compo nents such as suspension axles and tires Mount equipment base to metal bed or frame of vehicle Follow vehicle manufacturer s instructions POLARITY CONTROL AND CABLE SIZES With the engine off route the electrode and work cables through the strain relief bracket on the base and connect to the studs located below the fuel tank mounting rail See size recommendations below For Po
36. on gt Keep flammable material away RAYS can burn 4 Wear eye ear and body protection NM DUTY CYCLE The NEMA output rating of the Classic 300G is 300 amperes at 32 arc volts on a 60 duty cycle consult Specifications in this manual for alternate ratings Duty cycle is based on a ten minute period thus the welder can be loaded at rated output for six minutes out of every ten minute period CLASSIC 300G LINCOLN B 3 OPERATION B 3 CONTROL OF WELDING CURRENT CAUTION DO NOT TURN THE CURRENT RANGE SELEC TOR WHILE WELDING because the current may arc between the contacts and damage the switch The Current Range Selector provides five overlap ping current ranges The Fine Current Adjustment adjusts the current from minimum to maximum within each range Open circuit 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 to pop outs pre ferred for most welding To get this characteristic set the Current Range Selector to the lowest setting that still provides the current you need and set the Fine Current Adjustment near maximum For example to obtain 175 amps and a soft arc set the Current Range Selector to the 190 120 position and then adjust the Fine Current Adjustment for 175 amps When a forceful digging arc is requi
37. on Engine Will Not Pick Up Speed When The Arc is Struck Both Auxiliary Load Check for loose or disconnected 1 Check Idler circuit wiring Possible 1 Load too small Try load wire running between weld problems are wires from Current above 150 Watts selector switch and output stud Sensing Board reversed at idler 2 Check for loose switch or wires connected incorrectly disconnected wire running at Current Sensor Molex plug from black lead out of exciter 2 Replace current Sensing Board to CB2 circuit breaker CAUTION 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 CLASSIC 300G LINCOLN 5 E 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual Engine does not start Faulty Ignition switch Insufficient charging or complete discharge of the battery Charge Lack of fuel or air mixed in the fuel system Clogged fuel filter Irregular and faulty fuel supply Injector pump trouble Moisture or carbon on spark plugs Improper viscosity of the lubri cating oil Clogged air cleaner No compression Engine protection light is ON Irregular running of the Engine Air mixed in the fuel system Uneven fuel injection Faulty fuel injector pump If all recommended possible are
38. on and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided fo
39. ons have occurred The electronic governor will cor rect itself for the new operating conditions and normal operation will resume CLASSIC 300G LINCOLN 5 1 ACCESSORIES C 1 OPTIONAL EQUIPMENT Field Installed Accessory Set K704 Includes 35 ft 10 7m elec trode and 30 ft 9 1m work cables headshield work clamp and electrode holder A WARNING Pipe Thawing with an arc welder can cause fire explosion damage to electric wiring or to the arc welder if done improperly The use of an arc welder for pipe thawing is not approved by the CSA nor is it recommended or supported by Lincoln Electric Power Plug Kit K802D A 20 amp power plug kit for the auxiliary power receptacles is available Provides a plug for each receptacle Remote Control Kit K924 4 Contains switch receptacle remote control rheostat and 100 ft 30 5m cable for adjusting the OCV at the welding site Trailer K953 1 Two wheeled trailer with optional fender and light package For highway use consult applicable federal state and local laws regarding possible additional requirements Their is a choice of 2 hitches a fender amp a light package Order K953 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 1 Fender amp Light Kit K965 1 Cable Storage Rack Remote Control Kit K924 5 Contains a remote control rheostat and 100 ft 30 5m cable for adjust ing the OCV atthe welding site Remote Control Kit K2464
40. oting assistance before you proceed CLASSIC 300G LINCOLN Jequunu epoo eu SAIN e 104 BdIAIES ejqiGej s eui sjeued einsoj oue y euo uo eui LL episui pejsed si epoo sejnomed siy Aq 104 eq jou JO S SIUL LON 6111 av 900 DISSV10 JHL NI GALOSNNOO SAYIT X919 ANY IHL 41170938 TIM TOHLNOO 1 3HL OL SNIHOVW SIHL NO Q3193NNO9 LON A NO S3NIHOVIN I 2ISSV T2 NO 38 SHV SAYIT XV 18 IHL 5422 2 Met du d ONINNN 38 LON LSNW 3NIHOVIN ATHIN3SSV Old 9rd LO3NNOOSIQ 440 3NIHOVI SHI HIM GATIVISNI SI SINGOW ON 31 IVISOWSSHI O3103NNOONn LI ONIAV3 ASEAN 052 Hd FHL NASW IHL NO SI 3NO 41 Old GALOINNOONN X08 SGLSWOLIN3IOd 3HL 40 3504510 330 JHL G3TIVISNI SI SINGOW 0384 SHIM V 3l x x Hen TOHINCO NO 87 HOLO3NNOO OL 1051400 LOWY NO 84 ONTd 193NNO9 93N OL 103NNOO 87 HOLOZNNOO WOW NO ON ld LON 0504 1007 NI NMOHS FT ENva a 6 OM1NOO SLOWSY
41. ourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a e Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra o REPOR 7 amp nf dchsn zucct E GUB S Oa EERTE Xe uc Bp Weal AMI d ous uil el jad oa Y O Ales 1 gl uit slt All usu JS daas ule Y Jio moe Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e naedoe6 0o08 CIE REA 9 MR eis A Jo ALD al gll pis Ac AI Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschu
42. r your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page INStAN ATION e Section A Technical Specifications eene A 1 Safety Precautions te in o ee EE Y dad FREE even a A 2 Pre Operation Installation A 2 2 ss 2 Machine Grounding eoru rece Era Der tirent A 2 M ee Or A 2 HUcu cre A 2 Polarity Control and Cable Sizes A 3 Pre Operation Service dei fecti Fre font A 3 Oi toon bunt Lu A 3 3 Cooling System sise A 3 Battery etai lime A 4 m Section B General Description is B 1 D sign F atures B 1 Starting The GM 3 0L Engine B 2 Stopping the amp ngine oci Senet ede AeA B
43. re protected by the door The output terminals are labeled and Cranking System A 12 volt electric starter is standard CLASSIC 300G LINCOLN B 2 OPERATION B 2 Air Cleaner Heavy duty two stage dry type Muffler A Muffler and stainless steel exhaust outlet elbow are standard Engine Hour Meter A meter to record hours of oper ation Engine 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 restarting turn the ignition switch off then on High Idle RPM OCV Adjustment A potentiometer is mounted on the output rail that allows the operator to adjust the high idle engine speed between 1700 and 1800 RPM S in 20 RPM increments This is to allow further adjustment of the OCV Total OCV adjustment range is about 10 Volts STARTING THE CLASSIC 300G GM 3 0L GASOLINE ENGINE 1 Turn the IDLER switch to HIGH Optional 2 Turn the IGNITION switch to ON 3 Press the Start button When the engine starts run ning release button If the engine fails to start in 20 seconds wait 30 seconds and repeat the above procedure 4 Observe the oil pressure If no pressure shows with in 30 seconds stop the engine and consult the engine operating manual To stop the engine turn the IGNITION switch to OFF 5 Allow the engine to run at high idle speed
44. red usually for vertical and overhead welding use a higher Current Range Selector setting and lower open circuit volt age For example to obtain 175 amps and a forceful arc set the Current Range Selector to the 240 160 position and the Fine Current Adjustment setting to get 175 amps Some arc instability may be experienced with EXX10 electrodes when trying to operate with long arc tech niques at settings at the lower end of the open circuit voltage range CAUTION 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 IDLER CONTROL OPERATION The idle is controlled by the Idler toggle switch on the welder control panel The switch has two positions as follows 1 In the High e position and the engine goes to high idle speed The speed is controlled by the gov ernor 2 In the Auto lt gt position the engine operates as follows When welding or drawing power for lights or tools approximately 100 150 watts minimum from the receptacles the engine operates at high idle speed When welding ceases or the power load is turned off a preset time delay of about 10 seconds starts This time delay cannot be adjusted f the welding or power load is not re started before the end of the time delay
45. rs P379 Series A 1 Make Model GM 3 0 Liter Classic 300G K1754 1 Description 4 Oylinder 4 Cycle Water Cooled Gasoline Engine Cast Iron Cylinder Block Crankcase 53 0 HP 1800 RPM INSTALLATION TECHNICAL SPECIFICATIONS CLASSIC 300G K1754 1 INPUT GASOLINE ENGINE Speed RPM High Idle 1800 Full Load 1800 Low Idle 1360 Displacement cu in Ltrs 183 0 3 0 Ignition System Delco Voyager High Energy Distributor Type Electronic A 1 Capacities Fuel 15 gal 5 7 Ltrs Oil 4 5 Qts 4 3 Ltrs Cooling 9 9 Qts 9 4 Ltrs RATED OUTPUT WELDER DESCRIPTION RATED DC OUTPUT DUTY CYCLE VOLTS RATED AMPS 300 Amp DC Welder DC CURRENT RANGE Fine Adjustment in each Range 30V 250A All Copper Windings 40 350 Amps Pure DC Power NEMA Rating 32V 300A Generator OUTPUT GENERATOR Auxiliary Power 3000 Watts 60 Hz AC 26 Amps 115V 13 Amps 230V ENGINE OPERATING LOAD FUEL CONSUMPTION Low Idle 1360 RPM No Load 89 gal hr 3 37 Itrs hr High Idle 1800 RPM No Load 1 32 gal hr 5 00 Itrs hr AC Auxiliary 115 Volts 26 Amps 1 42 gal hr 5 32 Itrs hr 50 Amps 22 Volts 60 Duty Cycle 1 24 gal hr 4 70 Itrs hr 100 Amps 24 Volts 60 Duty Cycle 1 27 gal hr 4 82 Itrs hr 150 Amps 26 Volts 60 Duty Cycle 1 33 gal hr 5 04 Itrs hr 200 Amps Q 28 Volts 60 Duty Cycle 1 47 gal hr 5 57 Itrs hr 250 Amps 30 Volts
46. rushes With slight additional finger pres sure on top of the brushes pull the sandpaper around the circumference of the rings in direction of rotation only until brushes seat properly In addition stone slip ring 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 CONTROL MAINTENANCE CAUTION 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 polarity is negative ground Damage to the engine 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 f desired the welder can be used without automatic idling by setting the Idler switch to the High position NAMEPLATES Whenever routine maintenance is performed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those which are no longer clear Refer to the parts list for the replacement item number PURGING AIR FROM FUEL SYSTEM GM 3 0L ENGINE A WARNING Keep fuel clear of open flames or arcs allow engine to cool before working on the fuel system Wipe up any spilled fuel and do not start engine until fumes
47. s 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from t
48. s 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 suitable spark arrester must be installed and properly maintained CAUTION Use of an incorrect arrester may lead to engine dam age or performance loss Contact the engine manu facturer for specific recommendations LOCATION VENTILATION Always operate the welder with the doors closed Leaving the doors open changes the designed air flow and may cause overheating The welder should be located to provide an unrestrict ed flow of clean cool air Also locate the welder so that engine exhaust fumes are properly vented to an outside area INSTALLATION A 2 A CAUTION DO NOT MOUNT OVER COMBUSTIBLE SUR FACES Where there is a combustible surface directly under stationary or fixed electrical equipment the surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not more than 5 90 150mm beyond the equipment on all sides MACHINE GROUNDING According to the United States National Electrical Code the frame of this portable generator is not required to be grounded and is permitted to serve as the grounding means for cord connected equipment plugged into its receptacle Some state local or other codes or unusual operating circumstances may require the machine frame to
49. sitive 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 INSTALLATION A 3 When welding at a considerable distance from the welder be sure you use ample size welding cables RECOMMENDED COPPER CABLE SIZES Cables Sizes for Combined Length of Electrode Plus Work Cable Up to 200 ft 200 to 250 ft 60 96 m 200 to76 2 m Duty Cycle PRE OPERATION SERVICE CAUTION READ the engine operating and maintenance instruc tions supplied with this machine WARNING Stop engine while fueling Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling Wipe up spilled fuel and allow fumes to clear before starting engine Do not overfill tank fuel expan sion may cause overflow GASOLINE FUEL ONLY OIL This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W 30 oil This oil should be acceptable for most typical ambient temperatures Consult the engine operation manual for specific engine manufacturer s recommendations Upon receipt of the welder check the engine dipstick to be sure the oil is at the full mark DO NOT overfill GASOLINE can cause fire or explosion FUEL E Fill the fuel tank with the grade of fue
50. st en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la constructio
51. the throttle body controller reduces the engine to low idle speed AUXILIARY POWER The AC auxiliary power supplied as a standard has a rating of 3 0 kVA of 115 230 VAC 60 hertz With the 3 0 kVA 115 230 VAC auxiliary power one 115V duplex and one 230V duplex grounding type receptacle are provided The circuit is protected with circuit breakers The rating of 3 0 kVA permits a maximum continuous current of 13 amps to be drawn from the 230 volt duplex receptacle Or a total of 26 amps can be drawn from the 115 volt duplex receptacle The 115 volt duplex receptacle has a configuration which permits 20 amps to be drawn from either half The total com bined load of all receptacles is not to exceed 3 0 kVA An optional power plug kit is available When this kit is specified the customer is supplied with a plug for each receptacle THROTTLE BODY DEICING SYSTEM The welder has been designed to allow continuous year round operation Engine coolant is channeled through the Throttle Bottle Injector TBI housing to prevent the build up of ice on the TBI throat around the throttle plate The electronic controller is pro grammed to automatically compensate for the build up of ice on the throttle plate There will be no noticeable change in the operation of the welder should icing develop On start up there is a possibility for the engine to overspeed to a maximum of 2000 RPM for up to 10 seconds after throttle body icing condi ti
52. tz Use prote o para a vista ouvido corpo HAUSHERMRELTTF HEBS SOSRSHR ez 119 59 s ESSAI dise ule Lily vues al ad ne 4 aun y READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona
53. uty engine driven DC arc welding power source capable of providing constant current output for stick welding or DC TIG welding This welder is wound with all copper coils rated at 300 amps 32 Volts and provides other Classic features such as improved door latches and stainless hinges With the addition of the optional K623 1 Wire Feed Module the Classic 300G will provide constant voltage output for run ning the LN 7 LN 23P or LN 25 wire feeders The optional K924 4 Remote Control Kit field installed pro vides a switch or K924 5 Remote Control Kits provide a receptacle and a remote control rheostat for remote fine current and open circuit voltage adjustment The Classic 300G has an electronic Engine Protection system In the event of sudden low oil pressure or high coolant temperature the engine immediately shuts down The Classic 300G has a current range of 40 350 DC amps with output ratings as follows These units are also capable of providing 3 kVA of 115 230 volts of 60 cycle AC auxiliary power A CAUTION DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary or fixed electrical equipment the surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not more than 5 90 150mm beyond the equipment on all sides The Classic 300G uses the GM 8 0L industrial water cooled gasoline engine RATED OUTPUT DUTY CYCLE 250A 30V 300A Q 32V
54. y warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility Step 1 LOCATE PROBLEM SYMPTOM Look under the column 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 If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring 4 ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside 4 MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing AR e Keep away from moving parts i Remove guards only when necessary and replace wh

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