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IM995-A
®
April, 2010
CLASSIC 300 D PERKINS
For Machines with Code Numbers 11572, 11573, 11640, 11641
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act a
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 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
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ii ii SAFETY ARC RAYS can burn. ELECTRIC ShOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CuTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv 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 l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque d’incendie dû aux étincelles
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v v for selecting a QuALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• as much pride as we have in bringing this product to you! CuSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Linco
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vi vi TAbLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 General Description...............................................................................................A-2 Design Features .............................................................................................
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A-1 A-1 INSTALLATION TEChNICAL SPECIFICATIONS - CLASSIC® 300D PERKINS INPuT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System 4 Cylinder 135 cu. in 12VDC battery Fuel: 15 gal. 4 Cycle (2.2 ltrs) (Group 24, 650 57 L. Perkins Naturally Aspirated High Idle 1800 cold crank amps) 404D-22 Water-Cooled Low Idle 1400 bore x Stroke 2.0 KW Starter Oil: 10.30 Qts. EPA Diesel Engine Full Load 1725 9.75 L. Tier 4 interim Cast Iron Cylinder, 3.3” x 3.9”
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A-2 A-2 INSTALLATION A built-in time delay permits changing electrodes before the GENERAL DESCRIPTION engine slows to its low idle speed. The “Idler” control switch on the panel locks the idler in high The Classic® 300D Perkins is a heavy duty, engine driven, idle position when desired. DC arc welding power source, capable of providing constant current output for stick welding or DC TIG welding. This Auxiliary Power - 3.0 KVA of nominal 115/230V, 60Hz, AC. welder is wound with all copper co
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A-3 A-3 INSTALLATION PRE-OPERATION INSTALLATION CAuTION DO NOT MOuNT OVER COMbuSTIbLE SuRFACES. WARNING Where there is a combustible surface directly under sta- Do not attempt to use this equipment until you tionary or fixed electrical equipment, the surface shall have thoroughly read the engine manufacturer’s be covered with a steel plate at least .06”(1.6mm) thick, manual supplied with your welder. It includes which shall extend not more than 5.90”(150mm) beyond important safety precautions
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A-4 A-4 INSTALLATION 2. Proper support of, and attachment to, the base of PRE-OPERATION SERVICE the welding equipment so there will be no undue stress to the framework. CAuTION 3. Proper placement of the equipment on the trailer to READ the engine operating and maintenance ensure stability side to side and front to back when instructions supplied with this machine. being moved and when standing by itself while ------------------------------------------------------------------------ being op
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A-5 A-5 INSTALLATION bATTERY ChARGING WARNING GASES FROM bATTERY can explode. • Keep sparks, flame and cigarettes away. bATTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when boosting, charging or working near battery. To prevent ExPLOSION when: a) Installing a new battery - disconnect thenega- tive cable from the old battery first and connect the negative cable to the new battery last. b) Connecting a battery charger - remove the bat- tery from the welder b
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b-1 b-1 OPERATION 7. Allow the engine to run at high idle speed for sev- ENGINE OPERATION eral minutes to warm the engine. Stop the engine and recheck the oil level, after allowing sufficient WARNING time for the oil to drain into the pan. If the level is Do not attempt to use this equipment until you down, fill it to the full mark again. The engine con- have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes trols were properly set at the factory and should
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b-2 b-2 OPERATION DuTY CYCLE ENGINE bREAK-IN The NEMA output rating of the Classic® 300D Perkins is Lincoln Electric selects high quality, heavy-duty industrial 300 amperes at 32 arc volts on a 60% duty cycle (consult engines for the portable welding machines we offer. Specifications in this manual for alternate ratings). Duty While it is normal to see a small amount of crankcase oil cycle is based on a ten minute period; thus, the welder can consumption during initial operation, excessive oil
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b-3 b-3 OPERATION IDLER OPERATION AuxILIARY POWER Start the engine with the “Idler” switch in the “High” If a GFCI Module is tripped, See the MAINTENANCE position. Allow it to run at high idle speed for several section for detailed information on testing and reset- minutes to warm the engine. See Specifications for ting the GFCI Module. operating speeds. The AC auxiliary power, supplied as a standard, has a The idler is controlled by the “Idler” toggle switch on rating of 3.0 KVA of 115/230 VA
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C-1 C-1 ACCESSORIES TIG OPTIONS OPTIONAL FEATuRES (Field Installed) TIG Module K930-2 GENERAL OPTIONS Provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding applications. Its WARNING compact case is designed for easy carrying, complete with a handle. High frequency bypass is built in. Additionally, the K936-3 control cable is required if Pipe Thawing with an arc welder can cause fire, remote control is used. If remote control is not used explosion, damage to electric
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C-2 C-2 ACCESSORIES WIRE FEEDER OPTIONS Magnum Spool Gun K487-25 Wire Feed Module K623-1 Provides constant voltage (CV) output with improved Hand held semiautomatic wire feeder requires SG arc stability for Innershield welding. Excellent for MIG Control Module. 25 ft. length. welding. Recommended wire feeders are the LN-7, SG Control Module K488 (For Magnum Spool Gun) LN-23P and LN-25. (Factory installed on the K1643- 2). The interface between the power source and the spool gun. Provides con
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D-1 D-1 MAINTENANCE SAFETY PRECAuTIONS 4. Follow the engine service schedule in this manual and the detailed maintenance and troubleshooting WARNING 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® 300D Perkins is equipped with a pres- sary to remove safety guards to perform sure radiator. Keep the radiator cap tight to prevent required maintena
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D-2 D-2 MAINTENANCE Replace brushes when they wear within 1/4” of the PuRGING AIR FROM FuEL SYSTEM pigtail. A complete set of replacement brushes should (PERKINS 404D-22 ENGINE) be kept on hand. Lincoln brushes have a curved face to fit the commutator. Have an experienced mainte- nance man seat these brushes by lightly stoning the WARNING commutator as the armature rotates at full speed until contact is made across the full face of the brushes. Keep fuel clear of open flames or arcs, allow Aft
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D-3 D-3 MAINTENANCE CLASSIC® 300D PERKINS
