Lincoln Electric Classic 300D Manuel utilisateur
- Catégorie
- Système de soudage
- Taper
- Manuel utilisateur
CLASSIC
®
300D KUBOTA
OPERATOR’S MANUAL
For Machines with Code Numbers 11112, 11113, 11243, 11244, 11413, 11414, 11474, 11475
IM843-C
November, 2008
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.
• 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
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent
the engine exhaust fumes
outdoors.
____________________________________________________
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.
____________________________________________________
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.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
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.
___________________________________________________
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.
___________________________________________________
1.g. 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.
i
SAFETY
i
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.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & 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.
WARNING
Mar ʻ95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
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.
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 also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines
The Above For Gasoline Engines
ii
SAFETY
ii
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. I 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.
4.c. 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.
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.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
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.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
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.
5.d. 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.
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
CYLINDER may explode
if damaged.
7.a. 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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
iii
SAFETY
iii
Jan, 07
WELDING and CUTTING
SPARKS can
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.
6.b. 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.
6.c. 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.
6.d. 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).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
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.
6.g. 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.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
iv
SAFETY
iv
Mar. ʻ93
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du ray-
onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-
er à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
vv
Thank You
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
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 for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
CAUTION
Please Examine Carton 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.
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 Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
vi
vi
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
Cooling System ...............................................................................................A-4
Battery Charging .............................................................................................A-5
________________________________________________________________________
Operation .........................................................................................................Section B
Engine Operation...................................................................................................B-1
Starting The Kubota V2203M Engine.............................................................B-1
Cold Weather Starting.....................................................................................B-1
High Altitude Operation ...................................................................................B-1
Stopping the engine ........................................................................................B-1
Break-In...........................................................................................................B-1
Welder Operation...................................................................................................B-2
Duty Cycle.......................................................................................................B-2
Control of Welding Current..............................................................................B-2
Idler Operation ................................................................................................B-3
Auxiliary Power ...............................................................................................B-3
Fuel Consumption Data ..................................................................................B-3
________________________________________________________________________
Accessories.....................................................................................................Section C
Optional Features (Field Installed) ........................................................................C-1
Wire Feed Options.................................................................................................C-2
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
General Instructions ..............................................................................................D-1
Cooling System .....................................................................................................D-1
Bearings ................................................................................................................D-1
Commutator and Brushes .....................................................................................D-1
Idler Maintenance..................................................................................................D-2
Nameplates ...........................................................................................................D-2
Purging Air from Fuel System................................................................................D-2
Engine Service Chart ............................................................................................D-3
GFCI Receptacle Testing and Restting Procedure ...............................................D-4
________________________________________________________________________
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
Welder Troubleshooting ........................................................................................E-2
Electronic Idler Troubleshooting Guide...........................................................E-3,E-4
Engine Troubleshooting Guide ...............................................................E-5, E-6,E-7
________________________________________________________________________
Diagrams ..........................................................................................................Section F
Wiring Diagrams.......................................................................................F-1 thru F-5
Dimension Print......................................................................................................F-6
________________________________________________________________________
Parts List.....................................................................................................P-498 Series
INSTALLATION
CLASSIC 300D KUBOTA
A-1
A-1
TECHNICAL SPECIFICATIONS - CLASSIC 300D KUBOTA
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
4 Cylinder
4 Cycle 134.1 cu. in
12VDC battery
Fuel: 15 gal.
Naturally Aspirated (2.2 ltrs) (Group 24, 650 57 L
Kubota Water-Cooled High Idle 1800 cold crank amps)
V2203M Diesel Engine Low Idle 1400 Bore x Stroke
1.4 KW
Starter Oil: 8.0 Qts.
Cast Iron Cylinder, Full Load 1800 40 A. Alternator 7.6 L
Block/Crankcase 3.43” x 3.64” w/ built in reg. Coolant:
32.5HP @1800 RPM
9.5 Qts.
9.0 L
INPUT - DIESEL ENGINE
RATED OUTPUT @ 104°F(40°C) - WELDER
MODEL HEIGHT WIDTH DEPTH WEIGHT
K1643-5 CSA@ 1320 lbs.
With Out (599 kg)
Wire Feed Module
45.5 in. 24.00 in. 66.36 in.
K1643-6 CSA @ (1156 mm) (610 mm) (1686 mm) 1355 lbs.
With Wire Feed Module (615 kg)
RATED OUTPUT @ 104°F(40°C) - GENERATOR
DESCRIPTION RATED DC OUTPUT* Duty DC CURRENT RANGE
VOLTS @ RATED AMPS CYCLE
Fine Adjustments in each Range
40-350 Amps
220-Max.
300 Amp DC Welder 30V @ 250A 100% 160-240
All Copper Windings 32V @ 300A 60% 120-190
Pure DC Power Generator 99V DC Max. OCV @ 1800RPM 80-130
Min.-90
Auxiliary Power
(1)
3,000 Watts Continuous, 60 Hz AC
26 Amps @ 115V
13 Amps @ 230V
PHYSICAL DIMENSIONS
(2)
* Based on a 10 min. period.
(1)
Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to
rated capacity. When welding, available auxiliary power will be reduced.
(2)
Height to top of exhaust elbow.
A-2
INSTALLATION
CLASSIC 300D KUBOTA
A-2
GENERAL DESCRIPTION
The CLASSIC
®
300D KUBOTA is a heavy duty,
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 cop-
per 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 300D
KUBOTA will provide constant voltage output for run-
ning the LN-7, LN-23P, or LN-25 wire feeders. (The
Wire Feed Module is factory installed on the K1643-
6). The optional K924-5 Remote Control Kit, provides
a remote control rheostat for remote fine current and
open circuit voltage adjustment. See Section C for
description.
The CLASSIC 300D KUBOTA 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 300D KUBO-
TA has a current range of 40-350 DC amps with out-
put ratings as follows:
These units are also capable of providing 3 kVA of
115/230 volts of 60 cycle AC auxiliary power.
The CLASSIC 300D KUBOTA uses the Kubota
V2203M industrial water-cooled diesel engine.
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” rheostat. 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 tempera-
ture gauge, a battery charging ammeter, an oil pres-
sure gauge, two three prong grounding type recepta-
cles and circuit breakers for auxiliary power.
All Copper Windings - For long life and dependable
operation.
Engine Idler - The Classic 300D is equipped with an
electronic automatic engine idler. It automatically
increases and decreases engine speed when start-
ing and stopping welding or using auxiliary
power. A built-in time delay permits changing elec-
trodes 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 “C” channel base.
The output terminals are placed at the side of the
machines so that they are protected by the door. The
output terminals are labeled (+) and (-).
Cranking System - A 12 volt electric starter is stan-
dard.
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.
Refer to Troubleshooting section for all warning light
fault codes.
High Idle RPM (OCV) Adjustment - A Potentiometer
is mounted on the Control Panel that allows the oper-
ator to adjust the high idle engine speed between
1650 and 1800 RPMʼS. This is to allow further adjust-
ment of the OCV. Total OCV adjustment range is
about 15 volts.
Oil Drain Valve - A ball valve, hose and clamp are
standard.
Remote Control - The Remote/Local switch and
Receptacle are standard.
GFCI Receptacle - One UL approved 115V ground
fault circuit interupter duplex type receptacle is stan-
dard on codes 11243 and above. See MAINTE-
NANCE section for detailed information on testing and
resetting the GFCI receptacle.
250A @ 30V
300A @ 32V
100%
60%
RATED OUTPUT DUTY CYCLE
A-3
INSTALLATION
CLASSIC 300D KUBOTA
A-3
PRE-OPERATION INSTALLATION
EXHAUST SPARK ARRESTER
Some federal, state or local laws may require that engines
be equipped with exhaust spark arresters 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.
Use of an incorrect arrester may lead to engine damage or
performance loss. Contact the engine manufacturer for spe-
cific 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 unrestricted flow
of clean, cool air. Also, locate the welder so that engine
exhaust fumes are properly vented to an outside area.
ANGLE OF OPERATION
Engines are designed to run in the level condition which is
where the optimum performance is achieved. The maximum
angle of continuous operation is 20 degrees in all directions,
30 degrees Intermittent (less than 10 minutes continuous) in
all directions.
If the engine is to be operated at an angle, provisions must be
made for checking and maintaining the oil level at the normal
(FULL) oil capacity in the crankcase.
When operating the welder at an angle, the effective fuel
capacity will be slightly less than the amount specified.
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 circum-
stances may require the machine frame to 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 con-
nected 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 frame-
work of a building which has been effectively grounded. The
U.S. National Code lists a number of alternate means of
grounding electrical equipment.
LIFT BAIL
A lift bail is provided for lifting with a hoist.
Do not attempt to use this equipment until you have
thoroughly read the engine manufacturerʼs manual sup-
plied with your welder. It includes important safety pre-
cautions, detailed engine starting, operating and main-
tenance instructions, and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• 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.
------------------------------------------------------------------------
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 operatorʼs manual.
--------------------------------------------------------
---------
WARNING
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under sta-
tionary 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 side.
CAUTION
• Lift only with equipment of
adequate lifting capacity.
• Be sure machine is stable
when lifting.
• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trail-
er or gas cylinder.
FALLING • Do not lift machine if lift bale is
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bale.
------------------------------------------------------------------------
WARNING
PRE-OPERATION SERVICE
READ the engine operating and maintenance instruc-
tions supplied with this machine.
------------------------------------------------------------------------
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 manufacturerʼs recommendations.
Upon receipt of the welder, check the engine dipstick
to be sure the oil is at the “full” mark. DO NOT overfill.
FUEL
Fill the fuel tank with the grade of fuel recommended
in the Engine Operatorʼs manual. Make sure the valve
on the water separator is in the open position.
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
alternate antifreeze recommendations).
CAUTION
A-4
INSTALLATION
CLASSIC 300D KUBOTA
A-4
TRAILER (See Optional Features)
If the user adapts a non-Lincoln trailer, the user 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 Lincoln
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 operat-
ed; environmental conditions, likely maintenance.
5. Conformance with federal, state and local laws.
(1)
(1)
Consult your federal, state and local laws regarding specific
requirements for use on public highways.
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 positive 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.
When welding at a considerable distance from the
welder, be sure you use ample sized welding cables.
RECOMMENDED COPPER CABLE SIZES
Cables Sizes for Combined Length
of Electrode Plus Work Cable
Amps Duty Cycle Up to 200ft.(61m) 200 to 250ft.
(61 to 76m)
250 100% 1 1/0
300 60% 1/0 2/0
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 manufactureʼs instructions.
------------------------------------------------------------------------
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.
DIESEL FUEL ONLY
------------------------------------------------------------------------
WARNING
DIESEL FUEL
can
cause fire
A-5
INSTALLATION
CLASSIC 300D KUBOTA
A-5
Battery Charging
The CLASSIC 300D KUBOTA is equipped with a wet
charged battery. The charging current is automatical-
ly 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.
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
last.
b) 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.
c) 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:
a) Installing a new battery.
b) 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 BATTERY BUCKLING, tighten nuts on
battery clamp until snug.
------------------------------------------------------------------------
WARNING
B-1
OPERATION
B-1
ENGINE OPERATION
Operate the welder with the doors closed. Leaving the
doors open changes the designed air flow and can
cause overheating.
STARTING THE CLASSIC 300D KUBOTA V2203M
DIESEL ENGINE
1. Turn the “IDLER” switch to “HIGH”.
2. Turn the “IGNITION” switch to “ON”.
3. Press the Glow Plug button for 20 to 30 seconds.
(maximum 60 seconds).
4. Press the Glow Plug button and the Start button at the
same time. When the engine starts running, release
both buttons. If the engine fails to start in 20 seconds,
wait 30 seconds and repeat the above procedure.
5. Observe the oil pressure. If no pressure shows within
30 seconds, stop the engine and consult the engine
operating manual. To stop the engine, turn the “IGNI-
TION” switch to “OFF”.
6. If the engine protection warning light comes on during
cranking or after start up, the “IGNITION” switch must
be turned “OFF” to reset the engine protection system.
7. Allow the engine to run at high idle speed for several
minutes to warm the engine. Stop the engine and
recheck the oil level, after allowing sufficient time for
the oil to drain into the pan. If the level is down, fill it to
the full mark again. The engine controls were properly
set at the factory and should require no adjusting when
received.
CLASSIC 300D KUBOTA
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
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.
• 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.
--------------------------------------------------------
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 operatorʼs manual.
WARNING
COLD WEATHER STARTING:
With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
about -5°F (-20°C), it maybe desirable to install cold-
starting aides.
Note: Extreme cold weather staring may require
longer glow plug operation.
Under NO
conditions should ether or other
starting fluids be used!
------------------------------------------------------------------------
HIGH ALTITUDE OPERATION:
At higher altitudes, output derating may be necessary.
For maximum rating, derate the welder 4% for every
300 meters (984 ft.) above 1500 meters (4920 ft.).
Contact a Kubota Service Representative for any
engine adjustments that may be required.
STOPPING THE ENGINE
1. Turn the “IGNITION” switch to “OFF”
At the end of each dayʼs welding, check the crankcase
oil level, drain accumulated dirt and water from the
water separator 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
valve on the water separator.
If 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. Use qualified person-
nel to do this per the instructions in the MAINTE-
NANCE section of this manual.
ENGINE BREAK-IN
Lincoln Electric selects high quality, heavy-duty indus-
trial engines for the portable welding machines we
offer. While it is normal to see a small amount of
crankcase oil consumption during initial operation,
excessive oil use, wet stacking (oil or tar like sub-
stance at the exhaust port), or excessive smoke is not
normal.
WARNING
B-2
OPERATION
B-2
CLASSIC 300D KUBOTA
WELDER OPERATION
------------------------------------------------------------------------
DUTY CYCLE
The NEMA output rating of the CLASSIC 300D KUB-
OTA is 300 amperes at 32 arc volts on
a 60% duty
cycle (consult Specifications in this manual
for alter-
nate 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.
CONTROL OF WELDING CURRENT
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 required, 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.
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.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and ground.
FUMES & GASES can be dangerous.
• Keep your head out of the fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
WARNING
CAUTION
CAUTION
Larger machines with a capacity of 350 amperes and
higher, which are operated at low or no-load condi-
tions for extended periods of time are especially sus-
ceptible to the conditions described above. To
accomplish successful engine break-in, most diesel-
powered equipment needs only to be run at a reason-
ably heavy load within the rating of the welder for
some period of time during the engineʼs early life.
However, if the welder is subjected to extensive light
loading, occasional moderate to heavy loading of the
engine may sometimes be necessary. Caution must
be observed in correctly loading a diesel/generator
unit.
1. Connect the welder output studs to a suitable
resistive load bank. Note that any attempt to
short the output studs by connecting the welding
leads together, direct shorting of the output studs,
or connecting the output leads to a length of steel
will result in catastrophic damage to the generator
and voids the warranty.
2. Set the welder controls for an output current and
voltage within the welder rating and duty cycle.
Note that any attempt to exceed the welder rating
or duty cycle for any period of time will result in
catastrophic damage to the generator and voids
the warranty.
3. Periodically shut off the engine and check the
crankcase oil level.
B-3
OPERATION
B-3
CLASSIC 300D KUBOTA
IDLER OPERATION
Start the engine with the “Idler” switch in the “High”
position. Allow it to run at high idle speed for several
minutes to warm the engine. See Specifications for
operating speeds.
The idler is controlled by the “Idler” toggle switch on
the welder control panel. The switch has two posi-
tions as follows:
1. In the “High” position, the engine control unit
increases the engine to high idle speed.
2. In the “Auto” / position, the idler oper-
ates as follows:
a. When welding or drawing power for lights or tools
(approximately 100 watts minimum) from the recep-
tacles, the engine operates at high idle speed.
b. When welding ceases or the power load is turned
off, a preset time delay of about 15 seconds starts.
This time delay cannot be adjusted.
c. If the welding or power load is not re-started before
the end of the time delay, the engine control unit
reduces the engine to low idle speed.
AUXILIARY POWER
Start the engine and set the “IDLER” control switch to
the “High Idle” mode. Voltage is now correct at the
receptacles for auxiliary power. This must be done
before a tripped GFCI receptacle can be reset proper-
ly. See the MAINTENANCE section for detailed infor-
mation on testing and resetting the GFCI receptacle.
CLASSIC 300D WITH KUBOTA V2203M DIESEL ENGINE
TYPICAL FUEL CONSUMPTION DATA
Low Idle (1400 RPM)-No Load
High Idle (1800 RPM)-No Load
3,000 Watts
250 Amps @ 30 Volts
300 Amps @ 32 Volts
0.30 gal/hr ( 1.14 ltrs/hr)
0.46 gal/hr ( 1.74 ltrs/hr)
0.61 gal/hr ( 2.31 ltrs/hr )
1.01 gal/hr ( 3.82 ltrs/hr)
1.32 gal/hr ( 5.00 ltrs/hr)
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.
When the High Speed Adjustment knob is in the MIN
position, the frequency of the AC auxiliary output may
be reduced to approximately 55 Hertz. It is recom-
mended that the High Idle Speed Adjustment knob
should be in the MAX position when using the AC
auxiliary output.
C-1
ACCESSORIES
C-1
CLASSIC 300D KUBOTA
OPTIONAL FEATURES (Field Installed)
GENERAL OPTIONS
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 power plug kit for the
auxiliary power receptacles is available. (Provides a
plug for each receptacle.)
GFCI Receptacle Kit (K1690-1) - Includes one UL
approved 115V ground fault circuit interrupter duplex
type receptacle with cover and installation instruc-
tions. 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. (For Codes 11112,
11113). See MAINTENANCE section for detailed
information on testing and resetting the GFCI recepta-
cle.
Spark Arrestor Kit (K903-1) - Includes a heavy gage
steel, approved spark arrestor, clamp and adapter for
mounting to the muffler exhaust pipe.
TRAILER (K953-1) - Two-wheeled trailer with optional fender
and light package. For highway use, consult applicable feder-
al, state, and local laws regarding possible additional require-
ments. There is a choice of 2 hitches, a fender & a light pack-
age.
K953-1 Trailer
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-1 Fender & Light Kit
K965-1 Cable Rack
Service Indicator Kit K1858-1 - Provides a GO / NO-
GO visual indication of air cleaner element useful ser-
vice life. Filter service based on restriction readings
allows the longest life possible from the filter and best
engine protection.
STICK OPTIONS
K704 ACCESSORY SET - Includes 35 feet (10 m) of
electrode cable and 30 feet (9 m) of work cable, head-
shield, work clamp and electrode holder. Cable is
rated at 500 amps, 60% duty cycle.
Remote Control Kit (K924-5) - Contains remote
control rheostat and 100 ft. (30.5 m) cable for adjust-
ing the OCV at the welding site. (For Codes 10911
and above.)
Remote Control Kit (K2464-1) - Contains remote
control rheostat (for adjusting the CC “STICK” OCV),
and 100ft.(30.5m) cable. (See Wiring/Connection
Diagram Section F)
TIG OPTIONS
TIG Module (K930-2) - Provides high frequency and
shielding gas control for AC and DC GTAW (TIG)
welding applications. Its compact case is designed for
easy carrying, complete with a handle. High frequen-
cy bypass is built in. The K936-4 control cable is
required.
PTA-26V TIG Torch (K1783-9) - Air cooled 200 amp-
torch equipped with valve for gas flow control. 25Ft.
length.
Magnum Parts Kit For PTA-26V TIG TorchKP509
Control Cable (K936-4) (required for TIG Module) -
Control Cable for connecting the K930-2 Tig Module.
Arc Start Switch (K814) (required for TIG Module) -
Comes with a 25ft.(7.6m) cable. Attaches to the TIG
torch for convenient finger control.
Contactor Kit (K938-1) (required for TIG Module) -
Provide “Cold” tungsten Tip when welding with the
TIG Module.
Control Cable Extension (K937-45) - Allows the TIG
Module to be operated at distances up to 200 ft. from
the power source.Available in 45 ft. (13.7m).
Water Valve Kit (K844-1)- For use with a water-
cooled TIG torch. Installs inside TIG Module.
WARNING
C-2
ACCESSORIES
C-2
WIRE FEED OPTIONS
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. (Factory installed on the K1643-6).
LN-25 Wire Feeder (K449)-Portable CC/CV unit for
flux-cored and MIG welding. Includes Gas Solenoid &
Internal Contactor. Requires Wire Feed Module.
Remote Voltage Control Kit for LN-25 (K444-2)
Provides 25 ft. (7.5m) of remote output voltage control
and output jumper (2 and 4) for machines having 14
pin MS-type connector.
Magnum® 350 Innershield Gun (for LN-25)(K126-2)-
For self-shielded wire with 15 ft. (4.5m) cable. For
.062-3/32” (1.6-2.8mm) wire.
Magnum® 300 MIG Gun for LN-25 K1802-1 - With
15 ft. (4.5m) cable. For .035”-.045” (0.9-1.2mm) gas
shielded (Includes Connector Kit).
LN-23P Wire Feeder (K316L-1)-Portable CV unit for
Innershield pipe welding. Control cable operates con-
tactor inside Wire Feed Module for “cold” electrode.
Requires LN-23P Adapter Kit (K350-1) and Gun and
Cable Assembly.
LN-23P Adapter Kit (K350-1)-Required to adapt LN-
23P to any Lincoln power source. Makes 14 pin con-
nection at power source.
Magnum® 250 Innershield Gun (for LN-23P) (K355-10)-
For lighter weight and easier handling. Rated 250
amps, 60% duty cycle. For .068 through 5/64” (1.7
through 2.0 mm) Innershield wire and includes
reduced speed switch. For pipewelding, an M11476
62° gun tube is recommended.
62° gun tube for PipeWelding (KP1909-1)-
Recommended modification for K355-X or K345-X
guns with 90° gun tubes. Compatible with K126-1,-2
K264-8 and K355-10.
Magnum Spool Gun (K487-25)-Hand held semiauto-
matic wire feeder requires SG Control Module. 25 ft.
(7.6m)length.
SG Control Module (K488) (For Magnum Spool
Gun) -The interface between the power source and
the spool gun. Provides control of wire speed and gas
flow.
Input Cable (K691-10) ( For SG Control Module) -
For Lincoln engine drives with 14-pin MS-type con-
nection provides separate 115V NEMA receptacle and
output stud connections. 10 ft. (3.1m)length.
CLASSIC 300D KUBOTA
D-1
MAINTENANCE
D-1
MAINTENANCE
GENERAL INSTRUCTIONS
1. 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.
2. “Current Range Selector” contacts should not be
greased. To keep the contacts clean, rotate the cur-
rent control through its entire range frequently.
Good practice is to turn the handle from maximum
to minimum setting twice each morning before start-
ing to weld.
3. Put a drop of oil on the “Current Range Selector”
shaft at least once every month.
4
. Follow the engine service schedule in this manual
and the detailed maintenance and troubleshooting in
the engine manufacturerʼs manual.
COOLING SYSTEM
The CLASSIC 300D KUBOTA is equipped with a
pressure radiator. Keep the radiator cap tight to pre-
vent loss of coolant. Clean and flush the cooling sys-
tem periodically to prevent clogging the passage and
overheating the engine. When antifreeze is needed,
always use the permanent type.
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 insufficient
grease.
COMMUTATOR AND BRUSHES
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 300D KUBOTA
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.
•
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.
------------------------------------------------------------------------
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
front of this operatorʼs manual.
-----------------------------------------------------------
WARNING
WARNING
D-2
MAINTENANCE
D-2
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 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 brushes. 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 MAINTENANCE
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
Engine Control Unit can result from incorrect connec-
tion.
1. Proper operation of the idler requires good
grounding of the Engine Control Unit, current
sensing printed circuit board and battery.
2. If desired, the welder can be used without automat-
ic 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 replace-
ment item number.
PURGING AIR FROM FUEL SYSTEM
(KUBOTA V2203M ENGINE)
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 clear.
------------------------------------------------------------------------
If the engine is running rough and you suspect air has
been trapped in the fuel system, (e.g. the engine was
allowed to run out of fuel) perform the following steps
using qualified personnel:
1.
Fully open the air bleeding valve by turning it
counter clockwise, it is located on top of the fuel
injection pump next to the oil filler. (see figure D.1)
FIGURE D.1
2. Turn the engine by pressing the start button until
the engine runs smoothly (this should take approxi-
mately 10 seconds).
3. Fully close the air bleeding valve by turning it
clockwise.
Contact your Kubota Engine repair facility if problems
persist.
CLASSIC 300D KUBOTA
CAUTION
WARNING
Air Bleeding
Valve
D-3D-3
CLASSIC 300D KUBOTA
MAINTENANCE
If necessary use shorter periods.
These preventive maintenance periods apply to average conditions of operation.
Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.
(3) Fill slowly! Ensure correct quantity is used.
(2) Consult Engine Operators Manual for additional maintenance schedule information.
(1) Consult Engine Operators Manual for oil recommendations.
Notes:
ENGINE SERVICE
S25833
R = ReplaceC = CleanI = Inspect
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)
TYPE OR QUANTITY
I
I 50/50 Water/Ethylene Glycol
R 9.5 qrts., 9.0L
I
R R 8.0 qrts., 7.6L (including filter)
R R Kubota #16414-32430
C
R Kubota #16631-43560
C Kubota #15831-43380
I
I
R Kubota # 17480-97010
C
R Donaldson # P821575
I Intake .0071"-.0086", Exhaust .0071"-.0086"
I
I
I
I
MAINTENANCE ITEM
Coolant (NOTE 3)
Fuel filter canister
Coolant level
Concentration of antifreeze
Tension of alternator drive belt
Engine oil level (NOTE 1)
Engine oil (NOTE 1 & 3)
Engine oil filter
Drain water separator & fuel strainer
Fuel pre-filter element
Leaks or engine damage
Battery
Valve clearances
Electrical systems
All nuts and bolts for tightness
Alternator drive belt wear
Alternator drive belt
Air filter (earlier check may be req'd)
Air filter element
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Lincoln Electric Classic 300D Manuel utilisateur
- Catégorie
- Système de soudage
- Taper
- Manuel utilisateur
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