RETURN TO MAIN MENU CLASSIC 300D KUBOTA ® IM843-C November, 2008 For Machines with Code Numbers 11112, 11113, 11243, 11244, 11413, 11414, 11474, 11475 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.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines 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 Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ARC RAYS can burn. 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.
iii iii SAFETY 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.
iv iv SAFETY 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 suivantes: 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.
v v 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! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
vi TABLE OF CONTENTS vi Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 General Description ...............................................................................................A-2 Design Features ....................................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - CLASSIC 300D KUBOTA INPUT - DIESEL ENGINE Make/Model Kubota V2203M Description Speed (RPM) 4 Cylinder 4 Cycle Naturally Aspirated Water-Cooled High Idle 1800 Diesel Engine Low Idle 1400 Cast Iron Cylinder, Full Load 1800 Block/Crankcase Displacement 134.1 cu. in (2.2 ltrs) Bore x Stroke 3.43” x 3.64” Starting System Capacities 12VDC battery (Group 24, 650 cold crank amps) 1.4 KW Starter 40 A. Alternator w/ built in reg. 32.
A-2 INSTALLATION 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 copper coils, rated at 300 amps/32 Volts, and provides other Classic features such as improved door latches and stainless hinges.
A-3 A-3 INSTALLATION PRE-OPERATION INSTALLATION WARNING 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.
A-4 TRAILER A-4 INSTALLATION (See Optional Features) RECOMMENDED COPPER CABLE SIZES 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 damage 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.
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 the negative cable from the old battery first and connect the negative cable to the new battery last.
B-1 B-1 OPERATION ENGINE OPERATION COLD WEATHER STARTING: WARNING 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.
B-2 B-2 OPERATION Larger machines with a capacity of 350 amperes and higher, which are operated at low or no-load conditions for extended periods of time are especially susceptible to the conditions described above. To accomplish successful engine break-in, most dieselpowered equipment needs only to be run at a reasonably heavy load within the rating of the welder for some period of time during the engineʼs early life.
B-3 B-3 OPERATION IDLER OPERATION The AC auxiliary power, supplied as a standard, has a rating of 3.0 kVA of 115/230 VAC (60 hertz). Start the engine with the “Idler” switch in the “High” position. Allow it to run at high idle speed for several 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 positions as follows: 1.
C-1 ACCESSORIES OPTIONAL FEATURES (Field Installed) GENERAL OPTIONS 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 power plug kit for the auxiliary power receptacles is available.
C-2 ACCESSORIES 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.
D-1 D-1 MAINTENANCE MAINTENANCE 4. Follow the engine service schedule in this manual and the detailed maintenance and troubleshooting in the engine manufacturerʼs manual. WARNING Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. 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.
D-2 D-2 MAINTENANCE Replace brushes when they wear within 1/4”(3.5mm) of the pigtail. A complete set of replacement brushes should be kept on hand. Lincoln brushes have a curved face to fit the commutator. Have an experienced 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.
MAINTENANCE D-3 D-3 ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS FIRST SERVICE (50 HOURS) EVERY 100 HOURS OR 3 MONTHS EVERY 150 HOURS OR 4 MONTHS EVERY 30O HOURS OR 9 MONTHS EVERY 400 HOURS OR 12 MONTHS EVERY 500 HOURS OR 15 MONTHS EVERY 600 HOURS OR 18 MONTHS ENGINE SERVICE (NOTE 2) MAINTENANCE ITEM I I R I R R R R C R C I I R C R I I I I I I = Inspect Coolant level Concentration of antifreeze Coolant (NOTE 3) Engine oil level (NOTE 1) Engine oil (NOTE 1 & 3) Engine oil filter Drain water separator & f
D-4 MAINTENANCE GFCI RECEPTACLE TESTING AND RESETTING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage. • If the equipment has been shut down, it must be restarted.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Machine fails to hold the output (heat) consistently. Welder starts but fails to generate current. POSSIBLE CAUSE 1. Rough or dirty commutator. 2. Brushes may be worn down to Limit. 3. Field circuit may have variable resistance connection or intermittent open circuit due to loose connection or broken wire. 4. Electrode lead or work lead connection may be poor. 5.
E-3 E-3 TROUBLESHOOTING ELECTRONIC IDLER TROUBLESHOOTING GUIDE With Idler Control Switch in the Auto Position, Engine Will Not Return to Low Idle in Approximately 15 Seconds After Welding and Auxiliary Loads are Removed Set Idler Control Switch to the Auto Position Check for Continuity through Idler Control Switch Open Closed Check Voltage across Idler Control switch Replace Idler Control Switch 12 VDC Contact Kubota Engine Repair Facility 0 VDC Replace current Sensing PCB CAUTION If for any r
E-4 E-4 TROUBLESHOOTING ELECTRONIC IDLER CONTROL TROUBLESHOOTING GUIDE With Idler Control Switch in the AUTO Position, Engine Will Not Pick Up Speed When: The Arc is Struck Check for loose or disconnected wire running between weld selector switch and output stud. Both Auxiliary Load 1. Check Idler circuit wiring. Possible 1. Load too small. Try load Problems are wires from Current Sensing above 100 Watts. Board reversed at idler switch or wires 2.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine does not start. Engine does not turn over. POSSIBLE CAUSE 1. Lack of fuel. 2. Air mixed in the fuel system. 3. Clogged fuel filter. 4. Irregular and faulty fuel supply (Injector pump trouble). 5. Glow plug not heated. 6. Clogged air cleaner. 7. No compression. 8. Engine protection light is ON. 1. Faulty Ignition switch and or Injector pump solenoid. 2.
E-6 TROUBLESHOOTING E-6 Observe all Safety Guidelines detailed throughout this manual LIGHT CODE FAILURE DETECTED POSSIBLE CAUSE - CORRECTIVE MEASURE LONG 1, SHORT 1 RPM IS OVER 115% OF RATED RPM (2070 RPM) ACTUATOR IS STUCK - REMOVE ACTUATOR AND VERIFY PLUNGER PULLS IN WHEN ENERGIZED LONG 1, SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND LOW OIL - CHECK OIL LEVEL ON DIPSTICK FAULTY OIL PRESSURE SWITCH - CHECK THAT "WK" STUD IS OPEN WHEN ENGINE IS RUNNING LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY
E-7 E-7 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) White or Blue Smoke. POSSIBLE CAUSE 1. 2. RECOMMENDED COURSE OF ACTION 3. Excess engine oil. Too low viscosity of the engine oil. Faulty injection timing. Dark Grey Smoke. 1. 2. 3. 4. 5. Unsuitable fuel. Excess injection. Faulty function of the engine. Overloading. Clogged air cleaner. Faulty Charging. 1. 2. 3. 4. Loose fan belt. Faulty wiring. Faulty battery. Worn out alternator brush.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-5 DIAGRAMS CLASSIC 300D KUBOTA F-5
CLASSIC 300D KUBOTA 4.00 101.6 N.B. 4.00 101.6 23.00 584.2 41.66 1058.2 57.70 1465.6 N.A. 8.70 221 MOUNTING HOLE O .56/14.2 SKID 45.50 1155.7 37.12 942.8 18.50 469.9 20.62 523.7 24.00 609.6 A.01 S10766-12 40.94 1039.9 DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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