Safety Information
Safety Depends on You: Lincoln arc welding and cutting equipment is designed and built with safety in mind. Your overall safety can be increased by proper installation and thoughtful operation. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. Think before you act and be careful.
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 engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. (Applies to both Diesel and Gasoline Engines).
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand all safety highlights. For additional safety information, it is strongly recommended to purchase "Safety in Welding & Cutting - ANSI Standard Z49.1" from the American Welding Society or CSA Standard W117.2-1974. A free copy of "Arc Welding Safety" booklet E205 is available from Lincoln Electric Company.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
Refer to www.lincolnelectric.com/safety for additional safety information.
This manual also contains multi-language safety warnings in Spanish, French, German, Portuguese, Japanese, Chinese, Korean, and Arabic.
General Description
The CLASSIC® 300D PERKINS is a heavy-duty, engine-driven DC arc welding power source, designed for constant current output for stick welding or DC TIG welding. It features all-copper coils, improved door latches, and stainless hinges. With the optional K623-1 Wire Feed Module, it can also provide constant voltage output for wire feeders (LN-7, LN-23P, LN-25).
This model includes an Electronic Engine Protection System that shuts down the engine in case of low oil pressure or high coolant temperature. It provides a current range of 40-350 DC amps and 3 KVA of 115/230 volts of 60 cycle AC auxiliary power. The engine used is a Perkins 404D-22 industrial water-cooled diesel engine.
Design Features:
- Control Panel: Located at the exciter end, includes Current Range Selector, Fine Current Adjustment rheostat, Start button, Ignition switch, Idler control switch, Glow Plug button, engine temperature gauge, battery charging ammeter, oil pressure gauge, and auxiliary power receptacles (20 amp, 120VAC GFCI protected; 15 amp, 250VAC).
- All Copper Windings: Ensures long life and dependable operation.
- Engine Idler: Electronic automatic engine idler increases/decreases engine speed based on welding or auxiliary power usage.
- Auxiliary Power: 3.0 KVA nominal 115/230V, 60Hz, AC. Output voltage maintained within ± 10%.
- GFCI Module: Protects the 20 amp, 120V duplex receptacle against electric shock. Regular testing is recommended.
- Welder Enclosure: Rubber-mounted on a rugged steel "C" channel base with protected output terminals.
- Cranking System: Standard 12 volt electric starter.
- Air Cleaner: Heavy duty two-stage dry type.
- Muffler: Standard muffler and stainless steel exhaust outlet elbow.
- Engine Hour Meter: Records hours of operation.
- Engine Protection: System shuts down engine for low oil pressure or high coolant temperature.
- Oil Drain Valve: Standard ball valve, hose, and clamp.
- Remote Control: Remote / Local Switch and Receptacle are standard.
Technical Specifications
| Make/Model | Description | Speed (RPM) | Displacement | Starting System | Capacities |
|---|---|---|---|---|---|
| Perkins 404D-22 EPA Tier 4 interim Compliant | 4 Cylinder, 4 Cycle, Naturally Aspirated, Water-Cooled Diesel Engine, Cast Iron Cylinder, Block/Crankcase | High Idle 1800, Low Idle 1400, Full Load 1725 | 135 cu. in (2.2 liters), Bore x Stroke 3.3" x 3.9" (84mm x 100mm) | 12VDC battery (Group 24, 650 cold crank amps), 2.0 KW Starter, 65 A. Alternator w/ built in reg. | Fuel: 15 gal. (57 L), Oil: 10.30 Qts. (9.75 L), Coolant: 9.5 Qts. (9.0 L) |
| 32.7HP @1800 RPM |
| Description | Rated DC Output (Volts @ Rated Amps) | Duty Cycle | DC Current Range (Fine Adjustments in each Range) |
|---|---|---|---|
| 300 Amp DC Welder, All Copper Windings, Pure DC Power Generator | 30V @ 250A, 32V @ 300A, 99V DC Max. OCV @ 1800RPM | 100%, 60% | 40-350 Amps, 220-Max., 160-240, 120-190, 80-130, Min.-90 |
| Auxiliary Power (1) |
|---|
| 3,000 Watts Continuous, 60 Hz AC |
| 26 Amps @ 115V |
| 13 Amps @ 230V |
(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.
| Model | Height | Width | Depth | Weight |
|---|---|---|---|---|
| K1643-7 CSA w/o Wire Feed Module (Code 11572, 11640) | 45.5 in. (1156 mm) | 24.00 in. (610 mm) | 65.0 in. (1651 mm) | 1354 lbs. (616 kg) |
| K1643-8 CSA w/ Wire Feed Module (Codes 11573, 11641) | 1389lbs. (630 kg) |
(2) Height to top of exhaust elbow.
Installation
Proper installation is crucial for safety and optimal performance. Always read the engine manufacturer's manual supplied with your welder.
Key Installation Considerations:
- Exhaust Spark Arrester: Some laws may require an exhaust spark arrester. The standard muffler does not qualify. Use a suitable, properly maintained arrester.
- Location/Ventilation: Operate with doors closed to maintain designed air flow. Ensure unrestricted flow of clean, cool air and proper venting of engine exhaust fumes outdoors.
- Machine Grounding: The frame of this portable generator is not required to be grounded by the U.S. National Electrical Code, but local codes may require it. A grounding stud is provided.
- Lift Bail: Provided for lifting with a hoist. Lift only with adequate capacity equipment and ensure stability. Do not lift if the bail is damaged or if heavy accessories are attached.
- Trailer (Optional Features): If using a non-Lincoln trailer, ensure it meets design capacity, proper attachment, and load distribution for stability.
- Vehicle Mounting: Improperly mounted loads can cause instability. Transport on serviceable vehicles rated for such loads, distribute and secure loads, and do not exceed rated capacities.
- Polarity Control and Cable Sizes: With the engine off, route electrode and work cables through the strain relief bracket. Connect to the appropriate (+) or (-) studs for positive or negative polarity. Ensure connections are tight. Use ample sized welding cables for long distances. Refer to the manual for recommended copper cable sizes based on amperage and duty cycle.
Pre-Operation Service
Before operating, consult the engine operating and maintenance instructions.
Checks and Procedures:
- Fueling Safety: Stop engine and allow to cool before refueling. Do not smoke or overfill. Wipe up spilled fuel immediately. Use DIESEL FUEL ONLY (Low sulphur or ultra low sulphur fuel).
- Oil: The engine crankcase is factory-filled with SAE 10W/30 oil. Check the dipstick upon receipt and ensure it's at the "full" mark. Do not overfill.
- Fuel: Fill the tank with the recommended grade of fuel. Ensure the fuel valve on the water separator is open.
- Cooling System: The radiator is factory-filled with a 50-50 mixture of ethylene glycol antifreeze and water. Check and maintain the radiator level.
- Battery Charging: Gases from the battery can explode. Keep sparks, flame, and cigarettes away. Battery acid can burn eyes and skin; wear gloves and eye protection. Observe correct polarity (Negative Ground) when installing, boosting, or connecting batteries to prevent explosion or electrical damage.
Operation
Engine Operation:
Do not use this equipment without thoroughly reading the engine manufacturer's manual. Operate with doors closed to prevent overheating.
Starting the CLASSIC® 300D PERKINS 404D-22 Diesel Engine:
- Turn "IDLER" switch to "HIGH".
- Turn "IGNITION" switch to "ON".
- Press Glow Plug button for 20-30 seconds (max 60 seconds).
- Press Start button. Release both buttons when engine starts.
- Observe oil pressure. If no pressure shows within 30 seconds, stop engine and consult manual.
- If engine protection warning light comes on, turn "IGNITION" switch "OFF" to reset.
- Allow engine to warm up at high idle speed. Recheck oil level after draining into pan.
Cold Weather Starting:
A fully charged battery and proper weight oil should allow starting down to -15°F (-26°C). Cold-starting aids may be desirable. NEVER use ether or other starting fluids.
High Altitude Operation:
Engine runs correctly up to 600m (2000ft). Above this, fuel consumption and exhaust emissions may be excessive. Contact Perkins Application Department for adjustments.
Stopping the Engine:
- Turn "IGNITION" switch to "OFF".
At the end of each day, check crankcase oil, drain water separator, and refill fuel tank to minimize moisture condensation. Close fuel feed valve when hauling. If fuel supply is cut off, bleeding the fuel system may be necessary by qualified personnel.
Welder Operation:
Duty Cycle:
The NEMA output rating is 300 amperes at 32 arc volts on a 60% duty cycle (6 minutes out of every 10 minutes at rated output).
Control of Welding Current:
DO NOT TURN THE "CURRENT RANGE SELECTOR" WHILE WELDING as it may cause arcing and damage the switch.
The "Current Range Selector" provides five overlapping current ranges. The "Fine Current Adjustment" adjusts current and controls open circuit voltage for arc characteristics. A high open circuit voltage provides a soft "buttering" arc, while a higher Current Range Selector setting and lower open circuit voltage provide a forceful "digging" arc.
DO NOT attempt to set the "Current Range Selector" between the five points designated on the nameplate.
Idler Operation:
The "Idler" toggle switch has "High" and "Auto" positions. In "High", the engine runs at high idle speed. In "Auto", the engine idles up when welding or drawing auxiliary power (min. 100 watts) and returns to low idle after a 15-second delay when load is removed.
Auxiliary Power:
The AC auxiliary power is 3.0 KVA (115/230 VAC, 60 hertz). It includes one 120V GFCI-protected duplex receptacle and one 230V duplex grounding type receptacle. Maximum continuous current is 13 amps from 230V and 15 amps from 120V. Total combined load must not exceed 3.0 KVA.
| Condition | Fuel Consumption |
|---|---|
| Low Idle (1375 RPM)-No Load @ 45 Volts | 0.28 gal/hr (1.06 liters/hr) |
| High Idle (1800 RPM)-No Load @ 96.6 Volts | 0.42 gal/hr (1.59 liters/hr) |
| 3000 Watts | 0.59 gal/hr (2.23 liters/hr) |
| 250 Amps @ 30 Volts | 1.03 gal/hr (3.90 liters/hr) |
| 300 Amps @ 32 Volts | 1.37 gal/hr (5.19 liters/hr) |
Accessories
Various optional features and accessories are available for the CLASSIC® 300D PERKINS welder to enhance its functionality for different welding applications.
General Options:
- Power Plug Kit K802D: Provides plugs for auxiliary power receptacles.
- Spark Arrestor Kit K903-1: Heavy gauge steel, approved spark arrester for muffler exhaust pipe.
- TRAILER K953-1: Two-wheeled trailer with optional fender and light package for highway use.
- Ball Hitch K958-1 / Lunette Eye Hitch K958-2: Trailer hitch options.
- Fender & Light Kit K959-1: For the trailer.
- Cable Rack K965-1: For cable management.
- Service Indicator Kit K1858-1: Visual indication of air cleaner element service life.
Stick Options:
- ACCESSORY SET K704: Includes electrode cable, work cable, headshield, work clamp, and electrode holder. Rated 500 amps, 60% duty cycle.
- Remote Control Kit K924-5: Remote control rheostat and 100 ft. (30.5 m) cable for OCV adjustment.
TIG Options:
- TIG Module K930-2: Provides high frequency and shielding gas control for AC and DC GTAW (TIG) welding.
- PTA-26V TIG Torch K1783-9: Air cooled 200 amp torch with valve for gas flow control.
- Magnum Parts Kit For PTA-26V TIG Torch KP509
- Control Cable K936-4: Required for TIG Module connection.
- Arc Start Switch K814: For convenient finger control on TIG torch.
- Contactor Kit K938-1: Provides "Cold" tungsten tip.
- Control Cable Extension K937-45: Allows TIG Module operation up to 200 ft. from power source.
- Water Valve Kit K844-1: For water-cooled TIG torch.
Wire Feeder Options:
- Wire Feed Module K623-1: Provides constant voltage (CV) output for Innershield and MIG welding.
- LN-25 Wire Feeder K449: Portable CC/CV unit for flux-cored and MIG welding.
- Remote Voltage Control Kit for LN-25 K444-2: Remote output voltage control.
- Magnum® 350 Innershield Gun for LN-25 K126-2: For self-shielded wire.
- Magnum® 300 MIG Gun for LN-25 K1802-1: For gas shielded wire.
- LN-23P Wire Feeder K316L-1: Portable CV unit for Innershield pipe welding.
- LN-23P Adapter Kit K350-1: Adapts LN-23P to Lincoln power source.
- Magnum® 250 Innershield Gun for LN-23P K355-10: For lighter weight and easier handling.
- 62° gun tube for PipeWelding KP1909-1: Recommended modification for specific gun types.
- Magnum Spool Gun K487-25: Handheld semiautomatic wire feeder.
- SG Control Module K488: Interface between power source and spool gun.
- Input Cable K691-10: For SG Control Module.
Maintenance
Maintenance work should only be performed by qualified personnel. Always turn the engine off before working inside the machine. Exercise extreme care when working near moving parts.
General Instructions:
- Regularly blow out the welder and controls with an air hose.
- Rotate the "Current Range Selector" frequently to keep contacts clean.
- Apply oil to the "Current Range Selector" shaft monthly.
- Follow the engine service schedule in this manual and the engine manufacturer's manual.
Cooling System:
The welder has a pressure radiator. Keep the cap tight. Periodically clean and flush the cooling system. Use permanent type antifreeze when needed.
Bearings:
Equipped with double-shielded ball bearings. May require adding grease annually in constantly used or dirty locations. Avoid over-greasing and ensure cleanliness when greasing.
Commutator and Brushes:
Uncovered rotating equipment can be dangerous. Use care to avoid hands, hair, clothing, or tools catching in rotating parts. Protect yourself from particles when stoning the commutator.
Periodically inspect commutator, slip rings, and brushes. Clean with fine sandpaper or a commutator stone if black or uneven. Replace brushes when worn.
Idler Maintenance:
Before doing electrical work on the idler printed circuit board, disconnect the battery.
Proper idler operation requires good grounding. The idler solenoid is activated for low idle. The welder can be used without automatic idling by setting the "Idler" switch to "High".
Nameplates:
Inspect all nameplates and labels for legibility during routine maintenance (at least yearly) and replace if no longer clear.
Purging Air from Fuel System (Perkins 404D-22 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 runs rough due to trapped air, loosen the vent screw on the fuel inlet connection, operate the electric fuel pump until air-free fuel flows, then tighten the screw. Contact your Perkins Engine repair facility if problems persist.
Engine Service Chart:
A detailed engine service chart is provided in the manual, outlining maintenance items, types, and quantities, with recommended frequencies (e.g., every day/8 hours, 100 hours/3 months, 250 hours/6 months, etc.). This chart covers coolant, engine oil, filters, belts, air filter, engine breather, cylinder head, valve clearances, electrical systems, nuts/bolts, injector performance, leaks, and battery. These operations should be carried out by trained personnel.
GFCI Module Testing and Resetting Procedure:
The GFCI module should be tested monthly or whenever it trips. The procedure involves checking for damage, ensuring the equipment is running at high idle speed and providing sufficient voltage, resetting the circuit breaker if tripped, pushing the "Reset" button, plugging in a test product (e.g., night-light), pushing the "Test" button to confirm the product turns off, and then pushing "Reset" again to confirm it turns back on. If the GFCI module fails this test, contact a qualified electrician.
Troubleshooting
This guide helps identify and repair possible machine malfunctions. It follows a three-step procedure: locate the problem (symptom), identify possible causes, and determine the recommended course of action. For any procedures not understood or unable to be performed safely, contact your Local Lincoln Authorized Field Service Facility.
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs may result in danger and invalidate warranty.
Common symptoms addressed include machine failing to hold output, welder starting but not generating current, loud/spattering arc, incorrect welding current, arc continuously popping out, engine not starting, engine not turning over, irregular engine running, engine stopping with/without protection light, white/blue/dark grey smoke, faulty charging, starter motor issues, and no auxiliary power.
Diagrams and Parts List
The manual includes detailed wiring diagrams (F-1, F-2) for different code numbers, a dimension print (F-3), and a comprehensive parts list (P-594). These diagrams are for reference only and the specific diagram for a particular code is pasted inside the machine. For illegible diagrams or replacements, contact the Service Department with the equipment code number.
