Classic 300 D & 300 G
For Engine
Safety
Powered equipment
Electric Magnetic Fields
Can be dangerous
Electric Shock can kill ARC Rays can burn
Fumes and Gases
Classic 300D & 300G
Cylinder may explode
For Electrically
Iii
LES Machines À Souder À
Précautions DE Sûreté
Précautions DE Sûreté Pour
Transformateur ET À
Electromagnetic Compatibility EMC
L10093 3-1-96H
Master Table of Contents for ALL Sections
Table of Contents Installation Section
Welding Output Open Circuit Output Range Auxiliary Power
Installation
Technical Specifications Classic 300D
Height Width Depth Weight
Design Features
Optional Features
Rated Output Duty Cycle
PRE-OPERATION Installation
Diesel Fuel
PRE
Trailer
Vehicle Mounting
To prevent Explosion when
Battery Charging
Engine BREAK-IN
To prevent Electrical Damage when
Table of Contents Operation Section
See additional warning information at
Operation
Engine Operation
Cold Weather Starting
See Specifications for
Welder Operation
Do not Turn the Current Range Selec
Auxiliary Power
B1.4
Table of Contents Accessories Section
Maintenance section
Accessories
Optional Features
TIG Options
Magnum 250 Innershield Gun for LN-23P
Wire Feed Module K623-1 Provides constant volt
C1.3
Spool GUN Welder
C1.4 Classic 300D & 300G
Table of Contents Maintenance Section
Maintenance
Maintenance
Engine
Idler Maintenance
Purging Air from Fuel System Perkins
Nameplates
D1.4
For Codes 10658 and below
D1.5
For Codes 10911 and Above
Resetting Procedure
D1.6
Figure D1.7 Major Component Location
D1.7
D1.8 Classic 300D & 300G
A2.1
Model Height Width Depth Weight
Description Rated DC Output
DC Current Range Volts @ Rated Amps Cycle
Engine
When starting and stopping welding or using auxil
A2.3
Muffler
Lift Bail
Machine Grounding
Exhaust Spark Arrester
Do not Mount Over Combustible SU
Fuel Polarity Control and Cable Sizes
PRE-OPERATION Service
OIL
Cooling System
Battery Acid can burn eyes Skin
Battery Charging
A2.6 Gases from Battery can explode
A2.6
B2.1
Stopping the Engine
Maintenance sec
High Altitude Operation
Starting the Classic 300D Perkins
Contacts and damage the switch
B2.3
Idler Operation Auxiliary Power
B2.4
C2.1
Stick Options Accessory SET K704
TIG Options General Options
Trailer K953-1
Wire Feeder Options
Wire Feed Module K623-1 Magnum Spool Gun K487-25
C2.3
C2.4 Classic 300D & 300G
D2.1
Safety Precautions
Information at
Perkins 404C-22 Engine
Idler Maintenance
Purging AIR from Fuel System
Nameplates
Tension of alternator drive belt
Service Decal for Codes 11249 and below
D2.4
All nuts and bolts for tightness
MAINTENANCED2.5
Service Decal for Codes 11250 and Above
D2.5
D2.6MAINTENANCED2.6
Gfci Receptacle Testing and Reset Ting Procedure
Case Front Assembly
D2.7
D2.8 Classic 300D & 300G
A3.1
Technical Specifications Classic 300D Kubota
A3.2
Control Panel High Idle RPM OCV Adjustment
A3.3
Not Mount Over Combustible Surfaces
This operatorʼs manual
Angle of Operation
Falling
Polarity Control and Cable Sizes Fuel
Battery Charging Warning
GAS ES from Battery can explode
A3.6
B3.1
Starting the Classic 300D Kubota V2203M
Diesel Engine
B3.3
Control of Welding Current
B3.4
Idler Operation
C3.1
TIG Options
Stick Options
Wire Feed Options
C3.3
C3.4 Classic 300D & 300G
D3.1
D3.2
Air Bleeding
Kubota V2203M Engine
D3.3
Valve
Engine Service
D3.4
D3.5MAINTENANCED3.5
Figure D3.6 Major Component Location
D3.6
A4.1
A4.2
General Description
A4.3
See Optional Features
A4.4
Instructions supplied with this machine
Read the engine operating and maintenance
A4.5
Can
A4.6
B4.1
B4.2
404D-22 Diesel Engine
Selector setting and lower open circuit voltage
B4.3
B4.4
C4.1
C4.2
Power Plug Kit K802D
Service Indicator Kit K1858-1 Water Valve Kit K844-1
Ball Hitch K958-1 K958-2 Control Cable Extension K937-45
Magnum Spool Gun K487-25 Wire Feed Module K623-1
C4.3
C4.4 Classic 300D & 300G
D4.1
D4.2
Perkins 404D-22 Engine
D4.3
MAINTENANCED4.4
D4.4
D4.5MAINTENANCED4.5
Figure D4.6 Major Component Location
D4.6
A5.1
Technical Specifications Classic 300G K1754-1
A5.2
Description Rated DC Output Duty Cycle DC Current Range
Exhaust Spark Arrester Lift Bail
Do not Mount Over Combustible SUR
Gasoline
Vehicle Mounting
A5.5
A5.6 Classic 300D & 300G
B5.1
B5.2
Design Features
Starting and stopping welding or using auxiliary
Do not Mount Over Combustible Surfaces
Refer to the Engine
High Idle RPM OCV Adjustment- a potentiometer is
B5.3
Starting the Classic 300G GM 3.0L
B5.4
Throttle Body Deicing System
Idler Control Operation
C5.1
Optional Equipment
C5.2
D5.1
Bearings
Commutator and Brushes
General Instructions
Purging AIR from Fuel System GM
Idler Control Maintenance
Engine Maintenance
0L Engine
Engine Service
D5.4
Figure D5.5 Major Component Location
D5.5
D5.6 Classic 300D & 300G
1TABLE of CONTENTS-THEORY of Operation Section E-1
Theory of Operation
Gasoline Engine
Perkins
BATTERY, STARTER, Engine Alternator & Protection Circuits
Classic 300G, Zenith Fuel System/GM Engine
Classic 300D, Perkins Engine
Classic 300D, Kubota Engine
TOR and Rotor
Fine Current Adjustment
Adjustment Coils
Excitation Flashing
Figure E.8 Classic 300D, Perkins Engine
11472,
Engine Idler Circuit
11135 10657, 10658, 10911,
Theory of Operation
DC Generator Machines
Classic 300D & 300G
Troubleshooting and Repair
Table of Contents
Recommended
HOW to USE Troubleshooting Guide
Locate Problem Symptom
Perform External Tests
PC Board Troubleshooting Procedures
Electric Shock
Perform the Brush and Slip
Adjustment Test
Ring Service Procedure
Perform the Flash Voltage
Commutator Inspection
Service Procedure
Generator Brush
Shunt Field Coil
Output takes a long time to
Weld output is considerably
Rocker Adjustment
Adjustment Procedure if
Perform the Shunt Field Coil
Procedure
RPM Adjustment Test
Slip Ring Service
Exciter Rotor Resistance and Ground Test Shunt Field Coil
Brush and Slip
Welding
Flash Voltage
Engine will not crank when
Function Problems
System Voltage Tests
Verify that the engine control
Protection System Test
Perform the Engine Alternator
Machine will not idle down
Kubota powered units
For Classic 300G
Engine goes to low idle, but
Kubota powered Classic
Perkins powered models
Classic 300G Classic 300D Kubota Powered machines
Troubleshooting and Repair
Exciter/Auxiliary Power Alternator
23TROUBLESHOOTING and REPAIRF-23
Brush & Slip Ring Service Procedure
Procedure Description
Cleaning the Slip Rings
24TROUBLESHOOTING and REPAIRF-24
Procedure
Seating Brushes
25TROUBLESHOOTING and REPAIRF-25
Engine Alternator Test Procedure
Test Description
Engine Alternator Test Procedure
27TROUBLESHOOTING and REPAIRF-27
Engine Fuel System Voltage Test Procedure
Engine Fuel System Voltage Test Procedure
29TROUBLESHOOTING and REPAIRF-29
Engine Protection System Test Procedure
TED to RUN White Overheated or with
Engine Protection System Test Procedure
Warranty will not Cover the Damage
TOW OIL PRESSURE, Severe Engine DAM
31TROUBLESHOOTING and REPAIRF-31
Engine RPM Adjustment Test Procedure
Materials Needed Miscellaneous hand tools Strobe tachometer
Classic 300D Perkins only
Engine RPM Adjustment Test Procedure
Engine RPM Adjustment Procedure later in this section
Strobe-Tach Method
Low idle adjustment
Classic 300D & 300G
35TROUBLESHOOTING and REPAIRF-35
Flashing Voltage Test Procedure
Flashing Voltage Test Procedure
Rocker Adjustment Procedure
Initial rocker placement
38TROUBLESHOOTING and REPAIRF-38
Rocker Adjustment Procedure
Tighten
Check for Max output
Classic 300D & 300G
41TROUBLESHOOTING and REPAIRF-41
Exciter Rotor Resistance and Ground Tests Procedure
Exciter / Auxiliary Power Alternator
42TROUBLESHOOTING and REPAIRF-42
Static Tests
Dynamic Tests
43TROUBLESHOOTING and REPAIRF-43
Classic 300D & 300G
45TROUBLESHOOTING and REPAIRF-45
Shunt Field Coil Resistance and Ground Test Procedure
Test the shunt coil resistance
Shunt Field Coil Resistance and Ground Test
Shunt coil ground test
Shunt Field Coil Resistance and Ground
47TROUBLESHOOTING and REPAIRF-47
Shunt Field Circuit Voltage Test Procedure
Shunt Field Circuit Voltage Test Procedure
49TROUBLESHOOTING and REPAIRF-49
Exciter Stator Short Circuit & Ground Test Procedure
Exciter Stator Short Circuit & Ground Test Procedure
Weld Circuit Ground and Short Circuit Test Procedure
Weld circuit ground test
If the resistance is lower than 500k Ohms
53TROUBLESHOOTING and REPAIRF-53
Welding Generator Brush and Commutator
54TROUBLESHOOTING and REPAIRF-54
Inspection and Service Procedure
Perform the Weld Circuit Ground and Short Circuit Test
Uneven Commutator appearance
55TROUBLESHOOTING and REPAIRF-55
Pitted and Are Damaged Commutator
Examine the brushes
Classic 300D & 300G
57TROUBLESHOOTING and REPAIRF-57
Series Coil Short Circuit Test Procedure
Series Coil Short Circuit Test Procedure
16.6 ms
Scope Settings
High Idle no Load Fine Current Control Rheostat AT Maximum
CH1
60TROUBLESHOOTING and REPAIRF-60
Normal Open Circuit DC Weld Voltage Waveform
61TROUBLESHOOTING and REPAIRF-61
Machine Loaded Selector Switch AT Maximum Position
Typical DC Weld Output Voltage Waveform
Classic 300D & 300G
Description
63TROUBLESHOOTING and REPAIRF-63
Alternator Rotor Removal Replacement Procedure
Materials Needed 3/8 wrench
64TROUBLESHOOTING and REPAIRF-64
Replacement Procedure
Alternator Rotor Removal
Troubleshooting and Repair
66TROUBLESHOOTING and REPAIRF-66
Figure F.6 Rotor Removal
Replacement Procedure
Replacement
Classic 300D & 300G
69TROUBLESHOOTING and REPAIRF-69
Alternator Stator Removal and Replacement Procedure
Materials Needed 3/8 nut driver
Procedure
70TROUBLESHOOTING and REPAIRF-70
Alternator Stator Removal and Replacement
Perform the Alternator Rotor Removal
71TROUBLESHOOTING and REPAIRF-71
Figure F.8 Lead Disconnection Points
Replacement
Genernator Brush HOLDER/COIL Cables
73TROUBLESHOOTING and REPAIRF-73
Rotor Removal and Replacement pro
Classic 300D & 300G
75TROUBLESHOOTING and REPAIRF-75
Generator Frame Removal and Replacement Procedure
Generator Frame
76TROUBLESHOOTING and REPAIRF-76
Removal and Replacement
Perform the Alternator Stator Removal
Removal and Replacement
78TROUBLESHOOTING and REPAIRF-78
See Figure F.14 for steps 14
79TROUBLESHOOTING and REPAIRF-79
Rope Sling
80TROUBLESHOOTING and REPAIRF-80
81TROUBLESHOOTING and REPAIRF-81
Generator Armature Removal and Replacement Procedure
82TROUBLESHOOTING and REPAIRF-82
Removal and Replacement Procedure
Generator Armature
AC Auxiliary Power Receptacle Output
Current Rheostat at Maximum
RPM
Classic 300D & 300G
Table of Contents Diagram Section
Electrical Diagrams
Wiring Diagram Codes 10545, 10546, 10657, 10658 L10877
Classic 300G Wiring Diagram
Classic 300D Wiring Diagram
Wiring Diagram Codes 10911, 10927 L11865
Classic 300G Wiring Diagram
Wiring Diagram Codes 10912, 11135 L11866
Classic 300D Perkins Wiring Diagram
Wiring Diagram Codes 11110, 11111 M20499
Classic 300D Kubota Wiring Diagram
Wiring Diagram Codes 11112, 11113 M20432
Wiring Diagram Codes 11243, 11244 M20432-1
OU Tput Terminals
Wiring Diagram Codes 11248, 11249, 11280, 11281 M20616
Wiring Diagram Codes 11411, 11412 M21292
Wiring Diagram Codes 11413, 11414 M21293
Wiring Diagram Codes 11472, 11473 M21684
Wiring Diagram Codes 11474, 11475 M21563
To Iron
Schematic Complete Machine Codes 11110, 11111 L12412
L12412
Schematic Complete Machine Codes 11112, 11113 L12265
L12265
Schematic Complete Machine Codes 11243, 11244 L12265-1
L12265-1
L12561
Lower Left Machine
Schematic Complete Machine Codes 11411, 11412 L13096
L13096
Schematic Complete Machine Codes 11413, 11414 L13097
L13097
Schematic Complete Machine Codes 11472, 11473 L13672
L13672
Schematic Complete Machine Codes 11474, 11475 L13351
L13351
Wire Feed Module Wiring Diagram
Wiring Diagram Wire Feed Module Option L9259
Schematic Wire Feed Module Option G2562
Classic 300D & 300G
Electrical Diagrams
Schematic Current Sensor PC BD Kubota Engine only S25973