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