Classic 300 D & 300 G
Electric Magnetic Fields
Safety
Powered equipment
For Engine
Classic 300D & 300G
Electric Shock can kill ARC Rays can burn
Fumes and Gases
Can be dangerous
Iii
Cylinder may explode
For Electrically
Transformateur ET À
Précautions DE Sûreté
Précautions DE Sûreté Pour
LES Machines À Souder À
Electromagnetic Compatibility EMC
L10093 3-1-96H
Master Table of Contents for ALL Sections
Table of Contents Installation Section
Height Width Depth Weight
Installation
Technical Specifications Classic 300D
Welding Output Open Circuit Output Range Auxiliary Power
Rated Output Duty Cycle
Design Features
Optional Features
PRE-OPERATION Installation
Vehicle Mounting
PRE
Trailer
Diesel Fuel
To prevent Electrical Damage when
Battery Charging
Engine BREAK-IN
To prevent Explosion when
Table of Contents Operation Section
Cold Weather Starting
Operation
Engine Operation
See additional warning information at
Do not Turn the Current Range Selec
See Specifications for
Welder Operation
B1.4
Auxiliary Power
Table of Contents Accessories Section
TIG Options
Accessories
Optional Features
Maintenance section
Spool GUN Welder
Wire Feed Module K623-1 Provides constant volt
C1.3
Magnum 250 Innershield Gun for LN-23P
C1.4 Classic 300D & 300G
Table of Contents Maintenance Section
Maintenance
Maintenance
Nameplates
Idler Maintenance
Purging Air from Fuel System Perkins
Engine
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
DC Current Range Volts @ Rated Amps Cycle
Model Height Width Depth Weight
Description Rated DC Output
Muffler
When starting and stopping welding or using auxil
A2.3
Engine
Do not Mount Over Combustible SU
Machine Grounding
Exhaust Spark Arrester
Lift Bail
Cooling System
PRE-OPERATION Service
OIL
Fuel Polarity Control and Cable Sizes
A2.6
Battery Charging
A2.6 Gases from Battery can explode
Battery Acid can burn eyes Skin
B2.1
Starting the Classic 300D Perkins
Maintenance sec
High Altitude Operation
Stopping the Engine
B2.3
Contacts and damage the switch
B2.4
Idler Operation Auxiliary Power
C2.1
Trailer K953-1
Stick Options Accessory SET K704
TIG Options General Options
C2.3
Wire Feeder Options
Wire Feed Module K623-1 Magnum Spool Gun K487-25
C2.4 Classic 300D & 300G
D2.1
Information at
Safety Precautions
Nameplates
Idler Maintenance
Purging AIR from Fuel System
Perkins 404C-22 Engine
All nuts and bolts for tightness
Service Decal for Codes 11249 and below
D2.4
Tension of alternator drive belt
D2.5
MAINTENANCED2.5
Service Decal for Codes 11250 and Above
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
Falling
This operatorʼs manual
Angle of Operation
Not Mount Over Combustible Surfaces
Polarity Control and Cable Sizes Fuel
A3.6
Battery Charging Warning
GAS ES from Battery can explode
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
Valve
Kubota V2203M Engine
D3.3
Air Bleeding
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
Can
Read the engine operating and maintenance
A4.5
Instructions supplied with this machine
A4.6
B4.1
404D-22 Diesel Engine
B4.2
B4.3
Selector setting and lower open circuit voltage
B4.4
C4.1
Ball Hitch K958-1 K958-2 Control Cable Extension K937-45
Power Plug Kit K802D
Service Indicator Kit K1858-1 Water Valve Kit K844-1
C4.2
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
Description Rated DC Output Duty Cycle DC Current Range
Technical Specifications Classic 300G K1754-1
A5.2
Do not Mount Over Combustible SUR
Exhaust Spark Arrester Lift Bail
Vehicle Mounting
Gasoline
A5.5
A5.6 Classic 300D & 300G
B5.1
Do not Mount Over Combustible Surfaces
Design Features
Starting and stopping welding or using auxiliary
B5.2
Starting the Classic 300G GM 3.0L
High Idle RPM OCV Adjustment- a potentiometer is
B5.3
Refer to the Engine
Idler Control Operation
B5.4
Throttle Body Deicing System
C5.1
C5.2
Optional Equipment
D5.1
General Instructions
Bearings
Commutator and Brushes
0L Engine
Idler Control Maintenance
Engine Maintenance
Purging AIR from Fuel System GM
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
Excitation Flashing
Fine Current Adjustment
Adjustment Coils
TOR and Rotor
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
Perform External Tests
HOW to USE Troubleshooting Guide
Locate Problem Symptom
Recommended
Electric Shock
PC Board Troubleshooting Procedures
Perform the Flash Voltage
Adjustment Test
Ring Service Procedure
Perform the Brush and Slip
Shunt Field Coil
Service Procedure
Generator Brush
Commutator Inspection
Output takes a long time to
Weld output is considerably
Perform the Shunt Field Coil
Rocker Adjustment
Adjustment Procedure if
Exciter Rotor Resistance and Ground Test Shunt Field Coil
RPM Adjustment Test
Slip Ring Service
Procedure
Flash Voltage
Brush and Slip
Welding
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
Procedure Description
23TROUBLESHOOTING and REPAIRF-23
Brush & Slip Ring Service Procedure
Exciter/Auxiliary Power Alternator
Seating Brushes
24TROUBLESHOOTING and REPAIRF-24
Procedure
Cleaning the Slip Rings
Test Description
25TROUBLESHOOTING and REPAIRF-25
Engine Alternator Test Procedure
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
TOW OIL PRESSURE, Severe Engine DAM
Engine Protection System Test Procedure
Warranty will not Cover the Damage
TED to RUN White Overheated or with
Materials Needed Miscellaneous hand tools Strobe tachometer
31TROUBLESHOOTING and REPAIRF-31
Engine RPM Adjustment Test Procedure
Strobe-Tach Method
Engine RPM Adjustment Test Procedure
Engine RPM Adjustment Procedure later in this section
Classic 300D Perkins only
Low idle adjustment
Classic 300D & 300G
Flashing Voltage Test Procedure
35TROUBLESHOOTING and REPAIRF-35
Flashing Voltage Test Procedure
Rocker Adjustment Procedure
Tighten
38TROUBLESHOOTING and REPAIRF-38
Rocker Adjustment Procedure
Initial rocker placement
Check for Max output
Classic 300D & 300G
Exciter / Auxiliary Power Alternator
41TROUBLESHOOTING and REPAIRF-41
Exciter Rotor Resistance and Ground Tests Procedure
Dynamic Tests
42TROUBLESHOOTING and REPAIRF-42
Static Tests
43TROUBLESHOOTING and REPAIRF-43
Classic 300D & 300G
Shunt Field Coil Resistance and Ground Test Procedure
45TROUBLESHOOTING and REPAIRF-45
Shunt Field Coil Resistance and Ground
Shunt Field Coil Resistance and Ground Test
Shunt coil ground test
Test the shunt coil resistance
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
Perform the Weld Circuit Ground and Short Circuit Test
54TROUBLESHOOTING and REPAIRF-54
Inspection and Service Procedure
Welding Generator Brush and Commutator
Examine the brushes
55TROUBLESHOOTING and REPAIRF-55
Pitted and Are Damaged Commutator
Uneven Commutator appearance
Classic 300D & 300G
Series Coil Short Circuit Test Procedure
57TROUBLESHOOTING and REPAIRF-57
Series Coil Short Circuit Test Procedure
CH1
Scope Settings
High Idle no Load Fine Current Control Rheostat AT Maximum
16.6 ms
Normal Open Circuit DC Weld Voltage Waveform
60TROUBLESHOOTING and REPAIRF-60
Typical DC Weld Output Voltage Waveform
61TROUBLESHOOTING and REPAIRF-61
Machine Loaded Selector Switch AT Maximum Position
Classic 300D & 300G
Materials Needed 3/8 wrench
63TROUBLESHOOTING and REPAIRF-63
Alternator Rotor Removal Replacement Procedure
Description
Alternator Rotor Removal
64TROUBLESHOOTING and REPAIRF-64
Replacement Procedure
Troubleshooting and Repair
Figure F.6 Rotor Removal
66TROUBLESHOOTING and REPAIRF-66
Replacement
Replacement Procedure
Classic 300D & 300G
Materials Needed 3/8 nut driver
69TROUBLESHOOTING and REPAIRF-69
Alternator Stator Removal and Replacement Procedure
Perform the Alternator Rotor Removal
70TROUBLESHOOTING and REPAIRF-70
Alternator Stator Removal and Replacement
Procedure
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
Perform the Alternator Stator Removal
76TROUBLESHOOTING and REPAIRF-76
Removal and Replacement
Generator Frame
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
Generator Armature
82TROUBLESHOOTING and REPAIRF-82
Removal and Replacement Procedure
RPM
AC Auxiliary Power Receptacle Output
Current Rheostat at Maximum
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