Lincoln Electric CLASSIC 300 D PERKINS User manual

Classic®300D
Excellent for Pipelines, Construction
and Maintenance
The Classic®300D is popular throughout North America for
pipeline, construction and maintenance welding. It features
proven, simple and rugged construction, along with Lincoln’s
well-known pure DC generator design for excellent performance
on pipe. The Classic®300D is offered with a choice of 4-cylinder,
water-cooled industrial diesel engines from Perkins®and Kubota®!
The Classic®300D includes 3,000 watts of AC generator power to
run grinders and lights. CV wire welding can be added with the
optional Wire Feed Module. Also choose from several packages
available with trailers.
Processes
Stick, TI , MI (1), Flux-Cored(1), ouging
Publicati n E6.155 9/05
Web Update 3/08
www.linc lnelectric.c m
Advantage Lincoln
• Pure DC Generator Welding Output
− Produces the welding arc preferred by pipeline operators and
contractors for precise code consistency!
• All Copper Windings
− Enhances arc stability for a really smooth, high performance arc.
• Custom Arc®Dial
− Dial in the right arc, right now! Kubota®model includes 150 RPM high
idle OCV adjustment for enhanced fine tuning on pipe. (See inside)
(Not available on Perkins®model)
• Five Current Ranges with Overlap
− For stick welding and other processes where slope control is desired.
Fine-tuning within each range.
• 300 Amps Output @ 60% Duty Cycle
− Welds up to 7/32" (5.6 mm) Fleetweld®5P+, cellulosic and Excalibur®
low hydrogen electrode.
• Reliable Industrial Diesel Engines
− 4-Cylinder, water-cooled, 1800 RPM Perkins or Kubota engines run
smooth and quiet.
− Standard engine gauges allow you to monitor performance at a glance.
ENGINE DRIVEN WELDERS
TECHNICAL SPECIFICATIONS
No. HP & Dimensions Net
Product Rated Output Output Engine of peed H x W x D Weight
Name Current/Voltage/Duty Cycle Range Model Cyl. (rpm) inches (mm) lbs. (kg)
Perkins®404D-22 4 32.7 @ 1800 45.5 x 24.0 x 65.0 1354 (614)
Diesel (1156 x 610 x 1651) w/ Wire Feed
EPA Tier 4i Module1389 (630)
Classic®300D 250A DC / 30V / 100% 40-350 DC
300A DC / 32V / 60% 3000 watts Kubota®4 32.5 @ 1800 45.5 x 24.0 x 66.5 1329 (603)
V2403M Diesel (1156 x 610 x 1727) w/ Wire Feed
EPA Tier 4i Module 1364 (619)
Kub ta®mdel sh wn
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Output
Input
(1) With Wire Feed Module. Rated at 300 amps, 35 volts at 60% duty cycle, 325 amps, 34 volts at 35% duty cycle.

Classic®300D
www.linc lnelectric.c m
[2]
A CLOSER LOOK
FEATURES
• Choice of two industrial 4-cylinder, smooth-running, water-cooled
diesel engines:
– Perkins®404D-22
98.1 dB sound power (Lwa) at rated load.
– Kubota®V2403M
99.9 dB sound power (Lwa) at rated load.
• Gauges indicate oil pressure, engine temperature and battery
charging amps.
• Engine hour meter to track scheduled maintenance.
• 15 gallons (57 ltrs) fuel capacity to work an extended day
without refueling.
• Oil drain valve and tube are standard.
• Compact size for installation on truck beds.
• Local/Remote switch and recptacle are factory installed for easy
connection of the remote control.
Stick Welding
• Optional K924-5 Remote Control Kit for stick welding (for
Classic®300D codes 10911 and higher). Includes Remote Box
and 100 ft. cable. Make fine current adjustments up to 100 ft.
from the machine.
Wire Welding
• Optional Wire Feed Module for CV-wire welding. Increases pro-
ductivity and reduces welding costs. Recommended wire feeders
include LN-25 PRO or LN-15 Across-the-Arc models. Module has
14-pin connector for Lincoln wire feeders that use a control cable
with 115V AC input: LN-25, LN-23P, LN-7, LN-7 GMA and LN-8.
Built-in contactor for “cold-tip” electrode. (When CV wire welding
with optional Wire Feed Module, idler may need to be set to “high”
position for low current processes.)
• Optional K2464-1 remote control kit for stick and wire welding. For
machines that have the Wire Feed Module installed. Make output
adjustments up to 100 ft. from the machine.
“After our Local 375 school participated in the evaluation of Lincoln
Electric’s Classic®300D, the company generously donated the
machine to our facility. As an apprentice program for the Plumbers
&Pipefitters Union, we are grateful for the opportunity to use such
a high uality piece of e uipment. We especially benefit from the
Pure DC generator because it produces a superior arc. This
characteristic is ideal in pipe welding, therefore, the Classic®300D
allows us to provide our students with exemplary models for their
education.”
Bret Helms
Welding Instructor
Local 375 Plumber &Pipefitters
PERFORMANCE
Arc Performance
• Pure DC generator welding arc is preferred by pipeliners and
contractors for precise control of the arc in demanding code
applications.
• All copper windings enhance arc stability for that really smooth
high performance arc.
• Custom Arc®— Kubota®model includes 150 RPM igh Idle
(OCV) Adjustment Range — enhanced fine tuning for performance
on pipe.
• 300 amps @ 60% duty cycle. Welds with up to 7/32" (5.6 mm)
Fleetweld®5P+ cellulosic and Excalibur®low hydrogen electrode.
• Arc Gouging with up to 3/16" carbons.
Generator Performance
• 3,000 total watts of AC power from a 115V or 230V duplex
receptacle for power tools and lights.
• Circuit breaker protection. 115V AC 20 amp output will operate
up to a 9" grinder.
• Weather-protected receptacle covers.
• GFCI (Ground Fault Circuit Interrupter) 115V AC receptacles are
standard for added safety.
Use the igh Idle (OCV) engine speed adjustment dial to change the
heat input to the arc:
• Set the arc in the machine’s “sweet spot”.
• Dial in a softer or more digging arc.
• Reduce root pass internal undercut, especially on X60 and X70
pipe.
• Stack iron faster with low heat and a clear puddle on fill passes.
• Avoid arc breaks. Avoid slag that crowds the arc.
• Control fusion on the cap pass with good puddle size and clarity.
(Available on Kubota®model only.)

Classic®300D
www.linc lnelectric.c m
[3]
A CLOSER LOOK
QUALITY AND RELIABILITY
• Both engines have glow plugs for cold weather starting.
• Automatic shutdown protection for low oil pressure or high water
temperature.
• Electronic engine idler extends engine life and reduces fuel
consumption.
• Engine protection/control printed circuit board is trayed and potted
to provide a robust environmental shield.
• Single-side engine access for easy routine maintenance.
• Attractive and durable pearlescent gray finish paint.
• Three-year Lincoln warranty. (Engines warranted separately
by the manufacturers).
• Manufactured under a quality system certified to ISO 9001
requirements and ISO 14001 environmental standards.
• Approved by Canadian Standards Association (CSA).
1. Current Range Selector
2. On/Off Switch
3. Idler Control
4. Engine Protection Light
5. 230V AC Receptacles &Cover
6. 230V Circuit Breakers @ 20 Amps each
7. Engine Temperature Gauge
8. Battery Charging Ammeter
9. Engine Oil Pressure Gauge
10. CC-Stick/CV-Wire Switch
11. Local/Remote Control Wire for CV-Wire
12. CV Voltage Adjustment for Wire Welding
13. 14-Pin Wire Feeder Connector
14. Fine Current Adjustment for Stick Welding
15. Engine our Meter
16. Start Button
17. Glow Plug Button
18. Local/Remote Receptacle
19. Local/Remote Control Switch
20. 115V AC Receptacles & Cover
21. 115V Circuit Breaker @ 20 Amps
22. Custom Arc®igh Idle RPM (OCV)
Adjustment Dial (Kubota®Model only)
Key Controls
1
2
14
13
12
11
10
15
3
4
6
8
7
9
18
5
16
19
20
22
Kubota®Model Shown
with Wire Feed Module Controls
21
17
Cr ss-c untry pipe welding with Classic®300D.

Classic®300D
www.linc lnelectric.c m
[4]
A CLOSER LOOK
CLASSIC 300D MACHINE SPECIFICATIONS
Rated DC Output (1) DC Current
Product Ordering Current / Voltage / Fine Adjustment Auxiliary Dimension & Weight
Name Information Description Duty Cycle Range Power (2) H(3) x W x L lbs (kg)
Classic®300D K1643-7 300 Amp DC NEMA Ratings 40 - 350 Amps 3,000 Watts 45.5 x 24.0 x 65.0 in 1354
(Perkins®)Arc Welder 250A / 30V / 100% 60 Hz, AC (1156 x 610 x 1651mm) (614)
300A / 32V / 60% 220 - Max
K1643-8 All Copper 160 - 240 20 Amps @
w/ Wire Feed Module Windings 98V DC 120 - 190 115V 45.5 x 24.0 x 65.0 in 1389
(Perkins®)MAX OCV 80 - 130 with FCI (1156 x 610 x 1651mm) (630)
Pure DC Power Min - 90
enerator 13 Amps @
K1643-9 230V 45.5 x 24.0 x 66.5 in 1329
w/ Custom Arc®(1156 x 610 x 1727mm) (603)
(Kubota®)
K1643-10 45.5 x 24.0 x 66.5 in 1364
w/ Custom Arc®(1156 x 610 x 1727mm) (619)
&Wire Feed Module
(Kubota®)
CLASSIC®300D ENGINE SPECIFICATIONS
Engine Horsepower & Operating Fuel
Model Description Displacement Ignition Capacities peeds Consumption
Perkins®4 Cylinder 32.7 HP FUEL: FULL LOAD 1.4 als/Hr
404D-22 4 Cycle @ 1800 RPM Compression 15 als (57 Ltrs) 300A (1725 RPM) 5.2 Ltr/Hr
Diesel (4) Water-Cooled Ignited
EPA Tier 4i Diesel Engine 135.4 cu in OIL: HI H IDLE 0.4 als/Hr
Cast Iron Cylinders (2.2 ltrs) 8.5 Qts (8.0 Ltrs) 1,800 RPM 1.6 Ltr/Hr
Block/Crank Case
Mechanical overnor COOLANT: LOW IDLE 0.3 als/Hr
9.5 Qts (9.0 Ltrs) 1,400 RPM 1.1 Ltr/Hr
Kubota®4 Cylinder 32.5 HP
V2403M 4 Cycle @ 1800 RPM Compression FUEL: FULL LOAD 1.3 als/Hr
Diesel (5) Water-Cooled Ignited 15 als (57 Ltrs) 300A (1800 RPM) 5.0 Ltr/Hr
EPA Tier 4i Diesel Engine 149 cu in
Cast Iron Cylinders (2.4 ltrs.) OIL: HI H IDLE 0.5 als/Hr
Block/Crank Case 8.0 Qts (7.6 Ltrs) 1,650–1800 RPM 1.7 Ltr/Hr
Electronic overnor with custom arc dial
COOLANT: LOW IDLE 0.3 als/Hr
9.5 Qts (9.0 Ltrs) 1,400 RPM 1.1 Ltrs/Hr
(1) Based on a 10 minute period. High Altitude: Perkins®- For maximum rating, derate the output 2.5% to 3.5% for every 1,000 ft. (300 m). Kubota – for maximum rating, derate
the output 4% for every 1,000 ft (300 m) above 4,900 ft (1500 m).
(2) 115V will operate either 60 Hz, or 50/60 Hz power tools, lights, etc.
(3) Height is to top of exhaust elbow.
(4) Perkins®warranty is 2 years/2,000 hours, all components, 3 years major components. See warranty for details.
(5) Kubota®engine warranty for U.S. and Canada is 2 years/2,000 hours, 3 years major components. Some limitations exist for Canada. See warranty statement for details.

Classic®300D
www.linc lnelectric.c m
[5]
A CLOSER LOOK
SYSTEM SELECTION
One-Pak®Welding Packages
Order a Lincoln One-Pak®and get everything you need to complete
a welding package — all with one order number.
(Packages are not assembled.)
Each UNASSEMBLED Package Contains:
• Classic®300D (See Order Number Below)
• Medium Welder Trailer (K2636-1)
• Duo- itch™2" Ball/Lunette Eye itch (included)
• Fender and Light Kit (K2639-1)
• Cable Rack (K2640-1)
• Cable Connectors - two (K2487-1)
• Electrode Cable 2/0, two 50 ft. (15.3 m) lengths (K2485-2)
• Electrode Cable 2/0, 10 ft. (3 m) (K2483-2)
• Work Cable 2/0, 50 ft. (15.3 m) (K2484-2)
• 300A Electrode older (K909-7)
• 300A Work Clamp (K910-1)
Order:
K1 64-3 Classic®300D Perkins®One-Pak®Package
K23 6-3 Classic®300D Kubota®One-Pak®Package
Du -Hitch™2" Ball/Lunette Eye Hitch
(included)
K2640-1 Cable Rack
Ready-Pak®Welding Packages
Order a Lincoln Ready-Pak®and get an assembled welding package.
Each COMPLETELY ASSEMBLED Package Contains:
• Classic®300D (See Order Number Below)
• Medium Welder Trailer (K2636-1)
• Duo- itch™2" Ball/Lunette Eye itch (included)
• Fender and Light Kit (K2639-1)
• Cable Rack (K2640-1)
• Cable Connectors - two (K2487-1)
• Electrode Cable 2/0, two 50 ft. (15.3 m) lengths (K2485-2)
• Electrode Cable 2/0, 10 ft. (3 m) (K2483-2)
• Work Cable 2/0, 50 ft. (15.3 m) (K2484-2)
• 300A Electrode older (K909-7)
• 300A Work Clamp (K910-1)
Order:
K2242-3 Classic®300D Perkins®Ready-Pak®Package
K23 7-3 Classic®300D Kubota®Ready-Pak®Package
K2636-1 Medium Welder Trailer
Classic®300D
C mpletely Assembled Ready-Pak®

Classic®300D
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[6]
RECOMMENDED OPTIONS
GENERAL OPTIONS
Power Plug Kit
Provides two 115V plugs rated at
20 amps each, and two 230V plugs
rated at 15 amps each. 115V plugs
may not be compatible with
common household receptacles.
Order K 02D
Spark Arrestor Kit
Attaches to muffler exhaust tube.
Virtually eliminates spark emissions.
Order K903-1
Medium Welder Trailer
For heavy-duty road, off-road, plant
and yard use. Includes pivoting jack
stand, safety chains, and 13"
wheels. Stiff .120" welded
rectangular steel tube frame
construction is phosphate etched
and powder coat painted for
superior rust and corrosion
resistance. Low sway suspension
gives outstanding stability with
manageable tongue weight. Wheel
bearings are packed with high
viscosity, high pressure, low
washout Lubriplate®grease.
Includes a Duo- itch™–a2"
Ball/Lunette Eye combination
hitch. Overall width: 60".
Order:
K2636-1 Trailer
K2639-1 Fender &Light Kit
K2640-1 Cable Rack
Service Indicator Kit
Provides a GO/NO-GO visual
indication of air cleaner element
useful service life. Filter service
based on restriction readings allows
the longest life possible from the
filter and best engine protection.
Order K1 5 -1
Stainless Steel Sheet Metal Kit
Stainless steel roof and doors. Also
includes decals (mounted), door
latches, door hooks, bumpers and
all required mounting hardware. Fits
K6090-9 and -10 Pipeliner®200D
and K1643-1 thru -10 Classic®300D
Order K2423-1
STICK OPTIONS
Accessory Kit
For Stick welding. Includes 35 ft.
(10.7m) 2/0 electrode cable with
lug, 30 ft. (9.1m) 2/0 work cable
with lugs, headshield, filter plate,
work clamp and electrode holder.
400 amp capacity.
Order K704
Remote Control Kit
Contains remote control rheostat,
and 100 ft. (30.5m) control cable.
Order K924-5
TIG OPTIONS
PTA-26V TIG Torch
Air-Cooled 200 amp torch
equipped with valve for gas flow
control. 25 ft. length.
Order K17 3-9
Magnum®Parts Kit for PTA-26V
TIG Torch
Magnum®Parts Kit provides all the
torch accessories you need to start
welding. Parts kit provides collets,
collet bodies, a back cap, alumina
nozzles and tungstens in a variety
of sizes, all packaged in an easy to
carry reclosable pack.
Order KP509
TIG Module
Portable, high frequency unit with
gas valve for TIG welding. Rated at
300 amps/60% duty cycle.
Order K930-2
Control Cable
Connects welder and TIG Module
controls.
Order K936-4
Control Cable Extension
Allows the TIG Module to be
operated at distances up to 200 ft.
(61.9m) from the power source. 45
ft. (13.7m) length.
Order K937-45
Arc Start™Switch
Needed if an Amptrol®is not used
when TIG welding. Comes with a
25 ft. (7.6m) cable. Attaches to the
TIG torch for convenient finger
control.
Order K 14
Contactor Kit
For use with TIG Module and
Classic 300D.
Order K93 -1
Water Valve Kit
For use with a water-cooled TIG
torch. Installs inside of TIG Module.
Order K 44-1
115 Volt

Classic®300D
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[7]
RECOMMENDED OPTIONS
WIRE FEEDER OPTIONS
Wire Feed Module
Provides constant voltage (CV)
output with excellent arc stability
for Innershield welding and MIG
welding. Easy installation.
Recommended wire feeders are the
LN-25 and the LN-23P.
Order K623-1
Remote Control Kit
(Stick & Wire)
For Classic & Pipeliner machines
that have the wire feed module.
Contains a rheostat for stick
output, a potentiometer for wire
output and 100 ft. (30.5m) of
control cable.
Order K2464-1
LN-25 PRO Wire Feeder
Portable CC/CV unit for flux-cored
and MIG welding with MAXTRAC®
wire drive system. Includes Gas
Solenoid & Internal Contactor.
Requires Wire Feed Module.
Order K2613-1
Magnum®350 Innershield®Gun
(for LN-25 PRO)
For self-shielded wire with 15 ft.
(4.5 m) cable. For .062"-3/32"
(1.6-2.8 mm) wire.
Order K126-2
Drive Roll and Guide Tube Kit
(for LN-25 PRO,)
For cored or solid steel wire.
Order KP1697-06
for .068"-.072" (1.8 mm)
KP1697-5/64
for 5/64" (2.0 mm)
Magnum®300 MIG Gun
For .035"-.045" (0.9-1.2 mm)
gas-shielded wire with 15 ft.
(4.5m) cable.
LN-25 PRO
Order K1 02-1
(includes Connector Kit)
Drive Roll and Guide Tube Kit
(for LN-25 PRO)
For .035" and .045" (0.9-1.1 mm)
solid steel wire.
Order KP1696-1
WIRE FEEDER CONT.
LN-23P Wire Feeder
Portable CV unit for Innershield
pipe welding. Includes drive rolls
and guide tubes. Requires K2393-1
or -2 Input Cable Assembly and
Magnum®Innershield®Gun.
Order K316L-2
Input Cable Assembly
for LN-23P
8-socket to 14-pin control cable
with lugged electrode cable for
K316L-2 LN-23P Wire Feeder.
Order K2393-1 25 ft. (7.6 m)
K2393-1 75 ft. (22.9 m)
Magnum®350 Innershield®Gun
(for LN-23P)
Rated 350 amps, 60% duty cycle.
For .068"-5/64" (1.7-2.0 mm)
Innershield®wire and includes
reduced speed switch. Order
K345-10
Magnum®SG Spool Gun
and held semiautomatic wire
feeder. Requires SG Control
Module.
Order K4 7-25
SG Control Module
The interface between the power
source and the spool gun. Provides
control of the wire speed and gas
flow. For use with a spool gun.
Order K4
Input Cable
(For SG Control Module)
For Lincoln engine power sources
with 14-pin MS-type connection,
separate 115V NEMA receptacles
and output stud connections.
Order K691-10

THE LINCOLN ELECTRIC COMPANY®
22801 St. Clair Ave., Cleveland, O 44117-1199 • 216.481.8100 • www.lincolnelectric.com
CLASSIC®300D PERKINS®K1643-7
CLASSIC®300D PERKINS®W/ WIRE FEED MODULE K1643-
CLASSIC®300D PERKINS®ONE-PAK®K1 64-3
CLASSIC®300D PERKINS®READY-PAK®K2242-3
CLASSIC®300D KUBOTA®K1643-9
CLASSIC®300D KUBOTA®W/ WIRE FEED MODULE K1643-10
CLASSIC®300D KUBOTA®ONE-PAK®K23 6-3
CLASSIC®300D KUBOTA®READY-PAK®K23 7-3
RECOMMENDED GENERAL OPTIONS
Power Plug Kit (20 Amps) K802D
Spark Arrestor Kit K903-1
Medium Welder Trailer with Duo- itch™2" Ball/Lunette Eye itch K2636-1
-Fender & Light Kit K2639-1
- Cable Rack K2640-1
Service Indicator Kit K1858-1
Stainless Steel Sheet Metal Kit K2423-1
RECOMMENDED STICK OPTIONS
Accessory Kit K704
Remote Control Kit K924-5
RECOMMENDED TIG OPTIONS
PTA-26V Pro-Torch™TIG Torch K1783-9
Magnum®TIG Torch Parts Kit KP509
TIG Module K930-2
Control Cable (required) K936-4
Control Cable Extension K937-45
Arc Start™Switch (required) K814
Contactor Kit (required) K938-1
Water Valve Kit K844-1
RECOMMENDED WIRE FEEDER OPTIONS
Wire Feed Module K623-1
LN-25 PRO Wire Feeder K2613-1
Remote Control Kit K2464-1
Magnum®350 Innershield®Welding Gun K126-2
Drive Roll and Guide Tube Kit, .068"-.072" (for LN-25 PRO) KP1697-068
Drive Roll and Guide Tube Kit, 5/64" (for LN-25 PRO) KP1697-5/64
Magnum®300 MIG Gun — for LN-25 PRO (includes Connector Kit) K1802-1
Drive Roll and Guide Tube Kit (for LN-25 PRO) KP1696-1
LN-23P Wire Feeder K316L-2
- Input Cable Assembly, 25 ft. (7.6 m) K2393-1
- Input Cable Assembly, 50 ft. (15.2 m) K2393-2
Magnum®350 Innershield®Welding Gun K345-10
Magnum®SG Spool Gun K487-25
- SG Control Module K488
- Input Cable (for SG Control Module) K691-10
TOTAL:
PRODUCT DESCRIPTION ORDER NUMBER QUANTITY PRICE
CLASSIC®300D ORDER FORM
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. On occasion, purchasers may ask Lincoln Electric for information or advice about their use of our products. Our employees respond to
inquiries to the best of their ability based on information provided to them by the customers and the knowledge they may have concerning the application. Our employees, however, are not
in a position to verify the information provided or to evaluate the engineering requirements for the particular weldment. Accordingly, Lincoln Electric does not warrant or guarantee or assume
any liability with respect to such information or advice. Moreover, the provision of such information or advice does not create, expand, or alter any warranty on our products. Any express or
implied warranty that might arise from the information or advice, including any implied warranty of merchantability or any warranty of fitness for any customers’ particular purpose is
specifically disclaimed.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the
customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.