D300K 33 Operators Manual NEW

RED-D-ARC D300K 3+3

IM663-EJune, 2011

Red-D-Arc Spec-Built Welding EquipmentThis RED-D-ARC welder is built to RED-D-ARC Extreme Dutydesign specifications by Lincoln Electric.

Safety Depends on YouThis welder is designed and built with safety in mind.However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.And, most importantly, think before you act and be careful.

For use with machines having Code Numbers: 10567; 10956; 11214; 11488; 11549

The Global Leader in Welder Rentals

OPERATOR’S MANUAL

(

North America’s Largest Fleet of Welding Equipment

1-800-245-3660

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes outdoors.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing and

tools away from V-belts, gears, fans and all other moving

parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

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 the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

bE SuRE ThAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDuRES AREPERFORMED ONLY bY QuALIFIED INDIVIDuALS.

WARNING

ELECTRIC AND MAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes

localized Electric and Magnetic Fields (EMF). Welding

current creates EMF fields around welding cables and

welding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right

side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.3.a. The electrode and work (or ground) circuits

are electrically “hot” when the welder is on.Do not touch these “hot” parts with your bareskin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanicalventilation. In confined spaces or in some circum-stances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.

5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.d. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.f. Also see item 1.b.

iiiSAFETYiii

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:•Away from areas where they may be struck or subjected tophysical damage.

•A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.

Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work”, availablefrom NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

ivSAFETYiv

PRÉCAuTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructions

et les précautions de sûreté specifiques qui parraissent dans ce

manuel aussi bien que les précautions de sûreté générales suiv-

antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue

ou les vétements mouillés. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher

metallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande

partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état

defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder

parce que la tension entre les deux pinces peut être le

total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-électrode s’applicuent aussi au pistolet de

soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de n’importe quelle partie

du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray-

onnement de l’arc et des projections quand on soude ou

quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de

l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de

soudage. Se protéger avec des vêtements de protection libres

de l’huile, tels que les gants en cuir, chemise épaisse, pan-

talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de

la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible

de la zone de travail qu’il est pratique de le faire. Si on place

la masse sur la charpente de la construction ou d’autres

endroits éloignés de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, câbles de grue, ou autres circuits. Cela peut provoquer

des risques d’incendie ou d’echauffement des chaines et des

câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles

galvanisées plombées, ou cadmiées ou tout autre métal qui

produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant

d’opérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs

du solvant pour produire du phosgéne (gas fortement toxique)

ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,

voir le code “Code for safety in welding and cutting” CSA

Standard W 117.2-1974.

PRÉCAuTIONS DE SÛRETÉ POuRLES MAChINES À SOuDER ÀTRANSFORMATEuR ET ÀREDRESSEuR

1. Relier à la terre le chassis du poste conformement au code de

l’électricité et aux recommendations du fabricant. Le dispositif

de montage ou la piece à souder doit être branché à une

bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront

effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-

er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur

place.

vv

Thank You for selecting one of our QuALITY products. We want you to takepride in operating this product ••• as much pride as we have inbringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

CAuTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code (if available)______________________________________________________

Serial Number (if available)__________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above.

CuSTOMER ASSISTANCE POLICYThe business of our company is manufacturing and selling high quality welding equipment. Our challenge is tomeet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us foradvice or information about their use of our products. We respond to our customers based on the best informa-tion in our possession at that time. We are not in a position to warrant or guarantee such advice, and assume noliability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including anywarranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matterof practical consideration, we also cannot assume any responsibility for updating or correcting any such informa-tion or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty with respect to the sale of our products.

We are a responsive manufacturer, but the selection and use of specific products sold by us is solely within thecontrol of, and remains the sole responsibility of the customer. Many variables beyond our control affect theresults 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.

vi vi TAbLE OF CONTENTSPage

Installation .......................................................................................................Section ATechnical Specifications ........................................................................................A-1General Description ...............................................................................................A-2Design Features ....................................................................................................A-2Pre-Operation Installation ......................................................................................A-3

Safety Precautions ..........................................................................................A-3Exhaust Spark Arrester ...................................................................................A-3Location/Ventilation.........................................................................................A-3Machine Grounding.........................................................................................A-3Lift Bail ............................................................................................................A-3Trailers ............................................................................................................A-4Polarity Control and Cable Sizes ....................................................................A-4

Pre-Operation Service ...........................................................................................A-5Oil ....................................................................................................................A-5Fuel, Cooling System ......................................................................................A-5Battery Charging .............................................................................................A-5

________________________________________________________________________

Operation .........................................................................................................Section bEngine Operation...................................................................................................B-1

Safety Warnings..............................................................................................B-1Starting The Kubota Engine ............................................................................B-1Stopping the engine ........................................................................................B-1Break In Period ...............................................................................................B-2

Welder Operation...................................................................................................B-2Duty Cycle.......................................................................................................B-2Control of Welding Current..............................................................................B-2Auxiliary Power ...............................................................................................B-3

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Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1General Instructions ..............................................................................................D-1Cooling System .....................................................................................................D-1Bearings ................................................................................................................D-1Commutator and Brushes .....................................................................................D-1Slip Rings ..............................................................................................................D-2Battery ...................................................................................................................D-2Hardware...............................................................................................................D-2Nameplates ...........................................................................................................D-2Purging Air from Fuel System................................................................................D-2Engine Service Chart..............................................................................D-3, D-4,D-5GFCI Receptacle Testing and Resetting Procedure ....................................................D-6

________________________________________________________________________

Troubleshooting ..............................................................................................Section ESafety Precautions.................................................................................................E-1Welder Troubleshooting.................................................................................E-2, E-3Engine Troubleshooting Guide .....................................................................E-4, E-5

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Diagrams ..........................................................................................................Section FWiring Diagram ......................................................................................F-1, F-2, F-3

________________________________________________________________________

Parts Lists ...................................................................................................P-485 Series________________________________________________________________________

A-1INSTALLATION

D300K 3+3

A-1

TEChNICAL SPECIFICATIONS - Red-D-Arc D300K 3+3

Make/Model Description Speed (RPM) Displacement Starting CapacitiesSystem

Kubota 4 cylinder 113.6 cu. in Fuel: 15 gal.V1902BG1-RDA-1 33 HP @ (1861 cc) 57 LCODE: 10567 2800 RPM

4 Cycle bore x Stroke Oil: 9.5 Qts.Water Cooled 9.0 LDiesel Engine 3.35” x 3.23” Engine Coolant:

(85 mm x 82 mm) 1.2 gal.4.5 L

Kubota 4 cylinder 113.3 cu. in Fuel: 15 gal.V1903 26 HP @ (1857 cc) 57 LCODES 10956 1800 RPM High Idle 1800 12VDC

11214 4 Cycle Full Load 1700 bore x Stroke Battery Oil: 10.2 Qts.Water Cooled 9.7 LDiesel Engine 3.15” x 3.64” Engine Coolant:

(80 mm x 92 mm) 9.5 Qts.9.0 L

INPuT - ENGINE

RATED OuTPuT - WELDER

hEIGhT WIDTh DEPTh WEIGhT

40.94 in. 24.0 in. 65.0 in. 1354 lbs.

1040 mm 610 mm 1651 mm 616 kg.

OuTPuT - GENERATOR

Welding Output Volts at Rated Amps Duty Cycle1 Max. OCV @ 1800 RPM

250 Amps 40 volts 60% 98 volts DC

Auxiliary Power 2

3,000 Watts, 60 Hz120 Volts AC

100 % Duty Cycle

PhYSICAL DIMENSIONS

1. Duty cycle is based on a 10 minute period. This machine can be loaded to 250 amps for 6 minutes out of every 10 minuteperiod.

2. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up torated capacity. When welding, available auxiliary power will be reduced.

KubotaV2003-M-E3BG-RDACODES 11488

11549

4 Cylinder29.2 HP @1800 RPM4 CycleWater CooledDiesel Engine

121.9cu. in.(1998 cc)

Bore x Stroke3.27 x 3.64(83mm x 92mm)

Fuel: 15gal.(57L)

Fuel: 16gal.(60.6L)

Oil: 8.04qts.(7.6L)

Engine Coolant: 9.5qts.(9.0L)

LIFT bAIL WEIGhT RATING 2000 LbS. (907KG.) MAxIMuM

Code 11488

Code 11549

A-2INSTALLATION

D300K 3+3

A-2

GENERAL DESCRIPTION

The D300K 3+3 is a heavy duty, engine driven, DCarc welding power source, capable of providing con-stant current output for stick welding or DC TIG weld-ing. This welder is wound with all copper coils, ratedat 250 amps / 40 Volts, and provides other featuressuch as improved door latches and stainless hinges.

The D300K 3+3 has Diesel Engine Protection. In theevent of sudden low oil pressure or high coolant tem-perature, the engine immediately shuts down. TheD300K 3+3 has a current range of 40-325 DC amps.

This unit is also capable of providing 3 kVA of 120volts of 60 hertz AC auxiliary power.

DESIGN FEATuRES

Control Panel

Both the engine and the welder controls are locatedon one recessed panel at the exciter end of themachine. The welder controls consist of a five step“Current Range Selector” switch and a “Fine CurrentAdjustment” rheostat. The welder is equipped with a“Start” and “Glow Plug” switch for easier cold weatherstarting and a “Stop” (pull knob).

The control panel for Code 10567 contains a batterycharging ammeter, one three prong duplex groundingtype receptacle and two circuit breakers for auxiliarypower.

The control panel for Codes 10956, 11214, 11488 and11549 contains a battery charging ammeter, GFCIreceptacle and one circuit breaker for auxiliary power.If a GFCI receptacle is tripped, See the MAINTE-NANCE section for detailed information on testing andresetting the GFCI receptacle.

All Copper Windings - For long life and dependableoperation.

Auxiliary Power - 3.0 kVA of nominal 120V, 60Hz,AC. Output voltage is maintained within ± 10% at allloads up to rated capacity.

Welder Enclosure - The complete welder is rubbermounted on a rugged steel “C” channel base.

The output terminals are placed at the side of themachines so that they are protected by the door. Theoutput terminals are labeled (+) and (-).

Cranking System - A 12 volt electric starter is stan-dard.

Air Cleaner - Heavy duty two stage dry type.

Muffler - A muffler and exhaust outlet elbow are stan-dard.

Engine hour Meter - A meter to record hours of oper-ation.

Engine Protection - The system shuts the enginedown in the event of sudden low oil pressure or highcoolant temperature.

Fuel Consumption - Fuel consumption has beenoptimized by means of careful design of the combus-tion chamber, fuel feed and injection system andcross-flow cylinder heads. In order to enhancelongevity of the engine, the engine turns at a constant1800 RPM and no engine idler is used.

As a result, there is no waiting time for the welder toachieve operating speed when striking an arc.

Fuel consumption figures at average operating loadsare as follows:

Tank Capacity: 15 gallons, (57 L) Metal Tank or16 gallons, (60.6L) Plastic Tank.

Fuel Consumption: 0.44 gallons/hr, (1.65 L/hr)

Operating Interval: 35 hours per tank

250A @ 40V 60%

RATED OuTPuT DuTY CYCLE

A-3INSTALLATION

D300K 3+3

A-3

PRE-OPERATION INSTALLATION

Exhaust Spark ArresterSome federal, state or local laws may require thatengines be equipped with exhaust spark arresterswhen they are operated in certain locations whereunarrested sparks may present a fire hazard. Thestandard muffler included with this welder does notqualify as a spark arrester. When required by localregulations, a suitable spark arrester must be installedand properly maintained.

use of an incorrect arrester may lead to engine dam-age or performance loss. Contact the engine manu-facturer for specific recommendations.------------------------------------------------------------------------

Location / Ventilation

Always operate the welder with the doors closed.Leaving the doors open changes the designed air flowand may cause overheating.

The welder should be located to provide an unrestrict-ed flow of clean, cool air. Also, locate the welder sothat engine exhaust fumes are properly vented to anoutside area.

Machine Grounding

According to the United States National ElectricalCode, the frame of this portable generator is notrequired to be grounded and is permitted to serve asthe grounding means for cord connected equipmentplugged into its receptacle.

Some state, local, or other codes or unusual operatingcircumstances may require the machine frame to begrounded. It is recommended that you determine theextent to which such requirements may apply to yourparticular situation and follow them explicitly. Amachine grounding stud marked with the symbol isprovided on the welding generator frame foot. In gen-eral, if the machine is to be grounded, it should beconnected with a #8 or larger copper wire to a solidearth ground such as a metal water pipe going intothe ground for at least ten feet and having no insulat-ed joints, or to the metal framework of a buildingwhich has been effectively grounded. The U.S.National Code lists a number of alternate means ofgrounding electrical equipment.

Lift bail

A lift bail is provided for lifting with a hoist.

Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.------------------------------------------------------------------------

ELECTRIC ShOCK can kill.• Do not touch electrically live parts orelectrode with skin or wet clothing.• Insulate yourself from work andground• Always wear dry insulating gloves.

------------------------------------------------------------------------ENGINE ExhAuST can kill.• use in open, well ventilated areas orvent exhaust outside.

------------------------------------------------------------------------MOVING PARTS can injure.• Do not operate with doors open orguards off.• Stop engine before servicing.• Keep away from moving parts.

------------------------------------------------------------------------See additional warning information at thefront of this operator’s manual.------------------------------------------------------------

WARNING

CAuTION

• Lift only with equipment ofadequate lifting capacity.

• be sure machine is stablewhen lifting.

• Do not lift this machine usinglift bail if it is equipped with agas cylinder.

FALLING • Do not lift machine if lift bail is

EQuIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

• DO NOT ExCEED MAxIMuM LIFT bAIL WEIGhTRATING.

( SEE TEChNICAL SPECIFICATIONS PAGE)

------------------------------------------------------------------------

WARNING

A-4INSTALLATION

D300K 3+3

A-4

TrailerIf the user adapts a trailer, he must assume responsi-bility that the method of attachment and usage doesnot result in a safety hazard nor damage the weldingequipment. Some of the factors to be considered areas follows:

1. Design capacity of trailer vs. weight of equipmentand likely additional attachments.

2. Proper support of, and attachment to, the base ofthe welding equipment so there will be no unduestress to the framework.

3. Proper placement of the equipment on the trailer toensure stability side to side and front to back whenbeing moved and when standing by itself whilebeing operated or serviced.

4. Typical conditions of use, i.e., travel speed, rough-ness of surface on which the trailer will be operat-ed; environmental conditions, likely maintenance.

5. Conformance with federal, state and local laws. (1)

(1) Consult applicable federal, state and local laws regarding specificrequirements for use on public highways.

RECOMMENDED COPPER CAbLE SIzESCables Sizes for Combined Lengthof Electrode Plus Work Cable

Amps Duty Cycle up to 200 ft. 200 to 250 ft.

250 60% 1 1/0

VEhICLE MOuNTING

Improperly mounted concentrated loads maycause unstable vehicle handling and tires or othercomponents to fail.

• Only transport this Equipment on serviceablevehicles which are rated and designed for suchloads.

• Distribute, balance and secure loads so vehicleis stable under conditions of use.

• Do not exceed maximum rated loads for compo-nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame ofvehicle.

• Follow vehicle manufacturer’s instructions.------------------------------------------------------------------------

Polarity Control and Cable Sizes

With the engine off, route the electrode and workcables and connect to the studs located below the fueltank mounting rail. (See size recommendationsbelow.) For positive polarity, connect the electrodecable to the terminal marked “+”. For Negative polari-ty, connect the electrode cable to the “-” stud. Theseconnections should be checked periodically and tight-ened if necessary.

When welding at a considerable distance from thewelder, be sure you use ample size welding cables.

WARNING

A-5INSTALLATION

D300K 3+3

A-5

PRE-OPERATION SERVICE

READ the engine operating and maintenanceinstructions supplied with this machine.

Oil

This unit is supplied from the factory with the enginecrankcase filled with a high quality SAE 10W/30 oil.This oil should be acceptable for most typical ambienttemperatures. Consult the engine operation manualfor specific engine manufacturer’s recommendations.Upon receipt of the welder, check the engine dipstickto be sure the oil is at the “full” mark. DO NOT overfill.

Fuel

Fill the fuel tank with the grade of fuel recommendedin the Engine Operator’s manual. Make sure the fuelvalve on the sediment bowl is in the open position, forCodes 10950 and below.

Cooling System

The radiator has been filled at the factory with a 50-50mixture of ethylene glycol antifreeze and water.Check the radiator level and add a 50-50 solution asneeded (see engine manual or antifreeze container foralternate antifreeze recommendations).

bATTERY ChARGING

The D300K 3+3 is equipped with a wet charged bat-tery. The charging current is automatically regulatedwhen the battery is low (after starting the engine) to atrickle current when the battery is fully charged.

When replacing, jumping or otherwise connecting thebattery to the battery cables, the proper polarity mustbe observed. This system is NEGATIVE GROuND.

CAuTIONGASES FROM bATTERY can explode.• Keep sparks, flame and cigarettes

away.

bATTERY ACID can burn eyes andskin.• Wear gloves and eye protection and

be careful when boosting, chargingor working near battery.

To prevent ExPLOSION when:a) Installing a new battery - disconnect the negative

cable from the old battery first and connect thenegative cable to the new battery last.

b) Connecting a battery charger - remove the batteryfrom the welder by disconnecting the negativecable first, then the positive cable and batteryclamp. When reinstalling, connect the negativecable last.

c) Using a booster - connect the positive lead to thebattery first, then connect the negative lead to theground lead on the base.

To prevent ELECTRICAL DAMAGE when:a) Installing a new battery.b) Using a booster.

Use correct polarity - Negative Ground.

• To prevent BATTERY DISCHARGE, if you have anignition switch, turn it off when engine is not running.

• To prevent BATTERY BUCKLING, tighten nuts onbattery clamp until snug.

------------------------------------------------------------------------

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from

tank.

• Do not leave unattended while fuel-

ing.

• Wipe up spilled fuel and allow

fumes to clear before starting

engine.

• Do not overfill tank, fuel expansion

may cause overflow.DIESEL FuEL ONLY-Low sulphur fuel or ultra lowsulphur fuel in u.S.A. and Canada.------------------------------------------------------------------------

WARNING

DIESEL FuELcan cause fire.

b-1OPERATION

D300K 3+3

b-1

ENGINE OPERATION

Operate the welder with the doors closed. Leavingthe doors open changes the designed air flow and cancause overheating.

Starting the D300K 3+3 with KubotaDiesel Engine

Refer to the Welder Nameplate for starting instruc-tions.

The D300K 3+3’s engine is equipped with GLOWPLuGS. The GLOW PLuGS should always be usedto help start Kubota diesel engines. Follow the tablebelow for approximate GLOW PLuG on times to beused prior to attempted starting:

For Code 10567Temperature GLOW PLUGS ON time

Above 32ºF (0ºC) 15 sec.32ºF to -13ºF (0ºC to -25ºC) 30 sec.

Below -13ºF (-25ºC) 45 sec.

Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.------------------------------------------------------------------------

ELECTRIC ShOCK can kill.• Do not touch electrically live parts orelectrode with skin or wet clothing.• Insulate yourself from work andground• Always wear dry insulating gloves.

------------------------------------------------------------------------ENGINE ExhAuST can kill.• use in open, well ventilated areas orvent exhaust outside.

------------------------------------------------------------------------MOVING PARTS can injure.• Do not operate with doors open orguards off.• Stop engine before servicing.• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at thefront of this operator’s manual.

-----------------------------------------------------------

WARNING

For Codes 10956, 11214, 11488, 11549Temperature GLOW PLUGS ON time

Above 32ºF (0ºC) 3.0 sec.

Below 5ºF (-15ºC) 5.0 sec.

Note: Extreme cold weather starting may requirelonger glow plug operation as well as engine oil andcoolant heating (using a block heater).

under NO conditions should ether or otherstarting fluids be used!------------------------------------------------------------------------

Stopping the Engine

1. Pull the “STOP” knob out and hold it out until theengine stops completely.

At the end of each day’s welding, check the crankcaseoil level, drain accumulated dirt and water from thesediment bowl under the fuel tank for Codes 10956and below and refill the fuel tank to minimize moisturecondensation in the tank. Also, running out of fueltends to draw dirt into the fuel system.

When hauling the welder between job sites, close thefuel feed valve beneath the fuel tank for Codes 11214,11488 and 11549.

If the fuel supply is cut off or runs out while the fuelpump is operating, air may be entrapped in the fueldistribution system. If this happens, bleeding of thefuel system may be necessary. Use qualified person-nel to do this per the instructions in the MAINTE-NANCE section of this manual.

WARNING

b-2OPERATIONb-2

WELDER OPERATION

Duty Cycle

The output rating of the D300K 3+3 is 250 amperes at40 arc volts on a 60% duty cycle. Duty cycle is basedon a ten minute period; thus, the welder can beloaded at rated output for six minutes out of every tenminute period.

Control of Welding Current

DO NOT TuRN ThE “CuRRENT RANGE SELEC-TOR” WhILE WELDING because the current mayarc between the contacts and damage the switch.------------------------------------------------------------------------

The “Current Range Selector” provides five overlap-ping current ranges. The “Fine Current Adjustment”adjusts the current from minimum to maximum withineach range. Open circuit voltage is also controlled bythe “Fine Current Adjustment” permitting control of thearc characteristics.

A high open circuit voltage setting provides the soft“buttering” arc with best resistance to pop-outs pre-ferred for most welding. To get this characteristic, setthe “Current Range Selector” to the lowest setting thatstill provides the current you need and set the “FineCurrent Adjustment” near maximum. For example: toobtain 175 amps and a soft arc, set the “Current

ELECTRIC ShOCK can kill.• Do not touch electrically live parts or

electrode with skin or wet clothing.• Insulate yourself from work and ground.

FuMES & GASES can be dangerous.• Keep your head out of the fumes.• use ventilation or exhaust to remove

fumes from breathing zone.

WELDING SPARKS can cause fire orexplosion.• Keep flammable material away.

ARC RAYS can burn.• Wear eye, ear, and body protection.

WARNING

CAuTION

D300K 3+3

bREAK-IN PERIOD

Lincoln Electric selects high quality, heavy-duty indus-trial engines for the portable welding machines weoffer. While it is normal to see a small amount ofcrankcase oil consumption during initial operation,excessive oil use, wet stacking (oil or tar like sub-stance at the exhaust port), or excessive smoke is notnormal.

Larger machines with a capacity of 350 amperes andhigher, which are operated at low or no-load condi-tions for extended periods of time are especially sus-ceptible to the conditions described above. Toaccomplish successful engine break-in, most diesel-powered equipment needs only to be run at a reason-ably heavy load within the rating of the welder forsome period of time during the engine’s early life.However, if the welder is subjected to extensive lightloading, occasional moderate to heavy loading of theengine may sometimes be necessary. Caution mustbe observed in correctly loading a diesel/generatorunit.

1. Connect the welder output studs to a suitableresistive load bank. Note that any attempt to shortthe output studs by connecting the welding leadstogether, direct shorting of the output studs, or con-necting the output leads to a length of steel willresult in catastrophic damage to the generator andvoids the warranty.

2. Set the welder controls for an output current andvoltage within the welder rating and duty cycle.Note that any attempt to exceed the welder ratingor duty cycle for any period of time will result in cat-astrophic damage to the generator and voids thewarranty.

3. Periodically shut off the engine and check thecrankcase oil level.

Range Selector” to the 190-120 position and thenadjust the “Fine Current Adjustment” for 175 amps.

When a forceful “digging” arc is required, usually forvertical and overhead welding, use a higher “CurrentRange Selector” setting and lower open circuit volt-age. For example: to obtain 175 amps and a forcefularc, set the “Current Range Selector” to the 240-160position and the “Fine Current Adjustment” setting toget 175 amps.

Some arc instability may be experienced with EXX10electrodes when trying to operate with long arc tech-niques at settings at the lower end of the open circuitvoltage range.

DO NOT attempt to set the “Current Range Selector”between the five points designated on the nameplate.------------------------------------------------------------------------These switches have a spring loaded cam whichalmost eliminates the possibility of setting this switchbetween the designated points.

Auxiliary Power

The AC auxiliary power, supplied as standard, has arating of 3.0 kVA of 120 VAC (60 hertz).

With the 3.0 kVA, 120 VAC auxiliary power for Code10567, one 120V duplex grounding type receptacle isprovided. The circuit is protected with circuit breakers.Codes 10956, 11214, 11488 and 11549 uses oneGFCI with breaker.

The rating of 3.0 kVA permits a maximum continuouscurrent of 26 amps that can be drawn from the 120volt duplex receptacle. The 120 volt duplex receptacleor GFCI has a configuration which permits 20 amps tobe drawn from either half. The total combined load ofthe duplex receptacle or GFCI is not to exceed 3.0kVA.

If a GFCI receptacle is tripped, See the MAINTE-NANCE section for detailed information on testing andresetting the GFCI receptacle.

b-3OPERATIONb-3

CAuTION

D300K 3+3

If auxiliary power is used simultaneously with weld-ing, the current which can be used while maintainingvoltage regulation within 10% is as follows:

Welding Using TotalCurrent Amps 120V Auxiliary

(@ NEMA Circuit, Amps KVAArc Volts)

0 26 3.0100 16 1.8150 15 1.7200 15 1.7250 14 1.6

General Instructions

1. Blow out the welder and controls with an air hoseat least once every two months. In particularlydirty locations, this cleaning may be necessaryonce a week. Use low pressure air to avoid drivingdirt into the insulation.

2. ”Current Range Selector” contacts should not begreased. To keep the contacts clean, rotate thecurrent control through its entire range frequently.Good practice is to turn the handle from maximumto minimum setting twice each morning beforestarting to weld.

3. Put a drop of oil on the “Current Range Selector”shaft at least once every month.

D-1MAINTENANCED-1

D300K 3+3

SAFETY PRECAuTIONS

have qualified personnel do the maintenancework. Turn the engine off before working insidethe machine. In some cases, it may benecessary to remove safety guards to performrequired maintenance. Remove guards onlywhen necessary and replace them when themaintenance requiring their removal iscomplete. Always use the greatest care whenworking near moving parts.

Do not put your hands near any rotating parts. Ifa problem cannot be corrected by following theinstructions, take the machine to the nearestRed-D-Arc location.

-----------------------------------------------------------------------ELECTRIC ShOCK can kill.• Do not touch electrically live parts or

electrode with skin or wet clothing.• Insulate yourself from work and

ground• Always wear dry insulating gloves.

------------------------------------------------------------------------ENGINE ExhAuST can kill.• use in open, well ventilated areas or

vent exhaust outside.

------------------------------------------------------------------------MOVING PARTS can injure.• Do not operate with enclosure or

guards off.• Stop engine before servicing.• Keep away from moving parts.

------------------------------------------------------------------------See additional warning informationthroughout this operator’s manual andthe Engine manual as well.

-----------------------------------------------------------

WARNING

4. When necessary, remove the sediment bowl, if so equipped,from beneath the fuel tank and clean out any accumulateddirt and water.

5. Follow the engine service schedule in this manual and thedetailed maintenance and troubleshooting in the enginemanufacturer’s manual.

Cooling System

The D300K 3+3 is equipped with a pressure radiator. Keep theradiator cap tight to prevent loss of coolant. Clean and flush thecooling system periodically to prevent clogging the passageand overheating the engine. When antifreeze is needed, alwaysuse the permanent type. Code 10567 Capacity = 1.2 qts (4.5Ltrs.). Codes 10956, 11214, 11488, 11549 Capacity = 9.5 qts(9.0 Ltrs.).

bearings

This welder is equipped with a double-shielded ball bearinghaving sufficient grease to last indefinitely under normal ser-vice. Where the welder is used constantly or in excessively dirtylocations, it may be necessary to add one half ounce of greaseper year. A pad of grease one inch wide, one inch long, andone inch high weighs approximately one half ounce. Over-greasing is far worse than insufficient greasing.

When greasing the bearings, keep all dirt out of the area. Wipethe fittings completely clean and use clean equipment. Morebearing failures are caused by dirt introduced during greasingthan from insufficient grease.

Commutator and brushes

uncovered rotating equipment can be dangerous. usecare so your hands, hair, clothing or tools do not catch inthe rotating parts. Protect yourself from particles that maybe thrown out by the rotating armature when stoning thecommutator.------------------------------------------------------------------------------------

Shifting of the commutator brushes may result in:- Change in machine output- Commutator damage- Excessive brush wear

Periodically inspect the commutator, slip rings, and brushes byremoving the covers. DO NOT remove or replace these coverswhile the machine is running.Commutators and slip rings require little attention. However, ifthey are black or appear uneven, have them cleaned by anexperienced maintenance man using fine sandpaper or a commutator stone. Never use emerycloth or paper for this purpose.

Replace brushes when they wear within 1/4” of the pigtail. Acomplete set of replacement brushes should be kept on hand.

WARNING

D-2MAINTENANCED-2

1. When replacing, jumping, or otherwise connectingthe battery to the battery cables, the proper polaritymust be observed. Failure to observe the properpolarity could result in damage to the charging cir-cuit. The positive (+) battery cable has a red terminalcover.

2. If the battery requires charging from an externalcharger, disconnect the negative battery cable firstand then the positive battery cable before attachingthe charger leads. Failure to do so can result indamage to the internal charger components. Whenre-connecting the cables, connect the positive cablefirst and the negative cable last.

hardware

Both English and Metric fasteners are used in thiswelder.

Nameplates

Whenever routine maintenance is performed on thismachine - or at least yearly - inspect all nameplates andlabels for legibility. Replace those which are no longerclear. Refer to the parts list for the replacement itemnumber.

Purging Air from the Fuel System

Keep fuel clear of open flames or arcs, allow engineto cool before working on the fuel system. Wipe upany spilled fuel and do not start engine until fumesclear.------------------------------------------------------------------------If the engine is running rough and you suspect air hasbeen trapped in the fuel system, (EG. the engine wasallowed to run out of fuel) perform the following stepsusing qualified personnel:

1. Verify that there is sufficient fuel in the fuel tank.(Minimum of .50” of fuel).

2. If equipped with a fuel sediment bowl be sure that thevalve is open. (located on underside of fuel tank).

3. Open the air bleed screw on the fuel injection pump.Using the starter, crank the engine until engine starts.(use pre-heat if needed. DO NOT CRANK STARTERFOR MORE ThAN 1 MINuTE OuT OF 5 MINuTES.

4. Close air bleed screw when fuel is observed returningto the fuel tank. (Remove fuel cap to observe).

GASES FROM bATTERY can explode.• Keep sparks, flame and cigarettes away

from battery.

To prevent ExPLOSION when:• INSTALLING A NEW bATTERY - discon-

nect negative cable from old battery firstand connect to new battery last.

• CONNECTING A bATTERY ChARGER - Remove bat-tery from welder by disconnecting negative cablefirst, then positive cable and battery clamp. Whenreinstalling, connect negative cable last. Keep wellventilated.

• uSING A bOOSTER - connect positive lead to batteryfirst then connect negative lead to engine foot.

bATTERY ACID CAN buRN EYES ANDSKIN.• Wear gloves and eye protection and be

careful when working near battery.Follow instructions printed on battery.

--------------------------------------------------------------------------------

WARNING

Slip Rings

A slight amount of darkening and wear of the slip ringsand brushes is normal. Brushes should be inspectedwhen a general overhaul is necessary. If brushes areto be replaced, clean slip rings with a fine emerypaper.

Do not attempt to polish slip rings while engine isrunning.------------------------------------------------------------------------To seat slip ring brushes, position the brushes inplace. Then slide one end of a piece of fine sandpa-per between slip rings and brushes with the coarseside against the brushes. With slight additional fingerpressure on top of the brushes, pull the sandpaperaround the circumference of the rings - in direction ofrotation only - until brushes seat properly. In addition,stone slip ring with a fine stone. Brushes must beseated 100%.

battery

CAuTION

Have an experienced maintenance man seat thesebrushes by lightly stoning the commutator as thearmature rotates at full speed until contact is madeacross the full face of the brushes. After stoning, blowout the dust with low pressure air.

Arcing or excessive exciter brush wear indicates apossible misaligned shaft. Have an authorizedService Shop check and realign the shaft.

WARNING

D300K 3+3

D-3MAINTENANCED-3

I

EVERY 400 HOURS OR 12 MONTHSEVERY 200 HOURS OR 6 MONTHS

EVERY 100 HOURS OR 3 MONTHSFIRST SERVICE (50 HOURS)

EVERY DAY OR EVERY 8 HOURS

If necessary use shorter periods.These preventive maintenance periods apply to average conditions of operation.

Kubota- old 70000-3450-0, new 70000-4308-0

TYPE OR QUANTITY

Above operations to be carried out by trained personnel with reference to the workshop manual where necessary.

Red-D-Arc N&RFN700, Kubota 15521-3243-0, Fram PH43, Krawlinator L16

(3) Fill slowly! Ensure correct quantity is used.(4) To remove the air filter element for cleaning or replacement, the filter canister must be moved rearward toward the radiator in order to provide clearance with the fuel tank. This is accomplished by disconnecting the rubber canister straps and inlet pipe clamps. The air cleaner cover can then be removed and the element taken out.

9.5 qrts, (9.0 L)

(2) Consult Engine Operators Manual for additional maintenance schedule information.

4.7 qrts, (4.5 L)

(1) Consult Engine Operators Manual for oil recommendations.NOTES:

Alternator drive belt Kubota- 15469-9701-2, Mitsubishi- REMF-6410Alternator drive belt wear

R

Tension of alternator drive beltI

Drain water separator & fuel strainer

Engine oil (NOTE 1 & 3)

R

Engine oil level (NOTE 1)Coolant (NOTE 3)

MAINTENANCE ITEM

Concentration of antifreeze 50/50 Water/Ethylene Glycol

C

I

R

Coolant level

RRRR

I

ENGINE SERVICE

I

EVERY 600 HOURS OR 18 MONTHS

Fuel filter canister

Kubota- 70000-1108-0, Fram-CAK253, Donaldson-P11-9775

R = ReplaceC = Clean

BatteryLeaks or engine damage

I

Injector performanceAll nuts and bolts for tightness

I = Inspect

Electrical systems

II

Valve clearancesI

Tighten cylinder head

I

I

Check and adjust idle speedI

Air filter element (NOTE 4)Air filter (earlier check may be req'd.) (NOTE 4)

RI

CC

Engine oil filter

ENGINE SERVICE (NOTE 2)

V1902 ENGINEMACHINE CODE 10567

D300K 3+3

D-4MAINTENANCED-4

I





Kubota- 16631-43562

Kubota- 16414-32432

TYPE OR QUANTITY



10.2 qrts, (9.7 L)


3.9 qrts, (3.7 L)


Alternator drive belt Kubota- 15469-97012Alternator drive belt wear

R


Drain water separator & fuel strainer Kubota- 15831-43353


R


MAINTENANCE ITEM


C

I

R

Coolant level

RRRR

I

ENGINE SERVICE

I



Donaldson- P821575



I


I = Inspect

Electrical systems

II

Valve clearancesI


I

I



RI

CC

Engine oil filter


V1903 ENGINEMACHINE CODES 10956 11214

D300K 3+3

D-5MAINTENANCED-5

I





Kubota- 16631-43562

Kubota- 16414-32432

TYPE OR QUANTITY




9.5 qrts, (9.0 L)


Alternator drive belt Kubota- 17480-97010Alternator drive belt wear

R


Drain water separator & fuel strainer Kubota- 15831-43353


R


MAINTENANCE ITEM


C

I

R

Coolant level

RRRR

I

ENGINE SERVICE

I




Donaldson- P821575



I


I = Inspect

Electrical systems

I

I

Valve clearancesI


I

I



RI

CC

Engine oil filter


V2003 ENGINEMACHINE CODES 11488, 11549

D300K 3+3

D-6MAINTENANCED-6

GFCI RECEPTACLE TESTING AND RESET-TING PROCEDuRE

The GFCI receptacle should be properly tested atleast once every month or whenever it is tripped. Toproperly test and reset the GFCI receptacle:

• If the receptacle has tripped, first carefully removeany load and check it for damage.

• If the equipment has been shut down, it must berestarted.

• The equipment needs to be operating at high idlespeed and any necessary adjustments made on thecontrol panel so that the equipment is providing atleast 80 volts to the receptacle input terminals.

• The circuit breaker for this receptacle must not betripped. Reset if necessary.

• Push the "Reset" button located on the GFCI recep-tacle. This will assure normal GFCI operation.

• Plug a night-light (with an "ON/OFF" switch) or otherproduct (such as a lamp) into the GFCI receptacleand turn the product "ON".

• Push the "Test" button located on the GFCI recepta-cle. The night-light or other product should go"OFF".

• Push the "Reset" button, again. The light or otherproduct should go "ON" again.

If the light or other product remains "ON" when the"Test" button is pushed, the GFCI is not working prop-erly or has been incorrectly installed (mis-wired). Ifyour GFCI is not working properly, contact a qualified,certified electrician who can assess the situation,rewire the GFCI if necessary or replace the device.

D300K 3+3

E-1TROubLEShOOTINGE-1

D300K 3+3

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAuTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for thePossible Cause, generally it states to contact yourlocal Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Authorized Field Service Facility.

hOW TO uSE TROubLEShOOTING GuIDE

Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairsperformed on this equipment may result in danger to the technician and machine operator and willinvalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe allsafety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING


Observe all Safety Guidelines detailed throughout this manual


CAuTION

PRObLEMS(SYMPTOMS)

POSSIbLE CAuSE

RECOMMENDEDCOuRSE OF ACTION

Machine fails to hold the heat con-sistently.

Welder starts but fails to generatecurrent.

1. Rough or dirty commutator.Commutator should be turned orcleaned.

2. Brushes may be worn down tolimit. Replace brushes.

3. Field circuit may have variableresistance connection or intermit-tent open circuit due to loose con-nection or broken wire. Checkfield current with ammeter to dis-cover varying current. This appliesto both the main generator andexciter.

4. Electrode lead or work lead con-nection may be poor. Tighten allconnections.

5. Wrong grade of brushes mayhave been installed on generator.Use proper brushes.

6. Field rheostat may be makingpoor contact and overheating.Inspect and clean the rheostat.

1. Generator or exciter brushes maybe loose or missing. Be sure thatall brushes bear on the commuta-tor and have proper spring ten-sion.

2. Exciter may not be operating.Check exciter output voltage withvoltmeter or lamp.

3. Field circuit of generator or excitermay be open.Check for open circuits in rheo-stat, field leads, and field coils.Check rectifier bridge and fuses.

4. Exciter may have lost excitation.Flash fields. (1) Check flashingdiode at 5 o’clock brush holder ingenerator.

5. Series field and armature circuitmay be open-circuited. Check cir-cuit with ringer or voltmeter.

If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Authorized FieldService Facility.

D300K 3+3

WELDER TROubLEShOOTING




CAuTION

PRObLEMS(SYMPTOMS)

POSSIbLE CAuSE


Welding arc is loud and spattersexcessively.

Welding current too great or toosmall compared to indication on thedial.

Arc continuously pops out.

1. Current setting may be too high.Check setting and current outputwith ammeter.

2. Polarity may be wrong. Checkpolarity. Try reversing polarity ortry an electrode of the oppositepolarity.

1. Exciter output low causing lowoutput compared to indication.Check exciter field circuit.

2. Operating speed too low or toohigh. Adjust speed screw on gov-ernor. (High idle - 1800 RPM)

1. “Current Range Selector” switchmay be set at an intermediateposition. Set the switch at the cen-ter of the current range set at anintermediate position desired.


(1) FLASHING THE FIELDS:1. Stop the engine welder and remove the cover from the exciter.2. Turn the “Fine Current Adjustment” (rheostat) to “100” on the dial.3. Using a 12 volt automotive battery, connect it’s negative terminal to the negative brush holder.

The negative brush holder is the one nearest to the rotor lamination. See the wiring diagram. Withthe engine NOT running, touch the positive battery terminal to the positive brush holder. Removethe battery from the circuit.

4. Replace the exciter cover. Start the welder and the generator voltage should build up.

D300K 3+3

WELDER TROubLEShOOTING




CAuTION

PRObLEMS(SYMPTOMS)

POSSIbLE CAuSE


Engine does not start.

Irregular running of the engine.

1. Faulty Ignit ion switch and orInjector pump solenoid. Correctthe connection and contact.

2. Insufficient charging or complete dis-charge of the battery. Charge.

3. Lack of fuel. Supply fuel.

4. Air mixed in the fuel system.Bleed air (To be done by qualifiedpersonnel only)

5. Clogged fuel filter. Replace.

6. Irregular and faulty fuel supply(Injector pump trouble). Repair inan authorized field service shop.

7. Glow plug not heated. Breakageof the glow plug; replace.

8. Improper viscosity of the lubricat-ing oil. Inspect and replace.

9. Clogged air cleaner. Clean orreplace.

10. No compression. Repair in a fieldservice shop.

1. Air mixed in the fuel system.Bleed air (To be done by qualifiedpersonnel only).

2. Uneven fuel injection (Faulty fuelinjector pump). Repair in anauthorized field service shop.


4. Defective governor. Check andcorrect.

5. Engine itself defective. Repair inan authorized field service shop.


D300K 3+3

ENGINE TROubLEShOOTING




CAuTION

PRObLEMS(SYMPTOMS)

POSSIbLE CAuSE


Engine stops during operation.

(White or Blue) Smoke.

Dark Grey Smoke.

Faulty Charging.

Starter Motor does not run.

1. Lack of fuel in the fuel tank. Supplyfuel and bleed air (To be done byqualified personnel only)


3. Air mixed in the fuel system.Bleed air (To be done by qualifiedpersonnel only).

4. Faulty function of the engine.Repair in a service shop.

1. Excess engine oil.Inspect and cor-rect the level.

2. Too low viscosity of the engine oil.Inspect and replace the oil withproper grade.

3. Faulty injection timing. Repair in aservice shop.

1. Unsuitable fuel. Inspect andreplace with correct grade.

2. Excess injection. Inspect andadjust (in a field service shop).

3. Faulty function of the engine.Repair in a field service shop.

4. Overloading. Reduce the load.

5. Clogged air cleaner. Clean.

1. Loose fan belt. Correct the ten-sion.

2. Faulty wiring. Inspect and correct.

3. Faulty battery. Repair.

4. Worn out alternator brush.Replace.

1. Loose or damaged wiring. Inspectand tighten.

2. Dropped voltage of the battery.Charge the battery.

3. Damaged starter motor (includingsolenoid). Repair in a field serviceshop.


ENGINE TROubLEShOOTING

D300K 3+3

F-1DIAGRAMSF-1

D300K 3+3

NO

TE

: T

his

dia

gra

m is for

refe

rence o

nly

. It m

ay n

ot be a

ccura

te for

all

machin

es c

overe

d b

y this

manual. T

he s

pecific

dia

gra

m for

a p

art

icula

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n o

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erv

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epart

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quip

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um

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F-2DIAGRAMSF-2

D300K 3+3

NO

TE

: T

his

dia

gra

m is for

refe

rence o

nly

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ay n

ot be a

ccura

te for

all

machin

es c

overe

d b

y this

manual. T

he s

pecific

dia

gra

m for

a p

art

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aste

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machin

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n o

ne o

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nclo

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panels

. If th

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epart

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ive the e

quip

ment code n

um

ber.

F-3DIAGRAMSF-3

D300K 3+3

KUBO

TA 3+

3 W

IRIN

G DI

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M FO

R CO

DE 11

488

L133

17A.01

CONT

ROL

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L COM

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N AS

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OLOR

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+-

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0

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SLIP

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ON

A

54

32

1

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ORAU

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56

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ENG

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*

ON M

ACHI

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UG "P

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CON

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ON

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250

AMP

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W.F

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CONT

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PANE

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PLUG

(P5)

�

NO

TE

: T

his

dia

gra

m is for

refe

rence o

nly

. It m

ay n

ot be a

ccura

te for

all

machin

es c

overe

d b

y this

manual. T

he s

pecific

dia

gra

m for

a p

art

icula

r code is p

aste

d insid

e the

machin

e o

n o

ne o

f th

e e

nclo

sure

panels

. If th

e d

iagra

m is ille

gib

le, w

rite

to the S

erv

ice D

epart

ment fo

r a r

epla

cem

ent. G

ive the e

quip

ment code n

um

ber.

F-4DIAGRAMSF-4

D300K 3+3

CONT

ROL

PANE

L CO

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S SH

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AS V

IEW

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BOND

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1730

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* LEA

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CTED

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DET

AIL

ACTU

ATOR

* 57

* 56

GLOW

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D

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BATT

ERY

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50A

(U)*51B

54N.

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ALTE

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ORIG

212E

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*64

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9*9

3*9

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4

N.C.

225

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610A

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5

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0

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1

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GENE

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N

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48

GND-

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610

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(CC-

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.)

B

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LINE

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CONT

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L

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UG (P

5)

CONN

ECT

TO P

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SNE

G

#8 L

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#2 H

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LEA

D

#2 H

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D

608 60

9

250

AMP

THER

MOS

TAT

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MBL

Y

CONN

ECT

TO N

EGBR

USH

HOLD

ER

SLIP

RIN

G NE

ARES

T TO

IRON

SELE

CTOR

SW

ITCH

WEL

DER

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BLO

CK

ENGI

NE C

ONTR

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NIT

CONN

ECTO

R DE

TAIL

2618

645660E

449457

3425

17 1060

F

52B69

212D51B

9 1

93

70A

NOTE

: LEA

D 70

A IS

LEF

T OP

EN A

ND W

IRE

TIED

INTO

HAR

N ESS

.+ -

ACAC

UU

NN

MOV

-+

KUBO

TA 3+

3 W

IRIN

G DI

AGRA

M C

ODE

1154

9

M225

41N

OT

E: T

his

dia

gra

m is for

refe

rence o

nly

. It m

ay n

ot be a

ccura

te for

all

machin

es c

overe

d b

y this

manual. T

he s

pecific

dia

gra

m for

a p

art

icula

r code is p

aste

d insid

e the

machin

e o

n o

ne o

f th

e e

nclo

sure

panels

. If th

e d

iagra

m is ille

gib

le, w

rite

to the S

erv

ice D

epart

ment fo

r a r

epla

cem

ent. G

ive the e

quip

ment code n

um

ber.

NOTES

D300K 3+3

WARNING

AVISO DEPRECAuCION

ATTENTION

WARNuNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

l Keep your head out of fumes.l Use ventilation or exhaust to

remove fumes from breathing zone.

l Los humos fuera de la zona de res-piración.

l Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

l Gardez la tête à l’écart des fumées.l Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

l Vermeiden Sie das Einatmen vonSchweibrauch!

l Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

l Mantenha seu rosto da fumaça.l Use ventilação e exhaustão para

remover fumo da zona respiratória.

l Turn power off before servicing.

l Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

l Débranchez le courant avant l’entre-tien.

l Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

l Não opere com as tampas removidas.l Desligue a corrente antes de fazer

serviço.l Não toque as partes elétricas nuas.

l Do not operate with panel open orguards off.

l No operar con panel abierto oguardas quitadas.

l N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

l Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

l Mantenha-se afastado das partesmoventes.

l Não opere com os paineis abertosou guardas removidas.

WARNING

AVISO DEPRECAuCION

ATTENTION

WARNuNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

l Do not touch electrically live parts orelectrode with skin or wet clothing.

l Insulate yourself from work andground.

l No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

l Aislese del trabajo y de la tierra.

l Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

l Isolez-vous du travail et de la terre.

l Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

l Isolieren Sie sich von denElektroden und dem Erdboden!

l Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

l Isole-se da peça e terra.

l Keep flammable materials away.

l Mantenga el material combustiblefuera del área de trabajo.

l Gardez à l’écart de tout matérielinflammable.

l Entfernen Sie brennbarres Material!

l Mantenha inflamáveis bem guarda-dos.

l Wear eye, ear and body protection.

l Protéjase los ojos, los oídos y elcuerpo.

l Protégez vos yeux, vos oreilles etvotre corps.

l Tragen Sie Augen-, Ohren- und Kör-perschutz!

l Use proteção para a vista, ouvido ecorpo.

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

D300K 33 Operators Manual NEW

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Transcript of D300K 33 Operators Manual NEW