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ELECTRICAL DIAGRAMS
G-21
CLASSIC® 300D & 300G
SCHEMATIC - COMPLETE MACHINE - (CODES 11474, 11475) (L13351)
L13351
C
LASS
IC
300
D
K
UB
OTA
MACHIN
E
SCHEM
ATI
C
NO
NE
L13097
DO N
OT S
CA
LE
TH
IS
D
RAW
ING
EQU
IP
ME
NT
TYPE
:
SU
BJ
EC
T:
NA
CRM37
569
1
PA
GE
___
OF
___
1
ENGINE
ERING CONTROL
L
ED
MANUFACTURER:
No
T
HIS
DOC
UME
N
T C
ON
TAINS P
R
OP
RIETA
RY IN
FO
RMATIO
N
OW
NE
D BY L
IN
C
OLN
GLOBAL, IN
C. A
N
D MAY NOT BE
D
UPLI
CA
TE
D,
C
OMMU
NI
CA
TE
D
TO OT
HE
R PA
R
TIES O
R
USE
D
FO
R A
NY P
U
RP
OSE WIT
HOU
T THE E
X
PRESS
W
RITTE
N PE
RMISSIO
N
OF LIN
C
OLN
GLOBAL, IN
C.
PROPRI
ETA
RY & CONFIDE
NTIAL:
Ne
w
t
MAT
ERIAL TOLERANCE (
"
")
TO A
G
REE
WITH PUBLISHED
STANDARDS.
O
N ALL AN
GLES IS
±
.5
OF A
DEG
REE
ON
3
P
LA
C
E
DECIM
ALS
IS
±
.0
02
i
n.
(
±
0.05
mm)
O
N 2
PLACE DEC
IMALS IS
±
.02
in
. (
±
0.5
mm)
U
NLESS
OTHERW
ISE
SPE
C
IF
IE
D
TOLERA
N
CE
:
MANUFACTURIN
G
TOLERANCE PER
E2056
C
HA
N
GE DE
T
AIL:
REFE
RE
N
CE:
SCA
LE:
MATE
RIAL
DISPO
SITION:
APP
ROV
AL
DAT
E:
PRO
JE
CT
NU
MBE
R:
DOCUMENT
N
UMBER:
DOCUMENT
REVIS
I
ON:
U
NITS:
IF
PRIN
TED
@
A2
S
IZE
INC
H
1
1/
1
6/
2007
Maglietta
D. BE
N
DE
R
-
DR
A
WN
BY:
E
NG
IN
EE
R:
CLEVELAN
D
APP
RO
VE
D:
CO
NT
ROL:
A
L13351
EA
RTH
GROU
ND
FRAM
E
G
RO
UND
COMM
ON
LA
B
EL
S:
EX
.
1
2
PIN CONNECTOR
LATC
H
127
6
2
1
VIEW O
F
CONNECTOR ON PC BOARD
CO
NNE
CTOR
P
IN N
UM
BERS:
RESI
STO
R: O
HM
S/W
ATTS
CAPA
CITO
R:
MFD/
V
OLTS
COM
P
ON
E
NT
V
AL
UE
U
NIT
S:
B-BL
ACK
OR
GR
AY
G-GRE
EN
R-RE
D
OR
P
IN
K
U-BLU
E
W-
W
HIT
E
Y-Y
ELLO
W
N-BR
OWN
LE
A
D
COLO
R
CO
DE:
OIL PRESSURE SWITCH / SENDER
TEMPERATURE
SWITCH
TEMPERATURE
GAUGE
S
I
G
OIL PRESSURE
GAUGE
S
I
G
AMMETER
+
-
ENGINE CONTROL UNIT
(
ECU)
1
ENGINE
PROTECTION
LIGHT
ALTERNATOR
WK
G
NEGATIVE OUTPUT
TERMINAL
POSITIVE OUTPUT
TERMINAL
4
3
2
1
GENER
ATOR L
E
AD B
LOCK
SHOWN
A
SVI
EW
ED
WITH
ENGINE IN THIS DIRECTION
-
-
+
+
INTERPOLE
COILS
SHUNT
FIELD
SERIES FIELD
TYPICAL CURRENT
DRAW IS 40 AMPS
+
HOUR METER
12
11
10
9
8
7
65
4
3
2
1
P10
J5
SWITCH CLOSES
AT 6+/-2 PSI
SENDER OPERATION:
0PSI->10+/-5OHMS
40PSI -> 105+/-5 OHMS
80 PSI -> 187+/-5 OHMS
FJW-5AP
COILPAIR:
25.2 - 26.7
OHMS EACH
FLYBACK DIODE PREVENTS
VOLTAGESPIKES IN SHUNT FIELD
FROM DAMAGING LOCAL/REMOTE
TOGGLE SWITCH WHEN SWITCHED
SHOWN IN LOCAL
POSITION
3 TURN
S
2 TURN
S
SENSOR GROUNDS LEAD
ON SENSE OF WELD OR
AUXILIARY LOAD
Y
RHEOSTAT
W
G
X
REMOTE
RECEPTACLE
LOCAL / REMOTE
SWITCH
S
WITCH CLO
SES
AT
110v+/
-3
vC
S
END
ER OP
ER
ATION:
90v
C
->
51.
2+/
-4.3 OHMS
P9
J8
46531 2
64+/-6.4 OHMS MAX
WITH
AC AU
X
ILIARY POW
ER,
ROUTING
DIRECTIONS OF THES
E
LE
AD
S DOE
S NOT
M
AT
TER
BRUSH POSITION SHOWN AS
VIEWED FROM CONTROL PANEL
+
_
COLOR: RED
12 VOLT
NORMALLY OFF
SHOWN IN"OFF"
POSITION
53
51C
50
50A
51
51A
212D
43
200
54
44
212A
212B
61
844A
841
844
N
U
67A
602B
602
SELECTOR SWITCH
90-MIN
130-80
190-120
240-160
220-MAX
WELDING
GENERATOR
CCW
-40 TO 40 AMPS
AMMETER SHOWS FULL
DISCHARGE WHILE PRESSING
GLOW PLUG SWITCH
40AMP/12VOLT
IG
B
L
GLOW PLUGS
12.6 VOLTS MIN
ATREST
14-14.5 VOLTS
WHILE RUNNING
BACK, BOTTOM
OFMACHINE
JUMPER PLUG IS FOR CONNECTION
TO WIRE FEED MODULE
LOCATEDBEHINDUPPER PORTIONOF CONTROL PANEL
LOCATEDBEHINDUPPERLEFT
PORTION OFCONTROL PANEL
TYPICAL OCV(WARM MACHINE):
94-99.0 VOLTS AT MAX RHEOSTAT
44-54.5 VOLTS AT MIN RHEOSTAT
DRIVER
CIRCUITS
JUMPERPLUG ISWIRE-TIED UP
BEHIND LOCAL / REMOTESWITCHON
R IGHTS IDEOFM AC HINE(A SV IE WED
FROMCONTROL PANEL)
1
2
3
WATER
TEMP.
SENSOR
ENGINE
SPEED
SENSOR
31
60F
19
58
6
IGNITION
SWITCH
212C
12
START
BUTTON
7
52A
52B
55
62
STARTER
RELAY
RELAY CONTACTS FOR 52 AND 52A ARE NORMALLY
OPEN. THE STARTER MOTOR CAN ONLY BE ENGAGED
WHEN THE IGNITION SWITCH IS "ON" AND THEECU
SENSES LESS THAN 700 RPM. IF THE ENGINE IS SHUT
DOWN DUE TO A FAULT
(EVEN
IF T
H
AT
CO
ND
IT
IO
N
DO
ES
NOT
RES
ULT
IN A
FL
ASH
CO
DE, SUCH AS RUNNI
NG
OUT
OF
F
UE
L)
, THEIGNITIONSWITCHWILL NEED TOBE
TURNED OFF THEN BACK ON TO RESTART THE ENGINE.
4
87
86
88
11
2
3
10,000 +/- 1,000 OHMS MAX
TURN POT COUNTERCLOCKWISE TO
REDUCE RESISTANCE AND SUBSEQUENTLY
REDUCE RPM BY UP TO 150RPM
RATED VOLTAGE: 12V
RATED CURRENT: 22mA MAX
60
S
EN
SOR OPER
ATION:
-4
v
F
->
18.
8
0 kOH
MS
104
v
F
->
1.14
kOHM
S
212
v
F
->
.16 kOH
MS
RATED VOLTAGE: 12V
RATED CURRENT: 4.5A(MAX.)-TERMINAL #15
LEAKAGE CURRENT 10micro A (MAX.)-TERMINAL #16
57 34
RAT
ED VO
LT
AGE: 1
2V
RAT
ED CURRENT: 2
A
COIL RESI
ST
ENC
E:
2.8
+/-
.28 OH
M
S
AT
20vC
EN
ERGIZED FOR RUN
DE-ENERGIZED FOR STOP
ACTU
ATOR CONTROLS R
PM
DOWN THE
ENGINE A
T 1
15%
OF RATED
SPE
ED.
27
28
841A
9
212E
26
64
16
15
51B
70A
70B
CONNECT TO
GROUND FOR
800RPM
CONNECT TO
GROUND FOR
1600RPM, LEAVE
UNCONNECTED
FOR 1800RPM
30
32
61
0A
+
-
+
-
21
5
81
0
82
0
SLIPRINGS
21
4
AC
AC
48
GND-
T
11C
21
EXCITER STATOR
(ALTERNATOR)
11B
POSITIVESLIP RING
IS NEAREST TO IRON
EXCITER REVOLVING
FIELD(ROTOR)
400E
400D
15A
610
610
600B
600A
42
600
41
602A
67B
60E
INTERPOLE
COILS
ACTUATOR
56
18
69
13
60A
94
20
93 17
CCW
RPM CONTROL POTENTIOMETER
WIRE-TIEDTOHARNESS
BEHIND CONTROL PANEL
FUSE
BOTHOPENLEADSAREWIRE-TIED INSIDE THEHARNESS BEHINDCONTROLPANEL
SHOWN IN "AUTO
IDLE" POSITION
IDLER SWITCH
GND-B
841B
WINDING SPEC: ALT-241-3A
40.5 - 42.5 OHMS AT 25C
EXCITER CIRCUIT
LEAD 21A TO 21B
WINDING SPEC: ALT-214-2B
.488 OHMS MAX AT 25C
115
V
OLT
CIRCU
IT
L
EAD
8
10
TO
8
20
WINDI
NG
SPEC: A
LT-214
-2
C
.2
30
O
HM
S
M
AX
AT
2
5C
115
V
OLT
CIRCU
IT
L
EAD
8
20
TO
8
30
WINDI
NG
SPEC: A
LT-214
-2
D
.4
24
O
HM
S
M
AX
AT
2
5C
1
2 VO
LT
SU
PP
LY
THE
ECU WI
L
L INDICAT
E FAU
LT CONDITIONS BY FLA
SHING THE
ENGINE PROT
ECTION LIGHT IN A CODED SEQU
ENC
E, S
E
E CHAR
T
FOR FAULT CODE
S
AND CORRECTIV
E
MEA
SUR
E
S. WH
EN TH
E
ENGINE IS
SHUT DOWN DUE
TO A FAU
LT, TH
E IGNITION
S
WITCH
WI
L
L NE
ED TO B
E TURN
ED OFF THEN B
AC
K ON
TO RES
TAR
T THE
ENGINE.
1
2 VO
LT
SU
PP
LY
N
U
GLOW PLUG
BUTTON
+
BATTERY
STARTER
MOTOR
STARTER
SOLENOID
842
42
W
W
Y
Y
MOU NTEDTONEGATIVE
BRUSHHOLDER
THIS CIRCUIT USES THE
RESIDUAL MAGNETISM OF
THE GENERATOR TO FLASH
THE EXCITE THE ROTOR
WHICH IN TURN PROVIDES
THE EXCITATION FOR THE
GENERATOR
D
IO
DE AND
MO
V ASS
EM
BLY
IN
-LINE BOLT
ED CONNECTION
B
EHIND CONTROL PAN
EL
60
0C
FRONT, RIGHT SIDE
OF ENGINE
FRONT, LEFT SIDEOF ENGINE
BACK, LEFT SIDEOF ENGINE
JUMPER PLUGIS BEHINDLOWER
RIGHTSIDEOF CONTROL PANEL
LOWER, RIGHT SIDEOF CONTROL PANEL
DIODE
LOW ER,
RIGHT OF
CONTROL
PANEL
LOW ERLEFTOF
CONTROL PANEL
LOW ERLEFTOF
CONTROL PANEL
CENTER OF
CONTROL PANEL
BACK, RIGHT
S IDEO FENGINE
BACK, LEFT
SIDE OF ENGINE
BACK, RIGHT
SIDE OF ENGINE
CENTEROF
CONTROL PANEL
UNDERLEFT DOOR
LOWER RIGHT OF CONTROL PANEL
44
28
1
2 VO
LT
SU
PP
LY
ECU CONNECTOR DETAIL
9
17
25
34
26
18
10
1
FL
A
SH
E
S
A
LT
ERN
ATOR
S
EN
SE
S
A
LT
ERN
ATOR OUTPU
T
THE
P1
0 P
LUG IS ONLY
ON UN
ITS
WITHOUT TH
E
WIR
E FE
ED
MODU
L
E.
THE
WIR
E FE
ED
MODU
L
E HA
S
A
HARNE
S
S TH
AT
P
LUGS DIREC
TLY
INTO J5.
41
JUMPERPLUG IS
WIRE -TIE DU P
BEHIND LOCAL /
REMOTE SWITCH
ONRIGHT SIDEOF
MACHINE
SCHEMATIC S25973
CURRENT SENSING PC BOARD
602B
400F
WH
ITE
LOA
DWH
ITE
LI
NE
HOT
LOA
D
HOT
LI
NE
115 VOLT GFCI
RECEPTACLE
400D
CB2
15A
6A
810
230 VOLT
RECEPTACLE
7A
6A
GND-E
11A
CB1
20A
82
0
GND-S
FRONT, RIGHT SIDE
OF ENGINE
BACK, LEFT SIDE
OF ENGINE
TEMPERATURE
SENSOR
LIGHTCODE
FAILUREDETECTED
POSSI BLECAUSE-CORREC TIVEMEASURE
LONG 1, SHORT 1
RPM IS OVER 115% OF RATED RPM (2070 RPM)
ACTUATOR IS STUCK -REMOVEACTUATOR ANDVERIFYPLUNGER PULLSIN WHEN ENERGIZED
LOW OIL -CHECK OIL LEVEL ON DIPSTICK
FAULTY OILPRESSURE SWITCH -CHECKTHAT "WK"STUDIS OPEN WHEN ENGINE IS RUNNING
LEAD TO OIL PRESSURE SWITCH "WK" STUD MAY BE GROUNDED -CHECK
BROKEN OR LOOSE BELT - INSPECT
LEAD TO "L" TERMINAL ON ALTERNATORMAY BE SHORTED TO GROUND -CHECK
FAULTY ALTERNATOR -CHECK
AMOUNT OR QUALITY OF COOLANT INCORRECT -CHECK
FAULTY WATER TEMPERATURESWITCH- CHECK THAT "WK" STUDISOPEN WHEN ENGINE IS NOT RUNNING
LEADTO WATER TEMPERATURE SWITCHMAY BEGROUNDED- CHECK
LONG 1, SHORT 5
FAULTY RPM SENSOR - CHECKFOR GOODCONNECTION
FAULTY ECU - CHECK FOR 12 VOLTS ON SUPPLY LEAD TORPM SENSOR FROMECU
FAULTY ACTUATOR -CHECKFOR PROPER COIL RESISTANCE
LEADS TO ACTUATOR MAYBE OPENOR GROUNDED -CHECK
LONG 2, SHORT3
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSORMAY BE OPEN- CHECKFOR CONTINUITY
FAULTY WATER TEMPERATURE SENSOR - CHECK FOR PROPER RESISTANCE
LEAD TO WATER TEMPERATURE SENSORMAY BE GROUNDED - CHECK
LEAD TO "L" TERMINAL ON ALTERNATORMAY BE OPEN- CHECKFOR CONTINUITY
BROKEN OR LOOSE BELT - INSPECT
FAULTY ALTERNATOR -CHECK
INCORRECT BATTERY -INSPECT
FAULTY ALTERNATOR -CHECK
LONG 2, SHORT 8
LESSTHAN 4 VOLTS TO RPMSENSOR AND/OR
ACTUATOR SENSED BYECU
FAULTY ECU - CHECK FOR 12 VOLTS ON LEADS TO RPM SENSOR AND ACTUATOR FROM ECU
NOT ENABLEDFOR LINCOLN PRODUCTS
NOT ENABLEDFOR LINCOLN PRODUCTS
0 RPM IS DETECTED AND 12VIS DETECTED
FROM "L"TERMINAL ON ALTERNATOR
LONG 2, SHORT 1
LONG 1, SHORT 4
HIGH WATER TEMPERATURE DETECTED FOR1
SECOND
LONG 1, SHORT 2 LOW OIL PRESSURE DETECTED FOR 1 SECOND
LONG 1, SHORT 3
"L" TERMINALIS GROUNDEDON ALTERNATOR
FOR 1SECOND
LONG 2, SHORT 7 OVER 18 VOLTS DETECTEDFROM ALTERNATOR
CURRENT TOACTUATOR IS OUT OF LIMITLONG 2, SHORT 2
LONG 2, SHORT 6
0 VOLTSDETECTED FROM "L" TERMINAL ON
ALTERNATOR FOR 1 SECOND
LONG 2, SHORT 5 150C WATER TEMPERATURE DETECTED
-50C WATER TEMPERATURE DETECTED
LONG 2, SHORT4
K924-5 REMOTE CONTROL
(OPTIONAL)
RHEO
STAT
R
EM
OTE
CO
NTROL
BOX
2
5+/-1.
25
OHM
S
EACH
6
4+/-6.
4
OHM
S
MA
X
CCW
Y
W
G
X
R
EM
OTE
CO
NTROL
PL
UG
G-21
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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