RED-D-ARC GX 300 For use with machines having Code Numbers: IM10047-D August 2013 ( 11678, 11740, 11795, 11802, 12098, 12204 RETURN TO MAIN MENU OPERATOR’S MANUAL Red-D-Arc Spec-Built Welding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on You This 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.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 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 bare skin 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 full area of physical contact with work and ground.
iii iii SAFETY WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles. Pour 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 suivantes: 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 dʼincendie.
v v Thank You for selecting one of our QUALITY products. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for advice or information about their use of our products.
vi vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Machine Specifications ........................................................................................................A-2 Safety Precautions ..........................................................
vii TABLE OF CONTENTS Maintenance......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................................................D-1 Kohler Engine........................................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - GX300 (K2284-2) INPUT - GASOLINE ENGINE Make/Model Description Speed (RPM) Kohler CH23S CH680 CH730 2 cylinder 23 HP @ 3600 RPM Gasoline Engine Displacement cu. In.(cu. Cm.) Bore x Stroke inch (mm) Starting System 41(674) 3.15 x 2.64 (80 x 67) 12VDC Battery & Starter High Idle 3700 Capacities (Group 58; 435 Cold crank amps) Battery Charger Full Load 3500 44.2(725) Fuel: 12 gal. 45.4 L Oil: 2.0 qt. 1.9 ltr. 3.27 x 2.
A-2 A-2 INSTALLATION MACHINE SPECIFICATIONS - GX300 (K2284-2) RECEPTACLES AND CIRCUIT BREAKERS RECEPTACLES (2) 120VAC Duplex GFCI (5-20R)(1) 120/240VAC Dual Voltage Full KVA (14-50R) AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS Two 20AMP for Two Duplex GFCI Receptacle 20AMP for Battery Charging Circuit One 50AMP for Dual Voltage (2-Pole) 15AMP for 42V Wire Feeder Power GX 300
A-3 A-3 INSTALLATION LIFTING The GX 300 weighs approximately 539 lbs(244.5kg. A lift bail is mounted to the machine and should always be used when lifting the machine. SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.
A-4 A-4 INSTALLATION VEHICLE MOUNTING OIL WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail. • Only transport this Equipment on serviceable vehicles which are rated and designed for such loads. • Distribute, balance and secure loads so vehicle is stable under conditions of use. • Do not exceed maximum rated loads for components such as suspension, axles and tires. • Mount equipment base to metal bed or frame of vehicle.
A-5 A-5 INSTALLATION CAUTION An incorrect spark arrestor may lead to damage to the engine or adversely affect performance. ------------------------------------------------------------------------ HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K930-2 TIG Module is suitable for use with the GX 300. The GX 300 and any high frequency generating equipment must be properly grounded. See the K930-2 Operating Manual for completed instructions on installation, operation, and maintenance.
A-6 INSTALLATION A-6 CABLE INSTALLATION Install the welding cables to your GX 300 as follows. STANDBY POWER CONNECTIONS 1. The gasoline engine must be OFF to install welding cables. The GX 300 is suitable for temporary, standby or emergency power using the engine manufacturerʼs recommended maintenance schedule. 2. Remove the flanged nuts from the output terminals. 3. Connect the electrode holder and work cables to the weld output terminals. The terminals are identified on the case front. 4.
A-7 A-7 INSTALLATION CONNECTION OF GX 300 TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 60 Hz. 3-Wire Service 120 VOLT COMPANY 120 VOLT METER NEUTRAL BUS N LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. GROUND 40AMP 240 VOLT 50 AMP, 120/240 VOLT PLUG NEMA TYPE 14-50 240 VOLT PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION DOUBLE POLE CIRCUIT BREAKER GND N 50 AMP, 120/240 VOLT RECEPTACLE NOTE: No.
A-8 A-8 INSTALLATION CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Connection of the LN-25 to the GX 300 WARNING Shut off welder before making any electrical connections. -----------------------------------------------------------------------The LN-25 with or without an external contactor may be used with the GX 300. See the appropriate connection diagram in Section F. NOTE: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the GX 300. 1. Shut the welder off.
B-1 B-1 OPERATION SAFETY PRECAUTIONS ENGINE OPERATION Before Starting the Engine: WARNING • Be sure the machine is on a level surface. Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. -----------------------------------------------------------------------ELECTRIC SHOCK can kill.
B-2 B-2 OPERATION 14 13 1 12 2 11 10 3 9 8 7 6 4 5 WELDING CONTROLS 3. ARC CONTROL : 1. OUTPUT CONTROL: The ARC CONTROL WIRE/STICK dial is active in the WIRE, STICK and PIPE modes, and has different functions in these modes. This control is not active in the TIG mode. The CONTROL dial provides continuous control of the welding current or welding voltage depending on the selected welding mode.
B-3 OPERATION B-3 4. WELD OUTPUT TERMINALS WITH FLANGE NUT: 13. IDLER SWITCH- Has two positions as follows: Provides a connection point for the electrode and work cables. Output stud covers provided on code 11274 and above. 1) In the HIGH position, the engine runs at the high idle speed controlled by the engine governor. 2) In the AUTO position, the idler operates as follows: 5.
B-4 B-4 OPERATION CAUTION Operating the starter motor for more than 5 seconds can damage the motor. If the engine fails to start, release the switch and wait 10 seconds before operation the starter again. Do NOT push the START button while the engine is running because this can damage the ring gear and/or the starter motor.
B-5 B-5 OPERATION TIG WELDING The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the CONTROL dial is first set to the desired current and the tungsten is touched to the work. During the time the tungsten is touching the work there is very little voltage or current and, in general, no tungsten contamination. Then, the tungsten is gently lifted off the work in a rocking motion, which establishes the arc.
B-6 B-6 OPERATION ARC GOUGING The GX 300 can be used for limited arc gouging. For optimal performance, set the MODE switch to CCSTICK and the ARC CONTROL to +10. Set the CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following table.
C-1 ACCESSORIES OPTIONS/ACCESSORIES AND COMPATIBLE LINCOLN EQUIPMENT K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.).Order: K957-1 K958-1 K958-2 K959-2 K965-1 C-1 K704 ACCESSORY SET - Includes 35 ft. (10m) of electrode cable and 30 ft. (9.1m) of work cable, headshield, work clamp electrode holder.
D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS KOHLER ENGINE FREQUENCY WARNING Daily or Before Starting Engine • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. If guards are missing from the machine, obtain replacements from a Lincoln Distributor.
D-2 D-2 MAINTENANCE Engine Oil Change Drain the oil while the engine is warm to assure rapid and complete draining. • Remove the oil filler cap and dipstick. Remove the yellow cap from the oil drain valve and attach the flexible drain tube supplied with the machine. Push in and twist the drain valve counterclockwise. Pull the valve out and drain the oil into a suitable container. • Close the drain valve by pushing in and twisting clockwise. Replace the yellow cap.
D-3 D-3 MAINTENANCE AIR FILTER PAPER ELEMENT Spark Plug Service • Loosen the cover retaining knob and remove the cover. • Remove the pre-cleaner from the paper element. • Remove the element cover nut, element cover, and paper element. To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. • Remove the spark plug cap. • Clean any dirt from around the spark plug base. • Do not wash the paper element or use pressurized air, as this will damage the element.
D-4 CLEANING THE BATTERY FUEL FILTER • Check the fuel filter for water accumulation or sediment. • Replace the fuel filter if it is found with excessive water accumulation or sediment. ENGINE ADJUSTMENT OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM, no load. Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed.
D-5 MAINTENANCE GFCI RECEPTACLE TESTING AND RESETTING PROCEDURE Welder/Generator Maintenance STORAGE: Store the GX 300 in clean, dry protected areas. CLEANING: Blow out the generator and controls periodically with low pressure air. Do this at least once a week in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT: Itʼs normal for the brushes and slip rings to wear and darken slightly. Inspect the brushes when a generator overhaul is necessary.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Major Physical or Electrical Damage 1. Contact your local Authorized is Evident. Field Service Facility. Engine will not "crank". 1. Battery is low, Charge Battery. 2. Loose battery cable connections. Inspect, clean and tighten. 3. Faulty engine starter motor. 4. “Battery Circuit” circuit breaker is tripped. Engine will "crank" but not start.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE Engine will not idle down to low speed. 1. Idler switch in High idle position. Set switch to Auto. 2. External load on welder or auxiliary power. Remove all external loads. 3. Faulty PC board or idler solenoid. Engine will not go to high idle when attempting to weld. 1. Poor work lead connection to work. Make sure work clamp is tightly connected to clean base metal. 2.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE No welding power output. 1. Poor work lead connection to work. Make sure work clamp is tightly connected to clean base metal. 2. "Weld Terminals" switch in wrong position. Place switch in "Weld Terminals On" position when welding without control cable. 3. Faulty PC board or welder alternator. Welder has output but no control. 1.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION The welding arc is “cold.” The weld- 1. Make sure the MODE selector ing arc is not stable or is not satis- switch is in the correct position for factory. The engine runs normally. the process being used. (For The auxiliary power is normal. example, CV-WIRE, PIPE, CCSTICK.) 2. Make sure the electrode (wire, gas, voltage, current etc.
F-1 DIAGRAMS GX 300 F-1
F-2 DIAGRAMS GX 300 F-2
GX 300 + _ ELECTRODE CABLE TO WIRE FEED UNIT K595 CONTROL CABLE TO LN-8 INPUT CABLE PLUG TO WORK Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment. Do not operate with panels open. Disconnect NEGATIVE (-) Battery lead before servicing. Do not touch electrically live parts. N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS. SEE OPERATING MANUAL. N.B.
F-4 DIAGRAMS GX 300 F-4
F-5 DIAGRAMS GX 300 F-5
F-6 9/03 DIAGRAMS 2 F-6 GX 300
F-7 DIAGRAMS GX 300 F-7
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
GX 300 41.20 1046.5 42.10 1069.5 CENTER OF GRAVITY 24.86 631.3 23.50 596.9 20.80 528.3 TRUCK/UNDERCARRIAGE MOUNTING HOLES 2.62 66.5 17.50 444.5 16.75 425.4 19.50 495.3 CIRCUIT BREAKERS 10.28 261.0 7.22 183.3 10.78 273.9 DIMENSION DIAGRAM CODES 11678, 11740, 11795, 11802 29.80 756.9 36.24 920.4 A DIMENSION PRINT M22449 33.62 854.
GX 300 41.20 1046.5 42.00 1066.8 CENTER OF GRAVITY 24.45 621.0 20.80 528.3 TRUCK/UNDERCARRIAGE MOUNTING HOLES 2.62 66.5 17.50 444.5 11.00 279.4 19.50 495.3 DIMENSION DIAGRAM CODE 12098, 12204 CIRCUIT BREAKERS 10.28 261.0 7.22 183.3 10.78 273.9 29.80 756.9 33.62 854.0 A DIMENSION PRINT M24958 INCH MM 36.24 920.
NOTES GX 300
P-642 P-642 PARTS LIST FOR Red-D-Arc GX300 This parts list is provided as an informative guide only. It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electricʼs official Parts Book (BK-34). When ordering parts, always refer to Lincoln Electricʼs official Parts Book (BK-34) for the latest pages.
P-642-A P-642-A ILLUSTRATION OF SUB ASSEMBLIES 7 4 5 6 3 2 1 RED-D-ARC GX300 04-23-2013
P-642-A.1 P-642-A.1 Red-D-Arc GX300 For Codes: 11678, 11740, 11795, 11802, 12098 & 12204 Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed. PAGE NO. CODE NO. 1 2 3 4 5 6 7 Case Front (Lower) Base/Fuel Tank/Battery Assembly Engine Assembly Blower Baffle Assembly Stator/Rotor Assembly Covers & Case Back Assembly SUB ASSEMBLY PAGE NAME Miscellaneous Items Sub Assembly Item No.
P-642-B.2 # Indicates a change this printing. ITEM DESCRIPTION Spark Arrestor Clamp MISCELLANEOUS ITEMS P-642-B.2 (THESE ITEMS ARE NOT ILLUSTRATED) Use only the parts marked “x” in the column under the heading number called for in the model index page. PART NO. QTY.
NOTES RED-D-ARC GX300
P-642-C P-642-C Case Front (Upper) 3A 1A 9 27A 51A 51C 51B 23 27B 41 51A 8A 51B 28 33 31 38A 25 5A 33 4A 35A 34 37 RED-D-ARC GX300 04-23-2013
P-642-C.1 P-642-C.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. ITEM DESCRIPTION PART NO. QTY.
P-642-D P-642-D Case Front (Lower) 12A 12B 13 14 13 15 20C 20B 20A 50A 24 19 50B 18 20D 49A 16 7B 7A 17A 7E 7F 40 39 7D 22 45 39 21 7C 70B 70A 71 RED-D-ARC GX300 04-23-2013
P-642-D.1 P-642-D.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. ITEM DESCRIPTION PART NO. QTY.
P-642-E P-642-E Base/Fuel Tank/Battery Assembly 4C 10 4D 17E 4E 17F 17H 17G 4F 4G 5L 17C 17D 5M 5G 5N 5A 4B 17B 4A 17F 17H 5J 17A 8C 2A 8D 5B 8A 5C 7 8E 8B 5N 5K 1A 2B 1B 5P 20 RED-D-ARC GX300 Oct-13
P-642-E.1 P-642-E.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. ITEM DESCRIPTION PART NO. QTY.
P-642-E.2 P-642-E.2 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. ITEM DESCRIPTION PART NO. QTY.
NOTES RED-D-ARC GX300
P-642-F P-642-F Engine Assembly 1A 2A 1E 1B 1E 1F 1C RED-D-ARC GX300 04-23-2013
P-642-F.1 P-642-F.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9 1A 1A 1A 1B 1C 1D 1E 1F 1G 2A 2B 5 NSS NSS NSS S24344 CF000196 S9262-120 S9262-113 E106A-16 CF000067 G3574-4 M16999-1 M16980-1 1 1 1 2 2 2 6 2 2 1 2 1 X • • X X X X X X X X X Engine (M21300) - Kohler Engine (M22704) - Kohler Engine (M24866) - Kohler Rubber Mounting 3/8-16 x 2.
P-642-G P-642-G Blower Baffle Assembly 3A 3C 3B 9J 9K 9H 9B 3H 9A 7 2 13A 3G 5A 9F 3F 9D 9E 5B 4A 1 8C 8D 8A 16 8E 8F 15 RED-D-ARC GX300 04-23-2013
P-642-G.1 P-642-G.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. ITEM DESCRIPTION PART NO. QTY.
P-642-H P-642-H Stator/Rotor Assembly 2A 2C 2B 1A 7A 5A 5B 1G 1D 1E 9A 1F 8B 8A 1B 13 12 1C 11 10 RED-D-ARC GX300 04-23-2013
P-642-H.1 P-642-H.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. ITEM DESCRIPTION PART NO. QTY.
P-642-J P-642-J Covers & Case Back Assembly 9B 3A 16 9A 25A 7 25B 10 23 4B 8 19 18 4A 12 11 5A 27B 2A 6B 6A 6F 27A 1A 6C 13 RED-D-ARC GX300 04-23-2013
P-642-J.1 P-642-J.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. ITEM DESCRIPTION PART NO. QTY.
NOTES RED-D-ARC GX300
NOTES GX 300
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