IM930 RED-D-ARC GX 300 For use with machines having Code Numbers: November, 2006 11425 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 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 iv SAFETY PRÉCAUTIONS DE SÛRETÉ 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: Sûreté Pour Soudage A L’Arc 1. 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.
v v Thank You for selecting a QUALITY product . We want you to take pride in operating this ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
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) 2 cylinder High Idle 3700 Displacement cu. in. (cu. cm.) Full Load 3500 Capacities 12VDC Battery & Starter Bore x Stroke inch (mm) (Group 58; 435 cold crank amps) 3.15 x 2.64 (80 x 67) Battery Charger 41(674) Kohler CH23S 23 HP @ 3600 RPM Gasoline Engine Starting System Fuel: 12 gal. 45.4 L Oil: 2.0 Qts 1.
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 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. -----------------------------------------------------------------------ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing.
A-4 A-4 INSTALLATION VEHICLE MOUNTING 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 manufacturer’s 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 CAUTION If you are using an LN-25 without an internal contactor, the electrode will be energized when the GX 300 is started. -----------------------------------------------------------------------Connection of LN-7 or LN-8 to the GX 300 WARNING Shut off welder before making any electrical connections.
B-1 B-1 OPERATION SAFETY PRECAUTIONS ENGINE OPERATION Before Starting the Engine: WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s 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 15 14 13 1 12 2 11 10 3 9 8 7 6 4 5 WELDING CONTROLS 3. ARC CONTROL : 1. OUTPUT CONTROL: The CONTROL dial provides continuous control of the welding current or welding voltage depending on the selected welding mode. This control is not active in the CC-STICK, PIPE, and CV-WIRE modes when a remote control or wire feeder with remote control is connected to either the 3 pin or 14 pin Amphenol. 2.
B-3 B-3 OPERATION 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 CONSTANT WELDING 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. Carbon Diameter Current Range (DC, electrode positive) 1/8" The auxiliary power capacity is 10,000 watts Peak, 9500 Watts continuous of 60 Hz, single phase power.
C-1 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 ACCESSORIES Trailer Ball Hitch Lunette Eye Hitch Fender & Light Kit Cable Storage Rack K704 ACCESSORY SET - Includes 35 ft. (10m) of electrode cable and 30 ft. (9.
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 • Loosen the cover retaining knob and remove the cover. Spark Plug Service To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. • Remove the pre-cleaner from the paper element. • Remove the spark plug cap. • Remove the element cover nut, element cover, and paper element. • 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 D-4 MAINTENANCE 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 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: It’s normal for the brushes and slip rings to wear and darken slightly. Inspect the brushes when a generator overhaul is necessary. CAUTION Do not attempt to polish slip rings while the engine is running.
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 RECOMMENDED COURSE OF ACTION 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 F-1 DIAGRAMS GX 300
F-2 F-2 DIAGRAMS GX 300
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 F-4 DIAGRAMS GX 300
F-5 F-5 DIAGRAMS GX 300
F-6 9/03 DIAGRAMS 2 F-6 GX 300
F-7 F-7 DIAGRAMS GX 300
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.
F-9 DIMENSION PRINT GX 300 F-9
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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