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IM801
RED-D-ARC
September, 2002
GX 300
10851
For use with machines having Code Numbers:
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.
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.
1-866-733-3272
North America's Largest Fleet of Welding Equipment
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Table of Contents
Related Manuals for Lincoln Electric RED-D-ARC GX 300
Summary of Contents for Lincoln Electric RED-D-ARC GX 300
- Page 1 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 ...
- Page 2 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
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Page 3: Electric Shock Can Kill
SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”... - Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
- Page 5 SAFETY PRÉCAUTIONS DE SÛRETÉ zones où l’on pique le laitier. 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté...
- Page 6 QUALITY product by Lincoln Electric. We want you Thank You to take pride in operating this Lincoln Electric Company product ••• 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.
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Page 7: Table Of Contents
Welding Terminals ......................A-5 Welding Output Cables ....................A-5 Cable Installation......................A-5 Auxiliary Power Receptacles and Plugs ................A-6 Standby Power Connections ....................A-6 Premises Wiring ........................A-7 Connection of Lincoln Electric Wire Feeders ...............A-8 Operation.........................Section B Safety Precautions ......................B-1 General Description......................B-1 Design Features ........................B-1 Engine Operation........................B-1 Fuel ............................B-1... - Page 8 TABLE OF CONTENTS Maintenance......................Section D Safety Precautions ....................D-1 Routine Maintenance ....................D-1 Kohler Engine......................D-1 Engine Maintenance Components ................D-1 Engine Oil Change..................D-2 Engine Oil Refill Capacities................D-2 Engine Filter Change ..................D-2 Air Cleaner Service ..................D-2 Air Pre-Cleaner Service ..................D-2 Air Filter Paper Element ..................D-3 Spark Plug ......................D-3 Spark Plug Service ..................D-3 Fuel Filter ......................D-4...
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Page 9: Installation
INSTALLATION TECHNICAL SPECIFICATIONS - GX300 (K1725-5) INPUT - GASOLINE ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities cu. in. (cu. cm.) System 2 cylinder High Idle 3700 41(674) 12VDC Battery & Fuel: 12 gal. (K1725-5) 22 HP @ Bore x Stroke inch (mm) (Group 58; 435 Oil: 2.0 Qts l l u Battery Charger... -
Page 10: Machine Specifications
INSTALLATION MACHINE SPECIFICATIONS - GX300 (K1725-5) RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS (2) 120VAC Duplex GFCI Two 20AMP for Two Duplex GFCI Recptacle 25AMP for Battery Charging Circuit (5-20R)(1) 120/240VAC Dual Two 50AMP for Dual Voltage 15AMP for 42V Wire Feeder Power Voltage Full KVA (14-50R) GX 300... -
Page 11: Safety Precautions
INSTALLATION SAFETY PRECAUTIONS LIFTING The GX 300 weighs approximately 530 lbs. with a full WARNING tank of gasoline. A lift bail is mounted to the machine and should always be used when lifting the machine. Do not attempt to use this equipment until you ADDITIONAL SAFETY PRECAUTIONS have thoroughly read the engine manufacturer’s manual supplied with your welder. -
Page 12: Pre-Operation Engine Service
INSTALLATION The GX 300 is shipped with the negative battery cable PRE-OPERATION ENGINE SERVICE disconnected. Make certain that the RUN-STOP WARNING switch is in the STOP position. Remove the two screws from the rear battery tray using a screwdriver or a 3/8" socket. Attach the negative battery cable to READ the engine operating and maintenance instruc- the negative battery terminal and tighten using a 1/2"... -
Page 13: Electrical Connections
INSTALLATION The 14 pin connector is used to directly connect a WELDING TERMINALS wire feeder or TIG Module (K930-2) control cable. In The GX 300 is equipped with a toggle switch for the CV-WIRE mode, the GX 300 auto-sensing circuit selecting "hot"... -
Page 14: Standby Power Connections
INSTALLATION STANDBY POWER CONNECTIONS CAUTION The GX 300 is suitable for temporary, standby or • Loose connections will cause the output termi- emergency power using the engine manufacturer’s nals to overheat. The terminals may eventually recommended maintenance schedule. melt. • Do not cross the welding cables at the output The GX 300 can be permanently installed as a stand- terminal connection. -
Page 15: Premises Wiring
INSTALLATION CONNECTION OF GX 300 TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 120 VOLT 60 Hz. COMPANY 3-Wire 120 VOLT Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. -
Page 16: Connection Of Lincoln Electric Wire Feeders
INSTALLATION CONNECTION OF LINCOLN ELECTRIC CAUTION WIRE FEEDERS If you are using an LN-25 without an internal con- tactor, the electrode will be energized when the Connection of the LN-25 to the GX 300 GX 300 is started. ------------------------------------------------------------------------ Connection of LN-7 or LN-8 to the GX 300 WARNING 1. -
Page 17: Operation
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 • Open top engine door and remove the engine oil have thoroughly read the engine manufacturer’s dipstick and wipe it with a clean cloth. -
Page 18: Welding Controls
OPERATION 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 The CONTROL dial provides continuous control of the modes. This control is not active in the TIG mode. welding current or welding voltage depending on the selected welding mode. -
Page 19: Engine Controls
OPERATION 4. WELD OUTPUT TERMINALS WITH 13. IDLER SWITCH - Has two positions as follows: FLANGE NUT: 1) In the HIGH position, the engine runs at the high Provides a connection point for the electrode and idle speed controlled by the engine governor. work cables. -
Page 20: Stopping
OPERATION WELDER OPERATION • The engine will run at high idle speed for approxi- Stick Welding mately 12 seconds and then go to low idle speed. The GX 300 can be used with a broad range of DC Allow the engine to warm up at low idle for several stick electrodes. -
Page 21: Tig Welding
OPERATION TIG Welding When using the TIG Module, the OUTPUT control on The TOUCH START TIG setting of the MODE switch is the GX 300 is used to set the maximum range of the for DC TIG (Tungsten Inert Gas) welding. To initiate a CURRENT CONTROL on the TIG module or an weld, the CONTROL dial is first set to the desired current Amptrol if connected to the TIG Module. -
Page 22: Arc Gouging
OPERATION ARC GOUGING The auxiliary power capacity is 10,000 watts Peak, 9500 Watts continuous of 60 Hz, single phase power. The GX 300 can be used for limited arc gouging. For The auxiliary power capacity rating in watts is equiva- optimal performance, set the MODE switch to CC- lent to volt-amperes at unity power factor. -
Page 23: Accessories
ACCESSORIES OPTIONS/ACCESSORIES AND COM- K702 ACCESSORY KIT Accessory set includes 35 ft. (10.7 meters) 2 AWG PATIBLE LINCOLN EQUIPMENT electrode cable, 30 ft. (9.1 meters) 2 AWG work cable, K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR headshield with No. 12 filter, GC300 work clamp and SMALL WELDERS Cooltong 300 electrode holder. -
Page 24: Maintenance
MAINTENANCE KOHLER ENGINE FREQUENCY MAINTENANCE REQUIRED WARNING Daily or Before • Fill fuel tank. • Have qualified personnel do all maintenance Starting Engine • Check oil level. and troubleshooting work. • Check air cleaner for dirty, loose, • Turn the engine off before working inside the or damaged parts. -
Page 25: Engine Oil Change
MAINTENANCE • Refill the crankcase with the specified amount of the Engine Oil Change recommended oil. Reinstall the oil filler cap. Drain the oil while the engine is warm to assure rapid and complete draining. • Start the engine and check for oil filter leaks. •... -
Page 26: Air Filter Paper Element
MAINTENANCE AIR FILTER PAPER ELEMENT Spark Plug Service • Loosen the cover retaining knob and remove the cover. To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. • Remove the pre-cleaner from the paper element. •... -
Page 27: Fuel Filter
MAINTENANCE CLEANING THE BATTERY FUEL FILTER Keep the battery clean by wiping it with a damp cloth • Check the fuel filter for water accumulation or sedi- when dirty. If the terminals appear corroded, discon- ment. nect the battery cables and wash the terminals with an ammonia solution or a solution of 1/4 pound (0.1113 •... -
Page 28: Welder/Generator Maintenance
Do not attempt to polish slip rings while the engine is running. WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equip- ment may result in danger to the technician and machine operator and will invalidate your factory warranty. -
Page 29: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory 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. - Page 30 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION 1. Contact your local Lincoln Major Physical or Electrical Damage is Evident. Authorized Field Service Facility. Engine will not "crank". 1. Battery is low, Charge Battery 2.
- Page 31 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION Engine will not idle down to low 1. Idler switch in High idle position. speed. Set switch to Auto. 2. External load on welder or auxil- iary power.
- Page 32 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT (S) 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.
- Page 33 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) 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.
- Page 34 DIAGRAMS GX 300...
- Page 35 DIAGRAMS GX 300...
- Page 36 DIAGRAMS GX 300...
- Page 37 DIAGRAMS GX 300...
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- Page 41 DIAGRAMS GX 300...
- Page 42 DIAGRAMS GX 300...
- Page 43 F-10 DIAGRAMS F-10 GX 300...
- Page 44 NOTES GX 300...
- Page 45 Year AMERICAN EXPRESS USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or,...
- Page 46 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
- Page 47 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
- Page 48 • World's Leader in Welding and Cutting Products • • 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...