Lincoln Electric Airgas RED-D-ARC DX300e Operator's Manual
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Lincoln Electric Airgas RED-D-ARC DX300e Operator's Manual

Lincoln Electric Airgas RED-D-ARC DX300e Operator's Manual

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IM981
RED-D-ARC
June, 2009
(
DX300e (CE)
11527
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.
The Global Leader in Welder Rentals

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Summary of Contents for Lincoln Electric Airgas RED-D-ARC DX300e

  • 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.
  • Page 3 SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. 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 and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire.
  • Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté...
  • Page 6 SAFETY                !" #$ % & '& ( & &&  " % & '& (  ') -./0 %       *+,  & 0 $ 1...
  • Page 7 (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 8 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda- tions.
  • Page 9 viii viii for selecting one of our QUALITY products. We want you to take T T h h a a n n k k Y Y o o u u 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.

  • Page 10: Table Of Contents

    Machine Grounding .......................A-4 Welding Terminals ......................A-5 Welding Output Cables ....................A-5 Cable Installation......................A-5 Auxiliary Power ........................A-5 Standby Power Connections ....................A-5 Connection of Lincoln Electric Wire Feeders..............A-6, A-7 ________________________________________________________________________________ Operation.........................Section B Safety Precautions ......................B-1 General Description......................B-1 For Auxiliary Power ......................B-1 Engine Operation........................B-1 Add Fuel ..........................B-1...
  • Page 11 TABLE OF CONTENTS Maintenance......................Section D Safety Precautions ....................D-1 Routine Maintenance ....................D-1 Engine Maintenance Components ................D-1 Kubota Diesel Engine ....................D-1 Engine Oil Change..................D-2 Engine Oil Refill Capacities................D-2 Engine Oil Filter Change.................D-2 Air Cleaner Service ..................D-2 Service Instructions And Installation Tips for Engine Air Filter ......D-3 Cooling System .....................D-4 Fan Belt......................D-4 Fuel .........................D-4...

  • Page 12: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - DX300e (CE) ( K2753-1) INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities cu. in. (cu. cm.) System 3 cylinder, 4 stroke 43.88(789) 12VDC Battery & Fuel: 15.9 HP starter 45L (12 US.gal.) (12 KW) High Idle 3100 Bore x Stroke inch (mm) Oil:...

  • Page 13: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS LIFTING The machine weighs approximately 374 kg. (824 lbs) WARNING with a full tank of fuel. 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 have thoroughly read the engine manufacturer’s WARNING manual supplied with your welder.

  • Page 14: Towing

    INSTALLATION PRE-OPERATION ENGINE SERVICE TOWING READ the engine operating and maintenance instruc- Check with distributor for the recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle. If tions supplied with this machine. the user adapts a non-Lincoln trailer, he must assume responsi- WARNING bility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment.

  • Page 15: Battery Connections

    INSTALLATION ENGINE COOLING SYSTEM REMOTE CONTROL The machine is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for connecting the WARNING K857 or K857-1 Remote Control or for TIG welding, Air to cool the engine is drawn in the base sides the K870 foot Amptrol or the K963-3 hand Amptrol.

  • Page 16: Welding Terminals

    INSTALLATION When this welder is mounted on a truck or trailer, its CABLE INSTALLATION frame must be electrically bonded to the metal frame of Install the welding cables to your machine as follows: the vehicle. Use a #8 or larger copper wire connected 1.

  • Page 17: Connection Of Lincoln Electric Wire Feeders

    DX300e (CE). See the appropriate ----------------------------------------------------------------------- connection diagram in Section F. CONNECTION OF LINCOLN ELECTRIC NOTE: The LN-25 (K431) Remote Control Module WIRE FEEDERS and (K432) Remote Cable are not recommended for Connection of LN-15 to the DX300e (CE) use with the DX300e (CE).
  • Page 18 INSTALLATION Connection of LN-742 and Cobramatic to DX300e (CE). • Shut the welder off. • Connect per instructions on the appropriate connec- tion diagram in Section F. DX300e (CE) (RED-D-ARC)

  • Page 19: Operation

    OPERATION SAFETY PRECAUTIONS • Check radiator for proper coolant level. (Fill if nec- essary). • See Engine Owner’s Manual for specific oil and WARNING coolant recommendations. ADD FUEL Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder.
  • Page 20 OPERATION FIGURE B.1 WELDING CONTROLS (Figure B.1) When in the TOUCH START TIG mode and when a Amptrol is connected to the 6-Pin Connector, the OUT- 1. OUTPUT CONTROL: The OUTPUT dial is used PUT control is used to set the maximum current range of the CURRENT CONTROL of the Amptrol.

  • Page 21: Engine Controls

    OPERATION 10. WIRE FEEDER VOLTMETER SWITCH: 4. ARC CONTROL : The ARC CONTROL dial is active in Matches the polarity of the wire feeder voltmeter to the the CV-WIRE, CC-STICK and DOWNHILL PIPE modes, polarity of the electrode. and has different functions in these modes. This control is not active in the TIG mode.

  • Page 22: Stopping

    OPERATION 15. ELECTRIC FUEL GAUGE- 8. The engine will run at high idle speed for approxi- Provides accu- mately 12 seconds and then drop to low idle speed. rate, reliable indication of how much fuel is in the Allow the engine to warm up at low idle for several tank.

  • Page 23: Duty Cycle

    OPERATION WELDER OPERATION The OUTPUT CONTROL dial adjusts the full output range for stick welding. The ARC CONTROL dial sets the short DUTY CYCLE circuit current (arc-force) during stick welding to adjust for Duty Cycle is the percentage of time the load is being a soft or a more forceful digging arc(crisp).

  • Page 24: Wire Welding-Cv

    OPERATION When in the TOUCH START TIG mode and when a For any electrodes the procedures should be kept Amptrol is connected to the 6-pin Connector the OUT- within the rating of the machine. For additional elec- PUT dial is used to set the maximum current range of trode information see WWW.Lincolnelectric.com.

  • Page 25: Accessories

    ACCESSORIES FIELD INSTALLED OPTIONS / ACCESSORIES K704 ACCESSORY SET - Includes (10m) 35 ft. of electrode cable and (9.m) 30 ft. of work cable, head- shield, work clamp electrode holder. Cables are rated at 400 amps, 100% duty cycle. K857 (7.6m) 25 ft. or K857-1 (30.4m) 100 ft. REMOTE CONTROL - Portable control provides same dial range as the output control on the welder.

  • Page 26: Maintenance

    MAINTENANCE KUBOTA D722 DIESEL ENGINE SAFETY PRECAUTIONS FREQUENCY MAINTENANCE REQUIRED • FILL FUEL TANK. WARNING • CHECK OIL LEVEL. • CHECK COOLANT LEVEL. • Have qualified personnel do all maintenance • CHECK AIR CLEANER ELE- and troubleshooting work. MENT AND HOUSING FOR DIRTY, LOOSE OR DAMAGED PARTS.

  • Page 27: Engine Oil Change

    MAINTENANCE OIL FILTER CHANGE ENGINE OIL CHANGE • Drain the oil. Drain the engine oil while the engine is warm to assure rapid and complete draining. It is recommended that • Remove the oil filter with an oil filter wrench and each time the oil is changed the oil filter be changed as drain the oil into a suitable container.
  • Page 28 MAINTENANCE DX300e (CE) (RED-D-ARC)

  • Page 29: Cooling System

    MAINTENANCE FUEL COOLING SYSTEM WARNING At the end of each day’s use, refill the fuel tank to min- imize moisture condensation and dirt contamination in HOT COOLANT can burn skin. the fuel line. Do not overfill; leave room for the fuel to expand.

  • Page 30: Fuel Filter

    MAINTENANCE CLEANING THE BATTERY FUEL FILTER Keep the battery clean by wiping it with a damp cloth 1. Check the fuel filter and fuel pre-filter for water accu- when dirty. If the terminals appear corroded, discon- mulation or sediment. nect the battery cables and wash the terminals with an ammonia solution or a solution of 113g (1/4 pound) of 2.

  • Page 31: Welder / Generator Maintenance

    MAINTENANCE WELDER / GENERATOR MAINTENANCE STORAGE: Store the DX300e (CE) in clean, dry pro- tected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air. Do this at least once a week in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT: It’s nor- mal for the brushes and slip rings to wear and darken slightly.

  • Page 32: Troubleshooting

    TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by 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 33 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Major Physical or Electrical Damage 1. Contact your local Authorized is Evident. Field Service Facility. 1. Battery is low, Charge Battery. Engine will not "crank". 2.
  • Page 34 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Engine shuts down while under a 1. High radiator coolant tempera- load. ture. Reduce load if it is exceed- ing machine rating. Add coolant to system if low.
  • Page 35 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Engine will not go to high idle when 1. Auxiliary power load is less than using auxiliary power. 100 watts. Idler may not respond with less than a 100 watt load.
  • Page 36 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION No welding power output. 1. Poor work lead connection to Auxiliary Power OK. work. Make sure work clamp is tightly connected to clean base metal.
  • Page 37 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE 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 38 DIAGRAMS DX300e (CE) (RED-D-ARC)
  • Page 39 DIAGRAMS DX300e (CE) (RED-D-ARC)
  • Page 40 DIAGRAMS DX300e (CE) (RED-D-ARC)
  • Page 41 DIAGRAMS DX300e (CE) (RED-D-ARC)
  • Page 42 DIAGRAMS DX300e (CE) (RED-D-ARC)
  • Page 43 DIAGRAMS DX300e (CE) (RED-D-ARC)
  • Page 44 DIMENSION PRINT DX300e (CE) (RED-D-ARC)
  • Page 45 NOTES DX300e (CE) (RED-D-ARC)
  • Page 46 NOTES DX300e (CE) (RED-D-ARC)
  • Page 47 NOTES DX300e (CE) (RED-D-ARC)
  • Page 48 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 49 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 50 • 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...

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