Lincoln Electric Red-D-Arc GX300 Mode d'emploi

Catégorie
Système de soudage
Taper
Mode d'emploi
RED-D-ARC
GX 300
IM10047-D
August 2013
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.
For use with machines having Code Numbers:
11678, 11740, 11795, 11802, 12098, 12204
The Global Leader in Welder Rentals
OPERATOR’S MANUAL
(
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.
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.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment 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.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you de velop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
Always start and operate the engine in a
well-ventilated area.
If in an exposed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For
additional safety information, it is strongly recommended
that you purchase a copy of “Safety in Welding & Cutting -
ANSI Standard Z49.1” from the American Welding Society,
P.O. Box 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.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine
exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding
arc or when the engine is running. Stop the
engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact
with hot engine parts and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018
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.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
between the
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see It ems 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018
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. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
Away from areas where they may be struck or subjected
to physical damage.
A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018
iv
SAFETY
iv
GX 300
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 suiv-
antes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du ray-
onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
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.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-
er à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
vi
vi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Machine Specifications ........................................................................................................A-2
Safety Precautions ........................................................................................................A-3
Location and Ventilation................................................................................................A-3
Stacking ........................................................................................................................A-3
Angle of Operation ........................................................................................................A-3
Lifting.............................................................................................................................A-3
Additional Safety Precautions .......................................................................................A-3
High Altitude Operation .................................................................................................A-3
High Temperature Operation ........................................................................................A-3
Towing...........................................................................................................................A-3
Vehicle Mounting...........................................................................................................A-4
Pre-Operation Engine Service..............................................................................................A-4
Oil..................................................................................................................................A-4
Fuel ...............................................................................................................................A-4
Engine Coolant..............................................................................................................A-4
Battery Connections......................................................................................................A-4
Muffler Outlet Pipe ........................................................................................................A-4
Spark Arrester ...............................................................................................................A-4
High Frequency Generators for Tig Applications ..........................................................A-5
Remote Control .............................................................................................................A-5
Electrical Connections..........................................................................................................A-5
Machine Grounding.......................................................................................................A-5
Welding Terminals ........................................................................................................A-5
Welding Output Cables .................................................................................................A-5
Cable Installation...........................................................................................................A-6
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
Welder Controls ............................................................................................................B-2
Engine Controls.............................................................................................................B-3
Starting and Stopping the Engine .................................................................................B-3
Stopping .......................................................................................................................B-4
Welding Operation................................................................................................................B-4
DC Stick Welding ..........................................................................................................B-4
Constant Current (Stick) Welding..................................................................................B-4
Pipe Welding .................................................................................................................B-4
Fuel Consumption .........................................................................................................B-4
Tig Welding ...................................................................................................................B-5
Typical Current Ranges for Tungsten Electrodes .........................................................B-5
Wire Welding-CV...........................................................................................................B-5
Arc Gouging ..................................................................................................................B-6
Auxiliary Power .............................................................................................................B-6
Simultaneous Welding and Auxiliary Power Loads.......................................................B-6
Extension Cord Recommendations...............................................................................B-6
________________________________________________________________________
Accessories.....................................................................................................Section C
Options / Accessories and Compatible Lincoln Equipment.................................................C-1
________________________________________________________________________________
vii
vii
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
Oil 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
Engine Adjustment ..........................................................................................D-4
Battery Maintenance .......................................................................................D-4
Servicing Optional Spark Arrestor ...................................................................D-4
Welder / Generator Maintenance ........................................................................D-5
Storage ...........................................................................................................D-5
Cleaning..........................................................................................................D-5
Brush Removal and Replacement ..................................................................D-5
GFCI Receptacle Testing and Resetting Procedure.......................................D-5
________________________________________________________________________
Troubleshooting..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Troubleshooting Guide ..........................................................................................E-3
Troubleshooting Guide ..........................................................................................E-4
Troubleshooting Guide ..........................................................................................E-5
________________________________________________________________________
Diagrams and Dimension Print ......................................................................Section F
________________________________________________________________________
Parts List.................................................................................................................P-642
________________________________________________________________________
GX 300
1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to
rated capacity. When welding, available auxiliary power will be reduced.
A-1
INSTALLATION
A-1
TECHNICAL SPECIFICATIONS - GX300 (K2284-2)
INPUT - GASOLINE ENGINE
RATED OUTPUT @ 104° F (40° C) - WELDER
HEIGHT WIDTH DEPTH WEIGHT
30.00** in. 21.50 in 42.25 in.
762.0 mm 546.0 mm 1073.0 mm
LUBRICATION VALVE LIFTERS FUEL SYSTEM GOVERNOR
Full Pressure Hydraulic Mechanical Fuel Pump Mechanical Governor
with Full Flow Filter 5% Regulation
AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION
Low noise Muffler: Top outlet Shutdown on low oil
Duel Element Automatic Idler can be rotated. Made from pressure.
long life, aluminized steel.
ENGINE WARRANTY: 2 year unlimited hours (See engine manufacturer warranty for details.)Kohler
Welding Output Volts at Rated Amps Duty Cycle Max. OCV @ 3700 RPM
CC STICK DC Output 29 Volts @ 305 Amps 100%
CC STICK Output Range 20 to 305 Amps -------
PIPE DC Output 29 Volts @ 300 Amps 100%
PIPE Output Range 40 to 300 Amps -------
Touch Start™ TIG Output Range
30 to 250 Amps 100% 60 Volts
Touch Start™ TIG Output Range
20 to 250 Amps -------
CV WIRE DC Output 29 Volts @ 300 Amps 100%
CV WIRE Output Range 14 to 29 volts -------
Auxiliary Power
1
10,000 Watts Peak, 9500 Watts Continuous, 60 Hz
120/240 Volts
PHYSICAL DIMENSIONS
ENGINE COMPONENTS
RATED OUTPUT @ 104° F (40° C)
.
- GENERATOR
Speed (RPM)
High Idle 3700
Full Load 3500
Starting
System
12VDC Battery &
Starter
(Group 58; 435
Cold crank amps)
Battery Charger
Displacement
cu. In.(cu. Cm.)
41(674)
44.2(725)
Bore x Stroke
inch (mm)
3.15 x 2.64
(80 x 67)
3.27 x 2.64
(83 x 67)
Make/Model
Kohler
CH23S
CH680
CH730
Description
2 cylinder
23 HP @
3600 RPM
Gasoline
Engine
Capacities
Fuel: 12 gal.
45.4 L
Oil: 2.0 qt.
1.9 ltr.
Codes 11802 and below
463 lbs. (210kg.)
Code 12098
467 lbs. (212kg.)
A-2
INSTALLATION
A-2
GX 300
MACHINE SPECIFICATIONS - GX300 (K2284-2)
RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS
(2) 120VAC Duplex GFCI Two 20AMP for Two Duplex GFCI Receptacle
20AMP for Battery Charging Circuit
(5-20R)(1) 120/240VAC Dual One 50AMP for Dual Voltage (2-Pole)
15AMP for 42V Wire Feeder Power
Voltage Full KVA (14-50R)
RECEPTACLES AND CIRCUIT BREAKERS
A-3
INSTALLATION
A-3
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.
ADDITIONAL SAFETY PRECAUTIONS
• Lift only with equipment of
adequate lifting capacity.
Be sure machine is stable
when lifting.
• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trail-
er or gas cylinder.
FALLING • Do not lift machine if lift bale is
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bale.
------------------------------------------------------------------------
HIGH ALTITUDE OPERATION
At higher altitudes, output de-rating may be necessary. For
maximum rating, de-rate the welder output 3.5% for every 1000
ft. (305m). Contact an authorized engine service shop for modi-
fications to operate above 5,000 ft. (1524m).
HIGH TEMPERATURE OPERATION
At temperatures above 40°C, Welder output derating is neces-
sary. For maximum output ratings, derate the welder output 2
volts for every 10°C above 40°C.
TOWING
The recommended trailer for use with this equipment for road,
in-plant and yard towing by a vehicle(1) is Lincolnʼs K957-1. If
the user adapts a non-Lincoln trailer, he must assume responsi-
bility that the method of attachment and usage does not result
in a safety hazard nor damage the welding equipment. Some of
the factors to be considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln equipment and
likely additional attachments.
2. Proper support of, and attachment to, the base of the weld-
ing equipment so there will be no undue stress to the frame-
work.
3. Proper placement of the equipment on the trailer to insure
stability side to side and front to back when being moved
and when standing by itself while being operated or ser-
viced.
4. Typical conditions of use, i.e., travel speed; roughness of sur-
face on which the trailer will be operated; environmental con-
ditions; like maintenance.
5. Conformance with federal, state and local laws.
(1)
(1)
Consult applicable federal, state and local laws regarding
specific requirements for use on public highways.
GX 300
SAFETY PRECAUTIONS
Only qualified personnel should install,
use, or service this equipment.
LOCATION AND VENTILATION
The welder should be located to provide an unrestrict-
ed flow of clean, cool air to the cooling air inlets and to
avoid restricting the cooling air outlets. Also, locate the
welder so that the engine exhaust fumes are properly
vented to an outside area.
STACKING
GX 300 machines cannot be stacked.
ANGLE OF OPERATION
Engines are designed to run in the level condition
which is where the optimum performance is achieved.
The maximum angle of continuous operation is 15
degrees in any direction. If the engine is to be operat-
ed at an angle, provisions must be made for checking
and maintaining the oil level at the normal (FULL) oil
capacity in the crankcase.
When operating the welder at an angle, the effective
fuel capacity will be slightly less than the specified 12
gallons.
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.
Do not touch electrically live parts or
electrode with skin or wet clothing.
Insulate yourself from work and
ground
• Always wear dry insulating gloves.
-------------------------------------------------------
ENGINEEXHAUSTcan kill.
Use in open, well ventilated areas or
vent exhaust outside.
--------------------------------------------------------
MOVING PARTScan injure.
Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
front of this operatorʼs manual.
WARNING
WARNING
VEHICLE MOUNTING
Improperly mounted concentrated loads may cause
unstable vehicle handling and tires or other compo-
nents to fail.
Only transport this Equipment on serviceable vehi-
cles 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 compo-
nents such as suspension, axles and tires.
Mount equipment base to metal bed or frame of
vehicle.
• Follow vehicle manufactureʼs instructions.
---------------------------------------------------------------------------
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instruc-
tions supplied with this machine.
FUEL
USE GASOLINE FUEL ONLY
Stop fueling once the fuel gauge reads full. Do not top
off tank. Be sure to leave filler neck empty to allow
room for expansion.
Fill the fuel tank with clean, fresh fuel. The capacity of
the fuel tank is 12 gallons (45.4 liters). When the fuel
gauge reads empty the tank contains approximately 2
gallons of reserve fuel.
NOTE: The fuel tank is mounted below the engine so a
fuel shutoff valve is not required.
--------------------------------------------------------------------------------
A-4
INSTALLATION
A-4
OIL
The GX 300 is shipped with the engine crankcase filled with
high quality SAE 10W-30 oil. Check the oil level before
starting the engine. If it is not up to the full mark on the dip
stick, add oil as required. Check the oil level every four
hours of running time during the first 25 running hours.
Refer to the engine Operatorʼs Manual for specific oil recom-
mendations and break-in information. The oil change inter-
val is dependent on the quality of the oil and the operating
environment. Refer to the Engine Operatorʼs Manual for the
proper service and maintenance intervals.
ENGINE COOLING SYSTEM
Air to cool the engine is drawn in lower set of louvers on the
case back. It is important that the intake air is not restricted.
Allow a minimum clearance of 2 feet (0.6m) from the case
back to a vertical surface.
BATTERY CONNECTION
Use caution as the electrolyte is a strong acid that can
burn skin and damage eyes.
--------------------------------------------------------------------------------
The GX 300 is shipped with the negative battery cable dis-
connected. Make certain that the RUN-STOP 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 the negative battery terminal and
tighten using a 1/2" socket or wrench.
NOTE: This machine is furnished with a wet charged bat-
tery; if unused for several months, the battery may require a
booster charge. Be careful to charge the battery with the
correct polarity.
MUFFLER OUTLET PIPE
Using the clamp provided secure the outlet pipe to the outlet
tube with the pipe positioned such that it will direct the
exhaust in the desired direction. Tighten using a 9/16" sock-
et or wrench.
SPARK ARRESTER
Some federal, state or local laws may require that gasoline
or diesel engines be equipped with exhaust spark arresters
when they are operated in certain locations where unarrest-
ed sparks may present a fire hazard. The standard muffler
included with this welder does not qualify as a spark
arrester. When required by local regulations, a suitable
spark arrester, such as the S24647 must be installed and
properly maintained.
GX 300
WARNING
WARNING
WARNING
CAUTION
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away from tank.
• Do not leave unattended while fueling.
Wipe up spilled fuel and allow
fumes to clear before starting
engine.
Do not overfill tank, fuel expansion
may cause overflow.
GASOLINE FUEL ONLY
------------------------------------------------------------------------
WARNING
GASOLINE
can cause fire
or explosion.
FULL
A-5
INSTALLATION
A-5
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 generat-
ing equipment must be properly grounded. See the
K930-2 Operating Manual for completed instructions
on installation, operation, and maintenance.
REMOTE CONTROL
The GX 300 is equipped with a 3 pin and a 14 pin
connector.
When in the CC-STICK, PIPE, and CV-WIRE modes
and when a remote control is connected to the auto-
sensing circuit in the GX 300 automatically switches
the OUTPUT control from control at the welder to
remote control.
The 14 pin connector is used to directly connect a
wire feeder or TIG Module (K930-2) control cable. In
the CV-WIRE mode, the GX 300 auto-sensing circuit
automatically makes the GX 300 Output Control inac-
tive and the wire feeder voltage control active when
the control cable is connected to the 14 pin connector.
NOTE: When a wire feeder with a built in welding volt-
age control is connected to the 14 pin connector, do
not connect anything to the other connector.
ELECTRICAL CONNECTIONS
MACHINE GROUNDING
Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to
an earth ground, unless the machine is connected to
premises wiring (home, shop, etc.)
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must:
Be grounded to the frame of the welder using a
grounded type plug.
• Be double insulated.
Do not ground the machine to a pipe that carries
explosive or combustible material.
------------------------------------------------------------------------
When this welder is mounted on a truck or trailer, its
frame must be electrically bonded to the metal frame
of the vehicle. When this engine driven welder is con-
nected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth
ground. See further connection instructions in the sec-
tion entitled "Standby Power Connections" as well as
the article on grounding in the latest U.S. National
Electrical Code and the local code.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into
the ground for at least ten feet and having no insulat-
ed joints, or to the metal framework of a building
which has been effectively grounded.
The U.S. National Electrical Code lists a number of
alternate means of grounding electrical equipment. A
machine grounding stud marked with the symbol
is provided on the front of the welder.
WELDING TERMINALS
The GX 300 is equipped with a toggle switch for
selecting "hot" welding terminal when in the "WELD
TERMINALS ON" position or "cold" welding terminal
when in the "REMOTELY CONTROLLED" position.
WELDING OUTPUT CABLES
With the engine off connect the electrode and work
cables to the output studs. The welding process dic-
tates the polarity of the electrode cable. These con-
nections should be checked periodically and tightened
with a 3/4" wrench.
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
TABLE A-1
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable Length
0-100Ft. (0-30 meters)
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
Cable Size for
305 Amps
100% Duty Cycle
1 / 0 AWG
2 / 0 AWG
3 / 0 AWG
GX 300
WARNING
CAUTION
A-6
INSTALLATION
A-6
CABLE INSTALLATION
Install the welding cables to your GX 300 as follows.
1. The gasoline engine must be OFF to install welding
cables.
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 identi-
fied on the case front.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding (the
“work”) is properly connected to the work clamp and
cable.
6. Check and tighten the connections periodically.
Loose connections will cause the output termi-
nals to overheat. The terminals may eventually
melt.
Do not cross the welding cables at the output
terminal connection. Keep the cables isolated
and separate from one another.
------------------------------------------------------------------------
AUXILIARY POWER RECEPTACLES
The auxiliary power of the GX 300 consists of two 20
Amp-120 VAC (5-20R) duplex receptacles and one 50
Amp 120/240 VAC (14-50R) receptacle. The 240 VAC
receptacle can be split for single phase 120 VAC
operation.
The auxiliary power capacity is 10,000 watts Peak,
9500 Watts Continuous of 60 Hz, single phase power.
The auxiliary power capacity rating in watts is equiva-
lent to volt-amperes at unity power factor. The max
permissible current of the 240 VAC output is 40 Amps.
The 240 VAC output can be split to provide two sepa-
rate 120 VAC outputs with a max permissible current
of 40 Amps per output to two separate 120 VAC
branch circuits (these circuits cannot be paralleled).
Output voltage is within ± 10% at all loads up to rated
capacity. All auxiliary power is protected by circuit
breakers.
The 120 V auxiliary power receptacles should only be
used with three wire grounded type plugs or approved
double insulated tools with two wire plugs. The current
rating of any plug used with the system must be at
least equal to the current capacity of the associated
receptacle.
NOTE: The 240 V receptacle has two 120 V circuits,
but are of opposite polarities and cannot be paralleled.
STANDBY POWER CONNECTIONS
The GX 300 is suitable for temporary, standby or
emergency power using the engine manufacturerʼs
recommended maintenance schedule.
The GX 300 can be permanently installed as a stand-
by power unit for 240 VAC, 3 wire, single phase, 40
amp service. Connections must be made by a
licensed electrician who can determine how the
120/240 VAC power can be adapted to the particular
installation and comply with all applicable electrical
codes.
Install the double-pole, double-throw switch
between the power company meter and the premis-
es disconnect. Switch rating must be the same or
greater than the customerʼs premises disconnect
and service over current protection.
Take necessary steps to assure load is limited to
the capacity of the GX 300 by installing a 40 amp,
240 VAC double pole circuit breaker. Maximum
rated load for each leg of the 240 VAC auxiliary is
40 amperes. Loading above the rated output will
reduce output voltage below the allowable - 10% of
rated voltage which may damage appliances or
other motor-driven equipment and may result in
overheating of the GX 300 engine and/or alternator
windings.
Install a 50 amp, 120/240 VAC plug (NEMA Type
14-50) to the double-pole circuit breaker using No.
6, 4 conductor cable of the desired length. (The 50
amp, 120/240 VAC plug is available in the optional
K802R plug kit or as part number T12153-9.)
• Plug this cable into the 50 Amp, 120/240 Volt recep-
tacle on the GX 300 case front.
GX 300
CAUTION
A-7
INSTALLATION
A-7
240 Volt
60 Hz.
3-Wire
Service
POWER
COMPANY
METER
240 VOLT
120 VOLT
120 VOLT
LOAD
N
NEUTRAL
BUS
GROUND
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GND
N
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
240 VOLT
GROUNDED CONDUCTOR
40AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
50 AMP, 120/240 VOLT
RECEPTACLE
CONNECTION OF GX 300 TO PREMISES WIRING
Only a licensed, certified, trained electrician should install the machine to a premises or residential
electrical system. Be certain that:
• The installation complies with the National Electrical Code and all other applicable electrical codes.
• The premises is isolated and no feedback into the utility system can occur. Certain state and local
laws require the premises to be isolated before the generator is linked to the premises. Check your
state and local requirements.
A double pole, double throw transfer switch in conjunction with the properly rated double throw
circuit breaker is connected between the generator power and the utility meter.
GX 300
WARNING
A-8
INSTALLATION
A-8
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
Connection of the LN-25 to the GX 300
Shut off welder before making any electrical con-
nections.
------------------------------------------------------------------------
The LN-25 with or without an external contactor may
be used with the GX 300. See the appropriate con-
nection 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.
2
. For electrode Positive, connect the electrode
cable from the LN-25 to the "+" terminal of the
welder and work cable to the "-" terminal of the
welder. For electrode Negative, connect the elec-
trode cable from the LN-25 to the "-" terminal of
the welder and work cable to the "+" terminal of
the welder.
3. Attach the single lead from the front of the LN-25
to work using the spring clip at the end of the lead.
This is a control lead to supply current to the wire
feeder motor; it does not carry welding current.
4. Set the MODE switch to the "CV-WIRE " position.
5. Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON"
6. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
7. Set the "IDLE" switch to the "AUTO" position.
When not welding, the GX 300 engine will be at
the low idle speed. If you are using an LN-25 with
an internal contactor, the electrode is not ener-
gized until the gun trigger is closed.
8. When the gun trigger is closed, the current sens-
ing circuit will cause the GX 300 engine to go to
the high idle speed, the wire will begin to feed and
the welding process started. When welding is
stopped, the engine will revert to low idle speed
after approximately 12 seconds unless welding is
resumed.
If you are using an LN-25 without an internal con-
tactor, the electrode will be energized when the
GX 300 is started.
------------------------------------------------------------------------
Connection of LN-7 or LN-8 to the GX 300
1. Shut the welder off.
2.
Connect the LN-7 or LN-8 per instructions on the
appropriate connection diagram in Section F
3. Set the "WIRE FEEDER VOLTMETER" switch to
either "+" or "-" as required by the electrode being
used.
4. Set the "MODE" switch to the "CV WIRE " posi-
tion.
5. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
6. Set the "WELD TERMINALS" switch to the
"REMOTELY CONTROLLED" position.
7. Set the "IDLE" switch to the "HIGH" position.
Connection of LN-742, Spool Gun, and Cobramatic
to GX 300
1. Shut the welder off.
2. Connect per instructions on the appropriate con-
nection diagram in Section F.
GX 300
WARNING
CAUTION
B-1
OPERATION
B-1
SAFETY PRECAUTIONS
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.
Do not touch electrically live parts or
electrode with skin or wet clothing.
Insulate yourself from work and
ground
• Always wear dry insulating gloves.
Always operate the welder with the hinged door
closed and the side panels in place.
Read carefully the Safety Precautions page
before operating this machine. Always follow
these and any other safety procedures included
in this manual and in the Engine Instruction
Manual.
GENERAL DESCRIPTION
The GX 300 is a gasoline engine powered DC multi-
process welding power source and 120 / 240 volt AC
power generator. The engine drives a generator that
supplies three phase power for the DC welding circuit
and single phase power for the AC auxiliary outlets.
The DC welding control system uses state of the art
Chopper Technology (CT™) for superior welding per-
formance.
Codes 11795 and above meet EPA evaporative emis-
sion requirements.
DESIGN FEATURES
FOR AUXILIARY POWER:
If a GFCI receptacle is tripped, See the MAINTE-
NANCE section for detailed information on testing and
resetting the GFCI receptacle.
Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available
regardless of the welding control settings providing no
welding current is being drawn.
The auxiliary power of the GX 300 consists of two 20
Amp-120 VAC (5-20R) duplex GFCI receptacles and
one 50 Amp 120/240 VAC (14-50R) receptacle. The
240 VAC receptacle can be split for single phase 120
VAC operation.
ENGINE OPERATION
Before Starting the Engine:
• Be sure the machine is on a level surface.
Open top engine door and remove the engine oil
dipstick and wipe it with a clean cloth. Reinsert the
dipstick and check the level on the dipstick.
Add oil (if necessary) to bring the level up to the full
mark. Do not overfill. Close engine door.
• See Engine Ownerʼs Manual for specific oil recom-
mendations.
ADD FUEL
GASOLINE can cause fire or
explosion.
• Stop engine when fueling.
• Do not smoke when fueling.
• Do not overfill tank.
• Avoid contact with skin or breathing of vapor.
• Keep sparks and flame away from tank.
------------------------------------------------------------------------
• Remove the fuel tank cap.
Fill tank until the fuel gauge
reads full. DO NOT TOP OFF
TANK. Be sure to leave filler
neck empty for expansion.
• Replace the fuel cap and tighten securely.
See Engine Ownerʼs Manual for specific fuel recom-
mendations.
GX 300
WARNING
WARNING
FULL
B-2
OPERATION
B-2
WELDING CONTROLS
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. WELD MODE SELECTOR SWITCH:
(Provides four selectable welding modes)
CV-WIRE
PIPE
CC-STICK
TOUCH START TIG
3. ARC CONTROL :
The ARC CONTROL WIRE/STICK dial is active in the
WIRE, STICK and PIPE modes, and has different func-
tions in these modes. This control is not active in the TIG
mode.
CC-STICK, PIPE modes In these modes, the ARC CON-
TROL knob sets the short circuit current during stick
welding (arc-force). Increasing the number from -10 to
+10 increases the short circuit current and prevents stick-
ing of the electrode to the plate while welding. This can
also increase spatter. It is recommended that the ARC
CONTROL be set to the minimum number without elec-
trode sticking. Start with a setting at 0.
CV-WIRE mode: In this mode, turning the ARC CON-
TROL clock wise from –10 (soft) to +10 (crisp) changes
the arc from soft and washed-in to crisp and narrow. It
acts as an inductance control. The proper setting
depends on the procedure and operator preference. Start
with a setting of 0.
GX 300
1
9
6
3
8
4
7
10
11
12
5
14
13
2
B-3
OPERATION
B-3
4. WELD OUTPUT TERMINALS WITH
FLANGE NUT:
Provides a connection point for the electrode and work
cables. Output stud covers provided on code 11274 and
above.
5. GROUND STUD:
Provides a connection point for connecting the machine
case to earth ground for the safest grounding procedure.
6. 14-PIN CONNECTOR:
For attaching wire feeder control cables to the GX 300.
Includes contactor closure circuit , auto-sensing remote
control circuit, and 120V and 42V power. The remote
control circuit operates the same as the 3-Pin connector.
7. 3-PIN CONNECTOR:
For attaching optional remote control equipment. When
in the CC-STICK, PIPE, and CV-WIRE modes and when
a remote control is connected to the auto-sensing circuit
in the GX 300 automatically switches the OUTPUT con-
trol from control at the welder to remote control.
When using the TOUCH START TIG mode with a TIG
Module connected to the GX 300, the OUTPUT control
on the front of the GX 300 is used to set the maximum
current range of the CURRENT CONTROL on the TIG
Module.
8. WELD TERMINALS CONTROL SWITCH:
In the WELD TERMINALS ON position, the output is
electrically hot all the time. In the REMOTELY CON-
TROLLED position, the output is controlled by a wire
feeder or amptrol device, and is electrically off until a
remote switch is depressed.
9. WIRE FEEDER VOLTMETER SWITCH:
Matches the polarity of the wire feeder voltmeter to the
polarity of the electrode.
ENGINE CONTROLS:
10. RUN/STOP SWITCH
- RUN position energizes
the engine prior to starting. STOP position stops the
engine. The oil pressure interlock switch prevents battery
drain if the switch is left in the RUN position and the
engine is not operating.
11. CHOKE - When pulled out, it closes the choke
valve on the engine carburetor for quick starting.
12. START PUSH BUTTON - Energizes the starter
motor to crank the engine.
13. IDLER SWITCH- Has two positions as follows:
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:
When switched from HIGH to AUTO or after start-
ing the engine, the engine will operate at full
speed for approximately 12 seconds and then go
to low idle speed.
When the electrode touches the work or power is
drawn for lights or tools (approximately 100
Watts minimum), the engine accelerates and
operates at full speed.
When welding ceases or the AC power load is
turned off, a fixed time delay of approximately 12
seconds starts. If the welding or AC power load is
not restarted before the end of the time delay, the
idler reduces the engine speed to low idle speed.
The engine will automatically return to high idle
speed when there is welding load or AC power
load reapplied.
14.
ELECTRIC FUEL GAUGE/HOUR METER:
The electric fuel gauge gives accurate and reli-
able indication as to how much fuel is in the fuel
tank. The hour meter displays the total time that
the engine has been running. This meter is useful
for scheduling prescribed maintenance.
STARTING AND STOPPING THE ENGINE
Remove all plugs connected to the AC power
receptacles.
• Set IDLER switch to AUTO.
• Set the RUN/STOP switch to RUN.
• Pull the choke to the full out position.
Press and hold the engine START button until the
engine starts.
Release the engine START button when the engine
starts.
• Push the choke back in.
The engine will run at high idle speed for approxi-
mately 12 seconds and then go to low idle speed.
Allow the engine to warm up at low idle for several
minutes before applying a load and/or switching to
high idle. Allow a longer warm up time in cold
weather.
GX 300
B-4
OPERATION
B-4
Operating the starter motor for more than 5 sec-
onds 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.
------------------------------------------------------------------------
STOPPING
Remove all welding and auxiliary power loads and
allow the engine to run at low idle speed for a few min-
utes to cool the engine.
Stop the engine by placing the RUN-STOP in the
STOP position.
NOTE: A fuel shut off valve is not required on the GX
300 because the fuel tank is mounted below the
engine.
WELDER OPERATION
DUTY CYCLE
Duty Cycle is the percentage of time the load is being
applied in a 10 minute period. For example, a 60%
duty cycle represents 6 minutes of load and 4 minutes
of no load in a 10 minute period.
DC STICK WELDING
The GX 300 can be used with a broad range of DC
stick electrodes.
The MODE switch provides two stick welding settings
as follows:
CONSTANT CURRENT (CC-STICK)
WELDING
The CC-STICK position of the MODE switch is
designed for horizontal and vertical-up welding with all
types of electrodes, especially low hydrogen. The out-
put CONTROL dial adjusts the full output range for
stick welding.
The ARC CONTROL dial sets the short circuit current
(arc-force) during stick welding to adjust for a soft or
crisp arc. Increasing the number from -10(soft) to
+10(crisp) increases the short circuit current and pre-
vents sticking of the electrode to the plate while weld-
ing. This can also increase spatter. It is recommended
that the ARC CONTROL be set to the minimum num-
ber without electrode sticking. Start with the dial set at
0.
DOWNHILL PIPE WELDING
This slope controlled setting is intended for "out-of-
position" and "down hill" pipe welding where the oper-
ator would like to control the current level by changing
the arc length. The output CONTROL dial adjusts the
full output range for pipe welding. The ARC CON-
TROL dial sets the short circuit current (arc-force) dur-
ing stick welding to adjust for a soft or more forceful
digging arc (crisp). Increasing the number from -
10(soft) to +10(crisp) increases the short circuit cur-
rent which results in a more forceful digging arc.
Typically a forceful digging arc is preferred for root
and hot passes. A softer arc is preferred for fill and
cap passes where weld puddle control and deposition
(“stacking” of iron) are key to fast travel speeds. This
can also increase spatter. It is recommended that the
ARC CONTROL be set to the minimum number with-
out electrode sticking. Start with the dial set at 0.
GX 300
CAUTION
Low Idle - No Load
2400 R.P.M
High Idle - No Load
3700 R.P.M
DC Weld Output
240 Amps @ 29 Volts
DC Weld Output
300 Amps @ 29 Volts
Auxiliary Power
9,500 Watts
Kohler CH23S, CH680
Gal./hrs (liters/hr)
.51 (1.9)
.83 (3.2)
1.39 (5.3)
1.53 (5.8)
1.64 (6.2)
Running Time for
12 gallons -(hrs.)
23.5
14.5
8.6
7.8
7.3
Kohler CH730
Gal./hrs (liters/hr)
.43 (1.64)
.99 (3.74)
1.56 (5.91)
1.81 (6.86)
1.85(7.00)
Running Time for
12 gallons -(hrs.)
27.8
12.1
7.7
6.6
6.5
TYPICAL GX 300 FUEL CONSUMPTION
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45

Lincoln Electric Red-D-Arc GX300 Mode d'emploi

Catégorie
Système de soudage
Taper
Mode d'emploi