Lincoln Electric IM10047 User Manual

IM10047-D

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RED-D-ARC

GX 300

For use with machines having Code Numbers:

11678, 11740, 11795, 11802, 12098, 12204

August 2013

(

OPERATOR’S MANUAL

Red-D-Arc Spec-Built Welding Equipment

This

RED-D-ARC

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

welder is built to

RED-D-ARC Extreme Duty

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

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.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

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.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.

___________________________________________________

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.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

GX 300

ii

SAFETY

ii

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

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 Items 6.c. and 8.

skin or wet clothing. Wear dry, hole-free

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

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) 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. In confined spaces or in some circum­stances, outdoors, a respirator may 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
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
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.

ventilation and/or exhaust at the arc to keep

vapors

to

GX 300

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

iii

SAFETY

iii

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

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

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
1235 Jefferson Davis Highway, Arlington, VA 22202.

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.

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.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

GX 300

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A 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.

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 lev­age, 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.

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 ray­onnement 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, pan­talons 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.

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 debranch­er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

GX 300

for selecting one of our QUALITY products. We want you to take

Thank You

CUSTOMER ASSISTANCE POLICY

The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to
meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for
advice or information about their use of our products. We respond to our customers based on the best informa­tion in our possession at that time. We are not in a position to warrant or guarantee such advice, and assume no
liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any
warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter
of practical consideration, we also cannot assume any responsibility for updating or correcting any such informa­tion or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

We are a responsive manufacturer, but the selection and use of specific products sold by us is solely within the
control of, and remains the sole responsibility of the customer. Many variables beyond our control affect the
results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing.

pride in operating this 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. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

vv

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code (if available)______________________________________________________

Serial Number (if available)__________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

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

________________________________________________________________________________

vi

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

________________________________________________________________________

vii

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - GX300 (K2284-2)

INPUT - GASOLINE ENGINE

A-1

Make/Model

Kohler
CH23S
CH680

CH730

Description

2 cylinder

23 HP @

3600 RPM

Gasoline

Engine

Speed (RPM)

High Idle 3700

Full Load 3500

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)

Starting
System

12VDC Battery &

Starter

(Group 58; 435

Cold crank amps)

Battery Charger

RATED OUTPUT @ 104° F (40° C) - WELDER

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
Touch Start™ TIG Output Range
CV WIRE DC Output 29 Volts @ 300 Amps 100%
CV WIRE Output Range 14 to 29 volts -------

30 to 250 Amps 100% 60 Volts

20 to 250 Amps -------

RATED OUTPUT @ 104° F (40° C).- GENERATOR

Auxiliary Power

10,000 Watts Peak, 9500 Watts Continuous, 60 Hz

120/240 Volts

1

Capacities

Fuel: 12 gal.

45.4 L

Oil: 2.0 qt.

1.9 ltr.

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

Codes 11802 and below

30.00** in. 21.50 in 42.25 in.

762.0 mm 546.0 mm 1073.0 mm

463 lbs. (210kg.)

Code 12098

467 lbs. (212kg.)

ENGINE COMPONENTS

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

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.

GX 300

A-2

INSTALLATION

MACHINE SPECIFICATIONS - GX300 (K2284-2)

RECEPTACLES AND CIRCUIT BREAKERS

RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS

A-2

(2) 120VAC Duplex GFCI Two 20AMP for Two Duplex GFCI Receptacle
(5-20R)(1) 120/240VAC Dual One 50AMP for Dual Voltage (2-Pole)

Voltage Full KVA (14-50R)

20AMP for Battery Charging Circuit

15AMP for 42V Wire Feeder Power

GX 300

A-3

SAFETY PRECAUTIONS

WARNING

INSTALLATION

LIFTING

The GX 300 weighs approximately 539 lbs(244.5kg. A
lift bail is mounted to the machine and should always
be used when lifting the machine.

A-3

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.

-------------------------------------------------------

ENGINE EXHAUST can kill.

Use in open, well ventilated areas or

•
vent exhaust outside.

--------------------------------------------------------

MOVING PARTS can 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.

Only qualified personnel should install,
use, or service this equipment.

LOCATION AND VENTILATION

The welder should be located to provide an unrestrict­ed 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 operat­ed 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.

ADDITIONAL SAFETY PRECAUTIONS

WARNING

• 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 trail­er 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 modi­fications to operate above 5,000 ft. (1524m).

HIGH TEMPERATURE OPERATION

At temperatures above 40°C, Welder output derating is neces­sary. 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 responsi­bility 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 frame­work.

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 ser­viced.

4. Typical conditions of use, i.e., travel speed; roughness of sur­face on which the trailer will be operated; environmental con­ditions; like maintenance.

5. Conformance with federal, state and local laws.

(1)

Consult applicable federal, state and local laws regarding
specific requirements for use on public highways.

(1)

GX 300

A-4

INSTALLATION

A-4

VEHICLE MOUNTING

WARNING

Improperly mounted concentrated loads may cause
unstable vehicle handling and tires or other compo­nents to fail.

• Only transport this Equipment on serviceable vehi­cles which are rated and designed for such loads.

• Distribute, balance and secure loads so vehicle is
stable under conditions of use.

• Do not exceed maximum rated loads for compo­nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of
vehicle.

• Follow vehicle manufactureʼs instructions.

---------------------------------------------------------------------------

PRE-OPERATION ENGINE SERVICE

READ the engine operating and maintenance instruc­tions supplied with this machine.

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from tank.

• Do not leave unattended while fueling.

GASOLINE

can cause fire
or explosion.

• Wipe up spilled fuel and allow
fumes to clear before starting
engine.

• Do not overfill tank, fuel expansion
may cause overflow.

GASOLINE FUEL ONLY

------------------------------------------------------------------------

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.

FULL

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 recom­mendations and break-in information. The oil change inter­val 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

WARNING

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

CAUTION

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 dis­connected. 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 bat­tery; 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" sock­et or wrench.

WARNING

• 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.

--------------------------------------------------------------------------------

GX 300

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 unarrest­ed 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.

A-5

INSTALLATION

CAUTION

An incorrect spark arrestor may lead to damage to
the engine or adversely affect performance.

------------------------------------------------------------------------

HIGH FREQUENCY GENERATORS FOR
TIG APPLICATIONS

The K930-2 TIG Module is suitable for use with the
GX 300. The GX 300 and any high frequency generat­ing equipment must be properly grounded. See the
K930-2 Operating Manual for completed instructions
on installation, operation, and maintenance.

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 auto­sensing 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 inac­tive 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 volt­age control is connected to the 14 pin connector, do
not connect anything to the other connector.

A-5

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 con­nected 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 sec­tion 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 insulat­ed 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 dic­tates the polarity of the electrode cable. These con­nections should be checked periodically and tightened
with a 3/4" wrench.

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:

WARNING

• 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.

------------------------------------------------------------------------

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)

GX 300

Cable Size for

305 Amps

100% Duty Cycle

1 / 0 AWG

2 / 0 AWG

3 / 0 AWG

A-6

CABLE INSTALLATION

Install the welding cables to your GX 300 as follows.

INSTALLATION

A-6

STANDBY POWER CONNECTIONS

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 identi­fied 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.

CAUTION

• 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 equiva­lent 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 sepa­rate 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 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 stand­by 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 premis­es 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 recep­tacle on the GX 300 case front.

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.

GX 300

A-7

240 Volt

60 Hz.
3-Wire

Service

INSTALLATION

CONNECTION OF GX 300 TO PREMISES WIRING

240 VOLT

POWER



COMPANY



METER

DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.

120 VOLT

120 VOLT

40AMP

240 VOLT

GROUNDED CONDUCTOR

GROUND

NEUTRAL
BUS

A-7

N

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

LOAD

DOUBLE

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

240 VOLT

50 AMP, 120/240 VOLT

RECEPTACLE

POLE

CIRCUIT

BREAKER

GND

N

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

WARNING

• 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

A-8

INSTALLATION

A-8

CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS

Connection of the LN-25 to the GX 300

WARNING

Shut off welder before making any electrical con­nections.

------------------------------------------------------------------------

The LN-25 with or without an external contactor may
be used with the GX 300. See the appropriate con­nection diagram in Section F.

NOTE: The LN-25 (K431) Remote Control Module
and (K432) Remote Cable are not recommended for
use with the GX 300.

1. Shut the welder off.

. For electrode Positive, connect the electrode

2

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 elec­trode cable from the LN-25 to the "-" terminal of
the welder and work cable to the "+" terminal of
the welder.

CAUTION

If you are using an LN-25 without an internal con­tactor, the electrode will be energized when the
GX 300 is started.

------------------------------------------------------------------------

Connection of LN-7 or LN-8 to the GX 300

1. Shut the welder off.
Connect the LN-7 or LN-8 per instructions on the

2.
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 " posi­tion.

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 con­nection diagram in Section F.

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 ener­gized until the gun trigger is closed.

8. When the gun trigger is closed, the current sens­ing 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.

GX 300

B-1
SAFETY PRECAUTIONS

WARNING

OPERATION

ENGINE OPERATION

Before Starting the Engine:

• Be sure the machine is on a level surface.

B-1

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 multi­process 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 per­formance.

• 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 recom­mendations.

ADD FUEL

WARNING

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.

FULL

Codes 11795 and above meet EPA evaporative emis­sion requirements.

DESIGN FEATURES

FOR AUXILIARY POWER:

If a GFCI receptacle is tripped, See the MAINTE­NANCE 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.

• See Engine Ownerʼs Manual for specific fuel recom­mendations.

GX 300

B-2

OPERATION

B-2

14

1

2

13

12

11

10

3

9

8

7

4

6

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

5

3. ARC CONTROL :

The ARC CONTROL WIRE/STICK dial is active in the
WIRE, STICK and PIPE modes, and has different func­tions in these modes. This control is not active in the TIG
mode.

CC-STICK, PIPE modes In these modes, the ARC CON­TROL 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 stick­ing 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 elec­trode sticking. Start with a setting at 0.

CV-WIRE mode: In this mode, turning the ARC CON­TROL 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

B-3

OPERATION

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.

B-3

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:

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 con­trol 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 CON­TROLLED 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:

• When switched from HIGH to AUTO or after start­ing 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 reli­able 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.

10. RUN/STOP SWITCH

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

valve on the engine carburetor for quick starting.

- When pulled out, it closes the choke

12. START PUSH BUTTON

motor to crank the engine.

- RUN position energizes

- Energizes the starter

GX 300

• 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.

B-4

OPERATION

CAUTION

Operating the starter motor for more than 5 sec­onds can damage the motor. If the engine fails to
start, release the switch and wait 10 seconds
before operation the starter again. Do NOT push
the START button while the engine is running
because this can damage the ring gear and/or the
starter motor.

------------------------------------------------------------------------

STOPPING

Remove all welding and auxiliary power loads and
allow the engine to run at low idle speed for a few min­utes to cool the engine.

Stop the engine by placing the RUN-STOP in the
STOP position.

B-4

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 out­put 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 pre­vents sticking 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 electrode sticking. Start with the dial set at

0.

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:

TYPICAL GX 300 FUEL CONSUMPTION

Kohler CH23S, CH680

Gal./hrs (liters/hr)

Running Time for

12 gallons -(hrs.)

DOWNHILL PIPE WELDING

This slope controlled setting is intended for "out-of­position" and "down hill" pipe welding where the oper­ator 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 CON­TROL dial sets the short circuit current (arc-force) dur­ing 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 cur­rent 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 with­out electrode sticking. Start with the dial set at 0.

Kohler CH730

Gal./hrs (liters/hr)

Running Time for

12 gallons -(hrs.)

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

.51 (1.9)

.83 (3.2)

1.39 (5.3)

1.53 (5.8)

1.64 (6.2)

GX 300

23.5

14.5

8.6

7.8

7.3

.43 (1.64)

.99 (3.74)

1.56 (5.91)

1.81 (6.86)

1.85(7.00)

27.8

12.1

7.7

6.6

6.5

B-5
TIG WELDING

The TOUCH START TIG setting of the MODE switch is for DC
TIG (Tungsten Inert Gas) welding. To initiate a weld, the CON­TROL dial is first set to the desired current and the tungsten is
touched to the work. During the time the tungsten is touching the
work there is very little voltage or current and, in general, no
tungsten contamination. Then, the tungsten is gently lifted off the
work in a rocking motion, which establishes the arc.

OPERATION

• Set the "WELDING TERMINALS" switch to the "REMOTELY
CONTROLLED" position. This will keep the "Solid State" con­tactor open and provide a "cold" electrode until the Amptrol or
Arc Start Switch is pressed.

When using the TIG Module, the OUTPUT control on the GX­300 is used to set the maximum range of the CURRENT CON­TROL on the TIG Module or an Amptrol if connected to the TIG
Module.

When in the TOUCH START TIG mode and when a Amptrol is
connected to the 6-Pin connector the OUTPUT dial is used to set
the maximum current range of the current control of the Amptrol.

WIRE WELDING-CV

Connect a wire feeder to the GX-300 according to the instruc­tions in INSTALLATION INSTRUCTIONS Section.

The ARC CONTROL is not active in the TIG mode. To STOP a
weld, simply pull the TIG torch away from the work. When the
arc voltage reaches approximately 30 Volts the arc will go out
and the machine will reset the current to the Touch Start level.
To reinitiate the arc, retouch the tungsten to the work and lift.
Alternatively, the weld can be stopped by releasing the Amptrol
or arc start switch.

The GX-300 in the CV-WIRE mode, permits it to be used with a
broad range of flux cored wire (Innershield and Outershield)
electrodes and solid wires for MIG welding (gas metal arc weld­ing). Welding can be finely tuned using the ARC CONTROL.
Turning the ARC CONTROL clockwise from –10 (soft) to +10
(crisp) changes the arc from soft and washed-in to crisp and nar­row. It acts as an inductance/pinch control. The proper setting
depends on the procedure and operator preference. Start with

The GX-300 can be used in a wide variety of DC TIG welding

the dial set at 0.

applications. In general the ʻTouch Startʼ feature allows contami­nation free starting without the use of a Hi-frequency unit. If
desired, the K930-2 TIG Module can be used with the GX-300.
The settings are for reference.

Listed below are some wires suitable for use on this machine:

• Innershield - NR-311, NS-3M, NR-207, NR-203 Ni 1%,

NR-212.

• Outershield - 0S-70, 0S-71M, 0S-71 ELITE.

GX-300 settings when using the K930-2 TIG Module with an
Amptrol or Arc Start Switch:

• Solid wires for MIG welding - .035 (0.9 mm), and

.045 (1.1 mm), Super Arc L-50 and L-56, .035 (0.9 mm) and
.045 (1.1 mm) Blue Max MIG 308 LS.

• Set the MODE Switch to the TOUCH START TIG setting.
Contact your local authorized Lincoln Electric Distributor or the

• Set the "IDLER" Switch to the "AUTO" position.

Lincoln Electric Company for specific wires used on certain
applications with this machine.

B-5

TYPICAL CURRENT RANGES

Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH

Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)

1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel
Tungsten Tungsten

.010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #6

0.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)

0.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)

1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6

3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8
1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)

5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10
3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)

(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.
(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):

Pure EWP

1% Thoriated EWTh-1

2% Thoriated EWTh-2

Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.
(3) DCEP is not commonly used in these sizes.
(4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:

(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures

# 4 = 1/4 in. (6 mm)
# 5 = 5/16 in. (8 mm)
# 6 = 3/8 in. (10 mm)
# 7 = 7/16 in. (11 mm)
# 8 = _ in. (12.5 mm)
#10 = 5/8 in. (16 mm)

and high duty cycles.

(1)

FOR TUNGSTEN ELECTRODES

(2)

GX 300