GX200 2+4 Service Manual - Red-D
Contents
1. Stator 18 335 E ngine flange 18 281 Tie Rod 18 279 R otor 18 280 L ower Stator Cover 18 278 B earing Flange 18 642 B all Bearing 304 Internal Ring 305 OO NO UI wN Spring Washer 305 Clip Ring 307 Fan 310 Fan Ring 311 Power Rectifier Assy 18 377 Rectifier Cover 606 Tubular Frame Assy RGX200FRAME Shock A bsorber 40x40 mms 13 961 Shock A bsorber 30x30 mms 313 Spacer H 20 mms 622 Flange Tie Rod 18 078 Instrument Case 17 114 Aluminum Front Plate 18 378 K nob Cap 11 209 Throttle K nob 16 900 Throttle Cable Assembly 14 436 Ground Screw 15 721 Connection Block 6 Poles 10 364 S pacer H 70 mms 16 548 Shock Absorber 15x30 mms 320 Shock Absorber 15x30 mms 13 802 Capacitor Support Plate 19 799 Capacitor B racket 17 119 Capacitor 60 uF 11 333 R eactance Assembly 13 925 Right Side Cover 18 376 Lifting Hook 18 379 Air Deflector 18 284 Left Side Cover 17 450 Three Phase R eactance 13 927 Engine Support B racket 14 854 Screw M 5x27 mms 13 929 Rubber Protective Cover 14 658 Circuit Breaker 15A 13 640 Spring 14 139 Resistance Coil 14 432 Resistance Support 12 830 Resistance2. Thereafter change the crankcase oil every 100 hours using the proper grade of oil as recommended in the engine operating manual e Stop engine when fuelling e Do not smoke when fuelling 3 Oil classification SG SF CC CD e Remove cap slowly to Use viscosities as per the engine manual release pressure e Do not overfill tank e Wipe up spilled fuel and allow fumes to clear before starting engine e Keep sparks and flame away from tank Red D Arc Welderentals OPERATION CONTROL PANEL FEATURES De CRE ES Ht PA TIL A Sdt Grounding Screw OPTIONAL ELECTRICSTART LMN OPQ P 120V circuit breaker 10A Welding Socket negative 90 170A Hourmeter Tachometer Welding Socket negative 160 195A 120 240V Single Phase Outlet Throttle Control 240V signal lamp Welding Socket positive connection 240V circuit breaker 145A Welding Socket negative 40 90A Start Stop engine switch Serial Number Stop switch Electronic battery charger circuit breaker 120V signal lamp Low oil level signal lamp A B E D E F G H L 120V Single Phase outlet Red D Arc Welderentals Receptacle covers not shown OPERATION Fuel Consumption Replacement Parts Engine Specifications Fuel consumption has been optimized by means of careful design of the combustion cham ber fuel feed amp injection systems and cross flo
3. 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 Red D Arc Welderentals CYLINDER may explode gt 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located e Away from areas where they may be struck or subjected to physical damage eA safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PL Precautions for Safe Hand
4. the top of the oil filler neck with the recommended oil OIL CAPACITY 1 0 L 34 US oz DO NOT OVERFILL FUEL Fill the fuel tank with the grade of fuel recommended LOCATION VENTILATION The welder should be located to provide an unrestricted flow of clean cool air Also locate the welder so that engine exhaust fumes are properly vented to an outside area POLARITY CONTROL AND CABLE SIZES With the engine off connect the electrode and work cables of the appropriate size see the following table to the studs located on the front panel For positive polarity connect the electrode cable to the terminal marked Positive For Negative polarity connect the electrode cable to the Negative stud These connections should be checked periodically and tightened if necessary When welding at a considerable distance from the welder be sure you use ample size welding cables TABLE 2 RECOMMENDED COPPER CABLE SIZES AT 6096 DUTY CYCLE Total Combined Length of Electrode Plus Work Cable in feet tun 50 100 100 150 150 204 200 250 GR SAFETY SHUTDOWN SYSTEM All units are equipped with low oil pressure shutdown systems Engines should never be operated with shutdown system disconnected or inoperative GENERAL MAINTENANCE Check all external bolts engine mounts generator mounts etc at least once per year and tighten replace as required MANUAL START 1 Turn the fuel valve to the on position turn to right 2 Clo
5. 0Volt twist lock receptacle 4KW at 60 Hertz power The output circuit is protected with a 15Amp circuit breaker for the 120V and a 15Amp circuit breaker for the 240V Red D Arc Welderentals PRODUCT INFORMATION MAINTENANCE WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the machine In some cases it may be necessary to remove safety guards to perform required with skin or wet clothing Insulate yourself maintenance Remove guards only when necessary and replace from work and ground e Do not touch electrically live parts or electrode them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Keep flammable materials away Do not put your hands near the engine or generator fan If a e Wear eye ear and body protection problem cannot be corrected by following the instructions take the machine to the nearest RED D ARC location e Keep your head out of fumes e Use ventilation or exhaust to remove GENERAL INSTRUCTIONS fumes from breathing zone 1 Blow out the welder and controls with an air hose at least once o every two months In particularly dirty locations this cleaning may urn power off before servicing be necessary once a week Use low pressure air to avoid driving dirt into the insulation e Do not operate with panel open or guards off 2 Change oil after the first 20 hours of operation
6. SM GX200 2 4 RED D ARC m GX200 2 4 Gas Welder Red D Arc Welderentals SERVICE MANUAL Red D Arc Spec Built Welding Equipment This RED D ARC welder is built to RED D ARC Extreme Duty design specifications by Lincoln Electric Safety Depends on You This welder is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful 1 866 33 3272 North America s Largest Fleet of Welding Equipment SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline 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 pur chase a copy o
7. Terminal 11 439 Male Insulator 22 mms dia 17 603 Insulating Washer 7 mms dia 17 491 ch OO Insulating Washer 12 mms dia Red D Arc Welderentals 17 490 ASSEMBLY MISC ASSEMBLY PARTS LIST ITEM PART NAME amp DESCRIPTION NO REQ D PART NO 17 602 13 922 17 321 15 720 17 571 14 270 18 380 TT226NR 2C 17 117 17 322 17 323 17 324 18 285 MOB CB12B B2 R GX 200B OX R GX 200B OX 114203 117362 Female Insulator 22 mms dia L eft Protection Grate Side Plate L eft Side Plate Right Top Cover Washer S pacer Digital Tachometer H ourmeter Resistance Coil Resistance Cover Resistance Support Plate Cable Connector 12V 12Ah Battery Battery Bracket Battery Cover Panel Receptacle Cover 120 Volt Receptacle Cover 240 Volt Red D Arc Welderentals WIRING DIAGRAMS es 0 Y06 0 YOL1 06 Y002 091 wd parde d 19IP9U1IM0H SH douui2e9i Titi play Dx 2301839831 seeyd 2241 1499 494q FINI vor Y ox 1 y 1 7 ax I id hr or em r r r nid Y Q AOI dwe peur fl IL If a E ru e F l I I I I I I I l i A0F2Z 021 0 17 AdAL at apoeydasas 3 29 d 2221 Mala 10014 Mola 1UOJj i A J HOLYNYSLTY S IONOHHONASY si0yroedes 10118319X7 Red D Arc Welderentals 14
8. cant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispostifis de s ret leur place PRODUCT INFORMATION PRODUCT DESCRIPTION The GX200 is a portable engine driven arc welding power source capable of providing constant current output for stick welding or DC TIG welding GENERATOR The generator of the GX200 is asynchronous with capacitor excitation and therefore with excellent mechanical features of sturdiness and simplicity it requires no maintenance as it has no sliding parts such as slip rings and brushes The rotor consists of a laminar pack with die cast aluminum stand The sizing and setting up of these active parts represent a new principle which has made the asynchronous generator suitable for welding services and which has been appropriately patented The GX200 has a current range of 40 200 amps with a 6096 duty cycle at 170 Amps The unit is also capable of providing 2 KVA of 120 VAC and 4KVA of 240 VAC at 60 cycle PRE OPERATION MAINTENANCE OIL 1 Remove the oil filler cap and wipe the dipstick clean 2 Insert the dipstick into the oil filler neck but do not screw it in 3 If the level is low fill to
9. d welding near hydraulic lines Have a fire extinguisher readily available 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 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 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 Hecommended 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 Connect the work cable to the work as close to the welding area as practical
10. e de masse le c ble de soudage et la machine souder en bon et s r tat Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de la faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage cables de grue ou atres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fum es toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op erations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment roxique ou autres produits irritants defonctionnement PR CAUTIONS DE SURETE POUR LES Ne jamais plonger le porte lectrode dans l eau pour le MACHINES A SOUDER A TRANSFOR ER MATEUR ET A REDRESSEUR Ne jamais toucher simultan ment les parties sous ten sion des porte lectrodes connect s deux machi
11. f Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society PO Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE 5 t h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment AM ro j P g 1 a Turn the engine off before troubleshooting and maintenance 3 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 y QN 9 ELECTRIC AND MAGNETIC FIELDS Stal bb may be dangerous 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric current flowing through any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician Keep all equipment safety guards covers and before welding devices in positio
12. gine fan If a problem cannot be corrected by following the instructions take the machine to the nearest Red D Arc Location TROUBLE CAUSE WHAT TO DO 1 Engine won t start A Weather colder than 10C B Engine flooded C Fouled spark plug D Dirt or water in fuel E Clogged fuel line or fuel strainer A Use very light engine oil B Close fuel line drain carburetor amp bowl try again C Clean or replace spark plug D Drain tank and refill E Drain fuel line tank and refill Engine runs but generator does not produce power at output studs and AC outlets A Unit started with load plugged in B Loose connection or broken wire C Welding cables shorted together D Shorted diode E Bad condenser F Burned windings A Unplug load start engine and then plug load in B Repair mend or retighten connection BEFORE you do any major disassembly C Remove short D Replace rectifier E Replace condenser F Replace stator Engine runs well and produces AC power but no welding output A Broken wire to output studs B Opened diodes Red D Arc Welderentals A Repair B Replace rectifier ASSEMBLY MISCELLANEOUS ASSEMBLY a 3 S P g ESS A 4 ER fe Beie G OPTIONAL ELECTRIC START Receptacle covers not shown Red D Arc Welderentals 12 MISC ASSEMBLY PARTS LIST ASSEMBLY ITEM PART NAME amp DESCRIPTION NO REQ D PART NO
13. iate Red D Arc Welderentals SAFETY 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 e Semiautomatic DC Constant Voltage Wire Welder e DC Manual Stick Welder e AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and weld
14. iner 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 below Threshold Limit Values TLV 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 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 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 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 Also see item 1 b 7 WELDING SPARKS can lt gt 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 Avoi
15. ing machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 Red D Arc Welderentals 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 standards 4 6 Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 23 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 with electrodes which require special ventilation such as stainless or hard facing see instructions on conta
16. ling 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter tou jours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un planch er metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pinc
17. n 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 equip ment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 e In some cases it may be necessary to remove safety 2 d 1 Route the electrode and work cables together Secure guards to perform required maintenance Remove them with tape when possible guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 2 Never coil the electrode lead around your body Always use the greatest care when working near moving parts 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right Do not put your hands near the engine fan Do not attempt to side the work cable should also be on your right side override the governor or idler by pushing on the throttle con trol rods while the engine is running d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance d 5 Do not work next to welding power source work disconnect the spark plug wires distributor cap or magneto wire as appropr
18. nes souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines 1 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enroule le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnementde l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles Des gouttes de laiter en fusion sont mises de l arc de soudage Se prot ger avec es v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir ttout risque d incendie d tincelles Red D Arc Welderentals Relier a la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabri
19. se the choke turn to left 3 Turn the throttle control knob until half open 4 Turn the engine switch to the on position 5 Pull the start rope lightly until resistance is felt then pull briskly 6 As the engine warms up gradually move the choke lever to the open position 7 Let the engine run at low speed for 2 3 minutes to warm up ELECTRIC START 1 Turn the fuel valve to the on position turn to right 2 Close the choke turn to left 3 Turn the throttle control knob until half open 4 Turn start key switch to start 5 As the engine warms up gradually move the choke lever to the open position 6 Let the engine run at low speed for 2 3 minutes to warm up TO TURN OFF THE UNIT Turn the throttle knob in an counterclockwise direction until the furthest position after letting the engine run slowly for a few seconds turn the stop switch to the off positionMPORTANT Turn the fuel valve to the off position CONTROL OF WELDING CURRENT There is one continuous current control for each range which gives you complete adjustment of current from min to max within the range There is a low tap for ranges from 40 90Amps a medium tap for ranges from 90 170Amps and a high tap for ranges from 160 195Amps Always use the lowest possible range with fine current adjustment closest to max position AUXILIARY POWER Your GX200 is equipped with AC auxiliary power The AC unit provides 1 X 120Volt Duplex receptacle 2KW and 1 X 120 24
20. w cylinder heads In order to enhance longevity of the engine the engine turns at a constant 3600 RPM and no engine idler is used As a result there is no waiting time for the welder to achieve operating speed when striking an arc Fuel consumption figures at average operating loads are as follows Tank Capacity 6 5 litres 1 6 U S gallons Operating Interval 3 4 hours per tank Engine replacement parts are available from authorized HONDA dealers All other parts are available from anyRED D ARC location Model HONDA GX 340 No of Cylinders 1 Displacement 337cc Rotation Speed 3600 RPM Power 11 HP Cooling system Forced Air Ignition system Transistorized magnet Starting system Pull start with recoil cable Optional Electric Start PTO shaft rotation Counterclockwise F uel Automotive gasoline WELDING OUTPUT AUXILIAR Y OUTPUT 40 200 amps 25volts 120 Vac 15 amps 90 volts maximum O C V 1 duplex outlet 2 0 KVA 120 240 Vac 15 amps single outlet 4 0 KVA Red D Arc Welderentals 10 WARNING TROUBLESHOOTING Have qualified personnel do the troubleshooting work Turn the engine off before working inside the machine 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 e Do not put your hands near the en
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