Lincoln Global CROSS COUNTRY 300 SAFETY 12362 Operator'S Manual Download Page 32 | Manualshive

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If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility

for technical troubleshooting assistance before you proceed.

CROSS COUNTRY 300

CAUTION

This Troubleshooting Guide is provided to help you locate and
repair possible machine malfunctions. Simply follow the three-
step procedure listed below.

Step 1. LOCATE PROBLEM

(SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This
column describes possible symptoms that the machine may
exhibit. Find the listing that best describes the symptom that the
machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious
external possibilities that may contribute to the machine symp-
tom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause,
generally it states to contact your local Lincoln Authorized Field
Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your local
Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory
warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed through-
out this manual.

Warranty work performed on the engine contained in this machine, if not billable to the engine manufacturer, should be
pre-approved by calling The Lincoln Electric Company at 888-935-3877

__________________________________________________________________________

WARNING

TROUBLE SHOOTING

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Summary of Contents for CROSS COUNTRY 300 SAFETY 12362

Page 1: ...h machines having Code Numbers 12362 Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operation 8 00 AM to 6 00 PM ET Mon thru Fri After hours Use Ask the Experts at lincolnelectric com A Lincoln Service Representative will contact you no later than the following business day For Service outside the USA Email globalservice lincolnelectric com Save for future reference Dat...

Page 2: ...hing zone and the general area IN A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual symptoms see your supervisor Perhaps the welding atmosphere and ventilation system should be checked WEAR CORRECT EYE EAR BODY PROTECTION PROTECT your eyes and face wit...

Page 3: ...ment 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 ...

Page 4: ...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 fu...

Page 5: ...g through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 6 j Do not use a welding power source for pipe thawing C...

Page 6: ...ction of Lincoln Electric Wire Feeders A 8 _________________________________________________________________________________________ Operation Section B Safety Precautions B 1 For Auxiliary Power B 1 Engine Operation B 1 Add Fuel B 1 Break in Period B 1 Welding Controls B 2 Engine Controls B 3 Starting the Engine B 4 Stopping the Engine B 4 Welder Operation B 4 Duty Cycle and Electrode Information...

Page 7: ...e D 6 Cleaning D 6 Brush Removal and Replacement D 6 GFCI Testing and Resetting Procedure D 6 ________________________________________________________________________________ Troubleshooting Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 thru E 6 ________________________________________________________________________________ Connection Diagrams Wiring Diagrams and Dimens...

Page 8: ...ingle phase and Three Phase power for the AC auxiliary outlets The DC welding control system uses state of the art Chopper Technology CT for superior welding performance The CROSS COUNTRY 300 has an optional selectable VRD Voltage Reduction Device The VRD operates in the CV mode reducing the OCV to 13 volts increasing operator safety when welding is performed in environments with increased hazard ...

Page 9: ... top of exhaust pipe Add 4 97 126mm to top of Lift Bail Outside width of Base Add 3 00 76 2mm to outside of mounting feet 2 Reduced to less than 30V in the stick mode when VRD Voltage Reduction Device is on Optional VRD VOLTAGE REDUCTION DEVICE See Installation and Operation sections for an explanation OUTPUT 104 F 40 C WELDER Make Model Kubota V1505 RECEPTACLES 2 120VAC Duplex 5 20R GFCI Protecte...

Page 10: ...welder so that the engine exhaust fumes are properly vented to an outside area STACKING CROSS COUNTRY 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 20 degrees in all directions 30 degrees Intermittent less than 10 minutes continuous in all direction...

Page 11: ...ids be used with this engine TOWING Use a recommended trailer for use with this equipment for road in plant and yard towing by a vehicle 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 or dam age the welding equipment Some of the factors to be considered are as follows 1 Design capacity of trailer v...

Page 12: ...d damage eyes The CROSS COUNTRY 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 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 ...

Page 13: ...d having no insulated joints or to the metal framework of a building which has been effectively grounded The 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 OUTPUT Cables With the engine off connect the electrode and work cables to the output studs The welding...

Page 14: ...lugs 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 All auxiliary power is protected by circuit breakers The 120V has 20 Amp circuit breakers for each duplex r...

Page 15: ... 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 ...

Page 16: ... from the LN 25 Pipe to the CV terminal of the welder and work cable to the terminal of the welder 3 Attach the single lead from the front of the LN 25 Pipe 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 IDLE switch to the AUTO position W...

Page 17: ...ipstick 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 Check radiator for proper coolant level Fill if necessary See Engine Owner s Manual for specific oil and coolant recommendations ADD FUEL Stop engine while fueling Do not smoke when fueling Keep sparks and fla...

Page 18: ...ped This allows the operator to read the actual current and voltage just prior to when welding was ceased While the display is being held the left most decimal point in each display will be flashing The accuracy of the meters is 3 3 OUTPUT Adjusts output setting of machine 4 CONTROL Fine tunes the arc for optimal weld performance 5 WELD MODE SELECTOR SWITCH Provides Three selectable welding modes ...

Page 19: ...e engine will automatically return to high idle speed when the welding load or A C power load is reapplied 3 The Stop position stops the engine 10 START SWITCH Energizes the starter motor to crank the engine 11 GLOW PLUG PUSH BUTTON When pushed activates the glow plugs Glow plug should not be activated for more than 20 seconds continuously 12 DASH BOARD GAUGE The dash board gauge displays 5 gauges...

Page 20: ...leed the fuel system as indicated in Maintenance Section of this manual STOPPING THE ENGINE 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 switch in the STOP position NOTE A fuel shut off valve is located on the fuel pre filter WELDER OPERATION DUTY CYCLE Duty Cycle is the perce...

Page 21: ...ttom of a pipe with cellulosic electrodes The preset current may need to be adjusted slightly lower than the actual weld current WIRE WELDING CV Connect a wire feeder to the CROSS COUNTRY 300 according to the instructions in INSTALLATION INSTRUCTIONS Section The CROSS COUNTRY 300 in the CV WIRE mode permits it to be used with a broad range of flux cored wire Innershield and Outershield electrodes ...

Page 22: ...ith a rocking motion An arc will be established 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 Cross...

Page 23: ...1 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 applicati...

Page 24: ...10 000 42 8300 35 5300 22 3500 15 400 2 0 0 3 PHASE WATTS AMPS 11 000 27 8500 20 5700 14 3500 8 800 2 0 0 BOTH 1 3 PHASE WATTS AMPS 10 000 8300 5300 3500 400 0 0 CROSS COUNTRY 300 Simultaneous Welding and Power Loads TABLE B 5 CROSS COUNTRY 300 Extension Cord Length Recommendations Use the shortest length extension cord possible sized per the following table Current Amps 15 20 15 20 44 Voltage Vol...

Page 25: ...ing mode for environments with a higher risk of electrical shock Reduces the open circuit voltage at the output terminals when not welding K4213 1 Cold Weather Kit For starting and operation in extreme cold weather conditions down to 40 F 40 C with use of 0W40 synthetic oil and arctic fuel Includes 120V AC pan heater and radia tor grill tarp WIRE FEEDER OPTIONS K2613 5 LN 25 PIPE PORTABLE WIRE FEE...

Page 26: ...om Read the Safety Precautions in the front of this manual and in the Engine Owner s Manual before working on this machine Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from the gears fans and all other moving parts when starting operating or repairing the equipment ROUTINE MAINTENANCE At the end of each day s use refill ...

Page 27: ... on the oil container to be sure it includes the letters indicated Note An S grade oil must not be used in a diesel engine or damage may result It IS permissible to use an oil that meets S and C grade service classifications SAE 10W30 is recommended for general all temperature use 5F to 104F 15C to 40C See engine owner s manual for more specific information on oil viscosity recommendations OIL FIL...

Page 28: ...D 3 MAINTENANCE CROSS COUNTRY 300 ...

Page 29: ...n the pulleys It should deflect about 25 in 6 4 mm under a load of 20 lbs 9 Kg FUEL DIESEL FUEL ONLY Low sulphur fuel or ultra low sulphur fuel in U S A and Canada At the end of each day s use refill the fuel tank to minimize moisture condensation and dirt contamination in the fuel line Do not overfill leave room for the fuel to expand Use only fresh No 2D diesel fuel the use of No 1D diesel fuel ...

Page 30: ...tery vent plugs if equipped are tight so that none of the solution enters the cells After cleaning flush the outside of the battery the battery compartment and surrounding areas with clear water Coat the battery terminals lightly with petroleum jelly or a non conductive grease to retard corrosion Keep the battery clean and dry Moisture accumulation on the battery can lead to more rapid discharge a...

Page 31: ...e every month or whenever it is tripped To properly test and reset the GFCI If the GFCI has tripped first carefully remove any load and check it for damage If the equipment has been shut down it must be restarted The equipment needs to be operating at high idle speed and any necessary adjustments made on the control panel so that the equipment is providing at least 80 volts to the receptacle input...

Page 32: ...ED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Li...

Page 33: ...d replace main filter element and or Inline Fuel Filter 3 Out of fuel Fill tank and bleed fuel sys tem 4 High coolant temperature or low oil pres sure indictor lights lit Check oil and coolant levels Fill if required Check for loose or broken fan belt 5 ON OFF switch on for more then 60 sec onds before starting The ON OFF switch will need to be switched off and turned back on 6 Faulty fuel shutdow...

Page 34: ...openings on both sides of base and exhaust end case back 1 Dirty fuel or air filters Inspect and clean replace filters as needed Inspect and clean replace filters as needed 2 Water in fuel If water found in tank Empty fuel tank and refill then purge fuel lines 1 Faulty battery Replace 2 Loose connections at battery or alterna tor Clean and tighten connections 3 Faulty engine alternator or charger ...

Page 35: ...00 watts Idler may not respond with less than a 100 watt load Set idler to High 2 Faulty PC board Control or Idler 1 Faulty idler solenoid Check for bent linkage or broken spring 2 Faulty PC board Control or Idler 1 Fuel filter clogged Replace 2 Air filter clogged clean or replace 3 High idle setting incorrect check and adjust if required 4 Valves out of adjustment 5 Fuel contaminated with water o...

Page 36: ...e Shop 4 Fuel contaminated with water Check Main Filter Bowl and Inline Fuel filters for water Clean and replace as needed Replace fuel in tank 5 Cracked or loose fuel hose Replace hose and tighten clamps 6 Valves out of adjustment Contact autho rized local Engine Service Shop 1 Poor work lead connection to work Make sure work clamp is tightly connected to clean base metal 2 Weld Terminals switch ...

Page 37: ...t be accurate for all machines covered by this manual The specific diagram for a particular code is incuded with the machine If the diagram is illegible write to the Service Department for a replacement Give the equipment code number CROSS COUNTRY 300 WIRING DIAGRAM FOR CODE 12362 ...

Page 38: ...E 7 DIAGRAMS CROSS COUNTRY 300 CROSS COUNTRY 300 DIMENSION PRINT FOR CODE 12362 ...

Page 39: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 40: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 41: ...uch 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 Lincoln Electric is a responsive manufacturer but the selection and use of specific prod...

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