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Lincoln Electric GX 271 manual

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Table of contents for the manual

  • Page 1

    RED-D-ARC GX 271 Chopper IM603 March, 1999 Red-D-Ar c Spec-Built W elding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on Y ou This welder is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful [...]

  • Page 2

    GX 271 Chopper 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. _________________________________[...]

  • Page 3

    GX 271 Chopper ii SAFETY ii ARC RA YS 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 pr[...]

  • Page 4

    GX 271 Chopper FOR ELECTRICALL Y 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. Nation[...]

  • Page 5

    GX 271 Chopper iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a[...]

  • Page 6

    GX 271 Chopper Thank You for selecting this QUALITY product. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! 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 sa[...]

  • Page 7

    GX 271 Chopper vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications .......................................................................................................A-1 Installation Instructions. ......[...]

  • Page 8

    GX 271 Chopper vii T ABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine and Periodic Engine Maintenance ..........................[...]

  • Page 9

    A-1 INST ALLA TION GX 271 Chopper A-1 TECHNICAL SPECIFICA TIONS - Red-D-Arc GX-271 (K1623-1) Make/Model Description Speed (RPM) Displacement Starting Capacities System Honda 2 cylinder High Idle 3700 37.7 cu. in 12VDC battery Fuel: 9.0 gal. GX620 20.0 HP @ Low Idle 2400 (615 cc) (Group 58, 435 34 L Gas Engine 3600 RPM Full Load 3400 cold crank amps[...]

  • Page 10

    A-2 INST ALLA TION GX 271 Chopper A-2 TECHNICAL SPECIFICA TIONS - Red-D-Arc GX-271 (K1623-1)[...]

  • Page 11

    A-3 INST ALLA TION GX 271 Chopper A-3 INST ALLA TION INSTRUCTIONS SAFETY PRECA UTIONS Only qualified per sonnel should install, use, or ser vice this equipment. LOCA TION AND VENTILA TION Whenever you use the GX-271, be sure that clean cooling air can flow through the machine’s engine and the machine case. Avoid dusty, dirty areas. Also, keep the[...]

  • Page 12

    A-4 INST ALLA TION GX 271 Chopper A-4 HIGH AL TITUDE OPERA TION At high altitude, the standard carburetor air-fuel mix- ture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. High altitude performance can be improved by specific modifications t[...]

  • Page 13

    A-5 INST ALLA TION GX 271 Chopper A-5 FUEL Fill the fuel tank with clean, fresh regular grade lead- free gasoline. Observe the fuel gauge while filling to prevent overfilling. The GX-271 has a 9 U.S. gallon (7.5 Imp. Gal., 34L) fuel tank mounted below the generator. See the Engine Owners Manual for more details about the fuel. B A TTER Y CONNECTION[...]

  • Page 14

    A-6 INST ALLA TION GX 271 Chopper A-6 ELECTRICAL CONNECTIONS See Figure B.1 in the OPERATION section of this manual for location of the 120 and 240 volt recepta- cles, weld output terminals, circuit breakers and ground stud. MA CHINE GROUNDING Because the GX-271 creates its own power from its engine driven generator, and if the machine is not conne[...]

  • Page 15

    A-7 INST ALLA TION GX 271 Chopper A-7 A UXILIAR Y PO WER RECEPT A CLES, PLUGS, AND HAND-HELD EQUIPMENT The control panel of the GX-271 features three auxil- iary power receptacles: See Figure B.1. • Two 15 amp, 120 volt duplex (double outlet) recepta- cles. • One 50 amp 120/240 volt single outlet receptacle. Through these receptacles the machin[...]

  • Page 16

    A-8 INST ALLA TION GX 271 Chopper A-8 Connection of GX-271 to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes. 230 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 230 VOLT 115 VOLT 115 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVER[...]

  • Page 17

    B-1 OPERA TION GX 271 Chopper B-1 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your GX-271. SAFETY INSTR UCTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man- uals supplied with your machine. They include impor- tant safety precautions, detailed engine st[...]

  • Page 18

    GX 271 Chopper B-2 OPERA TION B-2 • One 50 amp 120/240 V AC, single phase power, dual voltage receptacle with two 35 amp circuit breakers . Supplies up to 33 amps of 240 V AC and up to 66 amps of 120 V AC single phase auxiliary power per side to separate branch circuits (not in parallel). Allows easy connection to premises wiring. • Welding and[...]

  • Page 19

    GX 271 Chopper B-3 OPERA TION B-3 CONTR OLS AND SETTINGS All generator/welder controls are located on the Output Control Panel of the machine case front. Idler control, and start/stop controls are also on the case front. See Figure B.1 and the explanations that follow. FIGURE B.1 OUTPUT P ANEL CONTROLS WELDER/GENERA TOR CONTR OLS See Figure B.1 for[...]

  • Page 20

    GX 271 Chopper B-4 OPERA TION B-4 ENGINE OPERA TION DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS. The maximum allowable high idle speed for the GX-271 is 3750 RPM, no load. Do NOT adjust the governor screw on the engine. Severe personal injury and damage to the machine can result if it is operated at speeds above the maximum rated speed. -------------[...]

  • Page 21

    B-5 OPERA TION B-5 ST OPPING 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 “Engine” switch in the “STOP” position. A fuel shut off valve is not required on the GX-271 because the fuel tank is mounted below the engine.[...]

  • Page 22

    GX 271 Chopper B-6 OPERA TION B-6 purposes in each mode. It is not active in the “PIPE” mode. “STICK/TIG” mode: In this mode, the “ARC CON- TROL” knob sets the short circuit (arc force) current during stick welding. Increasing the number from 1 to 10 increases the short circuit current. This prevents sticking of the electrode to the pla[...]

  • Page 23

    B-7 OPERA TION B-7 When the triggering device is pressed the contactor is closed and the welding terminals are “Hot.” When the triggering device is released the contactor is opened and the welding terminals are “Cold.” “MODE” Switch - Set to the desired process: STICK/TIG, PIPE, or WIRE FEED. “WIRE FEEDER V OL TMETER” Switch - If us[...]

  • Page 24

    GX 271 Chopper B-8 OPERA TION B-8 Tungsten Electrode Diameter in. (mm) 2-15 5-20 15-80 70-150 150-250 250-400 400-500 500-750 750-1000 (3) (3) (3) 10-20 15-30 25-40 40-55 55-80 80-125 3-8 (2-4) 5-10 (3-5) 5-10 (3-5) 9-13 (4-6) 11-15 (5-7) 11-15 (5-7) 13-17 (6-8) 18-22 (8-10) 23-27 (11-13) TIG TORCH Nozzle Size (4), (5) Approximate Argon Gas Flow Ra[...]

  • Page 25

    GX 271 Chopper B-9 OPERA TION B-9 T ABLE B.3 SUMMAR Y OF WELDING PR OCESSES AND MA CHINE SETTINGS CONTROL CABLE USED MODE SWITCH IDLER SWITCH OUTPUT CONTROL SWITCH WELDING TERMINALS SWITCH ELECTRODE WHEN NOT WELDING TO START WELDING PROCESS STICK - CC TIG - CC K930-1 TIG MODULE / K936-1 CONTROL CABLE (With Amptrol) WIRE FEED - CV, LN-25 WITH 42V RE[...]

  • Page 26

    GX 271 Chopper B-10 OPERA TION B-10 A UXILIAR Y PO WER Start the engine and set the "IDLER" control switch to the desired operating mode. Full power is available regardless of the welding output settings, if no welding current is being drawn. The auxiliary power of the GX-271 consists of two 15 Amp-120VAC (5-15R) duplex receptacles and on[...]

  • Page 27

    C-1 A CCESSORIES C-1 GENERAL OPTIONS / A CCESSORIES The following options/accessories are available for your GX-271: K886-1 Canvas Cover - To protect the GX-271 when it is not being operated. Made from attractive red can- vas material that is flame retardant, mildew resistant and water repellent. K889-2 Two Wheel Undercarriage - For moving by hand.[...]

  • Page 28

    C-2 A CCESSORIES C-2 SEMIA UT OMA TIC FCA W AND MIG WELDING OPTIONS / A CCESSORIES LN-25 Wire Feeder - This portable unit can be used for flux-cored arc welding (FCAW) and metal inert gas welding (MIG). LN-7 Wire Feeder - Semiautomatic constant speed wire feeder. NOTE : Gas-shielded welding requires a Magnum Gun. Gasless welding requires an Innersh[...]

  • Page 29

    GX 271 Chopper C-3 C-3 A CCESSORIES - CONNECTION DIA GRAMS        ?[...]

  • Page 30

    GX 271 Chopper C-4 C-4 A CCESSORIES - CONNECTION DIA GRAMS      ((07/3&9'*2083+( %&'(&)*+(,-*'(./*01(2, ((034356&%11%)*2703&,' 285./38*6*(90(&'%22(8'-%/[...]

  • Page 31

    GX 271 Chopper C-5 C-5 A CCESSORIES - CONNECTION DIA GRAMS > %&'(&)*+(,-*'(./*01(2, ((034356&%11%)*2703&,' ((07/3&9'*2083+(       A?[...]

  • Page 32

    GX 271 Chopper C-6 C-6 A CCESSORIES - CONNECTION DIA GRAMS ((034356&%11%)*2703&,' C      ?[...]

  • Page 33

    GX 271 Chopper C-7 C-7 A CCESSORIES - CONNECTION DIA GRAMS    [...]

  • Page 34

    GX 271 Chopper D-1 MAINTENANCE D-1 R OUTINE AND PERIODIC ENGINE MAINTENANCE At the end of each day’s use, refill the fuel tank to min- imize moisture condensation in the tank. Running out of fuel tends to draw dirt into the fuel system. Also, check the crankcase oil level and add oil if indicated. ENGINE MAINTENANCE P ARTS T ABLE D.1 * Oil capici[...]

  • Page 35

    GX 271 Chopper D-2 MAINTENANCE D-2 T ABLE D.2 HOND A ENGINE MAINTENANCE SCHEDULE T ABLE D.3 K OHLER ENGINE MAINTENANCE SCHEDULE Regular Service Period (3) Each Use First Month or 20 Hrs. Every 3 Months or 50 Hrs. Every 6 Months or 100 Hrs. Every Year or 300 Hours ITEM Perform at every indicated month or operating hour interval, whichever comes firs[...]

  • Page 36

    D-3 MAINTENANCE D-3 CHANGING THE ENGINE OIL Drain the oil while the engine is warm to assure rapid and complete draining. 1. Remove the oil filler cap and drain cap, and drain the oil into a suitable container. 2. Retighten the drain cap securely. 3. Refill to the upper limit mark on the dipstick with the recommended oil. Tighten the oil filler cap[...]

  • Page 37

    D-4 MAINTENANCE D-4 KOHLER ENGINE Air Precleaner Service 1. Loosen the cover retaining knob and remove the cover. 2. Remove the precleaner from the paper element. 3. Wash the precleaner in warm water with detergent. Rinse the precleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the precl[...]

  • Page 38

    GX 271 Chopper D-5 MAINTENANCE D-5 FUEL FIL TER SER VICE 1. Check the fuel filter for water accumulation or sedi- ment. 2. Replace the fuel filter if it is found with excessive water accumulation or sediment. ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM, no load. Do NOT tamper with gov[...]

  • Page 39

    D-6 MAINTENANCE D-6 After cleaning, flush the outside of the battery, the bat- tery compartment, and surrounding areas with clear water. Coat the battery terminals lightly with petrole- um jelly or a non-conductive grease to retard corro- sion. Keep the battery clean and dry. Moisture accumula- tion on the battery can lead to more rapid discharge a[...]

  • Page 40

    GX 271 Chopper E-1 TR OUBLESHOO TING E-1 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. CA UTION This Troubleshooting Guide is provided to help you locate and repai[...]

  • Page 41

    GX 271 Chopper E-2 TR OUBLESHOO TING E-2 Observe all Safety Guidelines detailed throughout this manual 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. CA UTION PROBL[...]

  • Page 42

    GX 271 Chopper E-3 TR OUBLESHOO TING E-3 Observe all Safety Guidelines detailed throughout this manual 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. CA UTION PROBL[...]

  • Page 43

    GX 271 Chopper E-4 TR OUBLESHOO TING E-4 Observe all Safety Guidelines detailed throughout this manual 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. CA UTION PROBL[...]

  • Page 44

    F-1 DIA GRAMS F-1 GX 271 Chopper       !" # # #    !   $ #          % &q[...]

  • Page 45

    F-2 DIA GRAMS F-2 GX 271 Chopper " " $!$  " " "  " " " " " ?[...]

  • Page 46

    GX 271 Chopper W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABR[...]

  • Page 47

    GX 271 Chopper W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to[...]