Lincoln Electric RED-D-ARC GX 271 Chopper Operator's Manual
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Lincoln Electric RED-D-ARC GX 271 Chopper Operator's Manual

Lincoln Electric RED-D-ARC GX 271 Chopper Operator's Manual

Lincoln electric welding system user manual
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IM603
RED-D-ARC
March, 1999
GX 271 Chopper
10527
For use with machines having Code Numbers:
RETURN TO MAIN MENU
OPERATOR'S 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.
1-800-245-3660
North America's Largest Fleet of Welding Equipment

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Summary of Contents for Lincoln Electric RED-D-ARC GX 271 Chopper

  • Page 1 OPERATOR’S 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 ...

  • Page 2: California Proposition 65 Warnings

    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.

  • Page 3: Electric Shock Can Kill

    (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 5.e. Also see item 1.b. GX 271 Chopper Mar ‘95...
  • Page 4 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. Mar ‘95 GX 271 Chopper...
  • Page 5 électricien qualifié. 3. Avant de faires des travaux à l’interieur de poste, la debranch- er à l’interrupteur à la boite de fusibles. 4. Garder tous les couvercles et dispositifs de sûreté à leur place. GX 271 Chopper Mar. ‘93...
  • Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. 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! _____________________________________ GX 271 Chopper...

  • Page 7: Table Of Contents

    Summary of Welding Processes and Machine Settings ...B-9 Auxiliary Power...B-10 Simultaneous Welding and Power Loads ...B-10 Accessories ...Section C General Options / Accessories ...C-1 TIG Welding Options / Accessories...C-1 Semiautomatic FCAW and MIG Welding Options / Accessories...C-2 Connection Diagrams for Accessories ...C-3 Page GX 271 Chopper...
  • Page 8 Welder / Generator Maintenance ...D-6 Storage ...D-6 Cleaning...D-6 Brush Removal and Replacement ...D-6 Troubleshooting ...Section E Safety Precautions...E-1 How to Use Troubleshooting Guide...E-1 Troubleshooting Guide ...E-2 Wiring Diagram & Dimension Print...Section F Parts Lists ...P325 Series TABLE OF CONTENTS GX 271 Chopper Page...

  • Page 9: Installation

    8,000 Watts, 60 Hz 120/240 Volts 100 % Duty Cycle 42 Volt Auxiliary Power for Wire Feeders PHYSICAL DIMENSIONS DEPTH 42.0 in. 1067 mm GX 271 Chopper Starting Capacities System 12VDC battery Fuel: 9.0 gal. (Group 58, 435 34 L cold crank amps) Oil: 1.59 Qts.
  • Page 10 INSTALLATION TECHNICAL SPECIFICATIONS - Red-D-Arc GX-271 (K1623-1) GX 271 Chopper...

  • Page 11: Installation Instructions

    If you do operate it at a slight angle, be sure to check the oil regularly and keep the oil level at the FULL mark as it would be in its normal level condition. Also, fuel capacity will be a little less at an angle. GX 271 Chopper...

  • Page 12: High Altitude Operation

    START THE ENGINE. If it is not full, add enough oil to fill it to the full mark. For more information on oil viscosity and service con- ditions, see the MAINTENANCE section of this manu- al and the engine Operator’s Manual. GX 271 Chopper CAUTION WARNING...

  • Page 13: Fuel

    GX- 271. See the ACCESSORIES section of this manual for more information. An incorrect spark arrester may lead to damage to the engine or reduce performance. ------------------------------------------------------------------------ GX 271 Chopper CAUTION CAUTION...

  • Page 14: Electrical Connections

    Cable diameters are increased for long cable lengths to reduce voltage drops. Lincoln Electric offers a welding accessory kit with the properly specified welding cables. ACCESSORIES section of this manual for more infor- mation.

  • Page 15: Auxiliary Power Receptacles, Plugs, And Hand-Held Equipment

    4 conductor cable of the desired length. (The 50 amp 120/240 volt plug is available in the optional power plug kit. 4. Plug this cable in to the 50 amp 120/240 volt recep- tacle on the GX-271 case front. GX 271 Chopper WARNING...

  • Page 16: Extension Cord Length Recommendations

    (18) (30) (27) (23) Figure A.1 115 VOLT 115 VOLT 35 AMP 230 VOLT DOUBLE POLE CIRCUIT 230 VOLT BREAKER WARNING GX 271 Chopper 6 AWG 4 AWG (38) (53) (91) (69) (107) (183) (53) (84) (137) (46) (69) (76)

  • Page 17: Safety Instructions

    • Power a 1-1/2 HP motor (provided it is started under no load). • Two 15 amp industrial grade 120 V AC duplex receptacles for up to 60 amps of 120 VAC power. GX 271 Chopper...

  • Page 18: Additional Safety Precautions

    Read and understand all Safety Precautions before operating this machine. Always follow these and any other safety procedures included in this manual and in the Engine Owner’s Manual. Only qualified personnel should install, use, or service this equipment. GX 271 Chopper...

  • Page 19: Controls And Settings

    12 seconds after a welding or auxiliary power load is removed. Engine goes to high speed when the load is re-applied. 19. BATTERY CHARGER AMMETER 20. ENGINE HOUR METER GX 271 Chopper PUSHBUTTON SWITCH:...

  • Page 20: Engine Operation

    NOTE: When starting a GX-271 for the first time, after an extended period of not operating, it will take longer than normal because the fuel pump has to fill the fuel line and carburetor. GX 271 Chopper ) position. Pull the choke Position.

  • Page 21: Stopping The Engine

    1.53 US gallons/hour (1.20 Imp. gal./hr., 5.45 liters/hour) 1.67 US gallons/hour (1.28 Imp. gal./hr., 5.80 liters/hour) 1.56 US gallons/hour (1.22 Imp. gal./hr., 5.55 liters/hour) GX 271 Chopper .40 US gallons/hour .87 US gallons/hour 1.27 US gallons/hour 1.37 US gallons/hour 1.44 US gallons/hour 1.53 US gallons/hour...

  • Page 22: Welding Operation

    REMOTELY CONTROLLED” position, the contactor operation is controlled by an Amptrol, Arc Start Switch or some other type of triggering device through the use of a control cable connected to the 6 pin or 14 pin amphenol. GX 271 Chopper “REMOTE” Switch...

  • Page 23: Stick Welding

    State” contactor open and provide a “cold” elec- trode until the triggering device (Amptrol or Arc Start Switch) is pressed. e. Set the “ARC CONTROL” to minimum. See Table B.2 for Typical Current Ranges for Tungsten Electrodes. GX 271 Chopper This will keep the “Solid...

  • Page 24: Wire Welding

    For any electrodes, including the above recommenda- tions, the procedures should be kept within the rating of the machine. For additional electrode information, see Lincoln publications N-675, GS-100 and GS-210. GX 271 Chopper TIG TORCH Nozzle Size (4), (5) #4, #5, #6...

  • Page 25: Summary Of Welding Processes And Machine Settings

    CONTACTOR COLD CONTROLLED COLD HIGH REMOTE CONTACTOR CONTROLLED GX 271 Chopper TO START WELDING Touch electrode to work. Welding starts immediately and engine goes to high idle. Press Amptrol. GX-271 contactor closes. Welding starts immediately and engine goes to high idle.

  • Page 26: Auxiliary Power

    (not both at the same time). TABLE B.4 Available Auxiliary Permissible Power - Watts Auxiliary Current (Unity Power in Amperes @ Factor) 120V 8000 7400 6300 4800 3400 1800 1000 GX 271 Chopper B-10 Permissible Auxiliary Current in Amperes @ 240V...

  • Page 27: Accessories

    K930-1 TIG Module to energize the GX-271 output terminals via the TIG module. K963 Hand Amptrol - Remote output control and contactor control. K870 Foot Amptrol - Remote output control and con- tactor control. GX 271 Chopper...

  • Page 28: Semiautomatic Fcaw And Mig Welding Options / Accessories

    Requires the K488 SG Control Module. Includes 50 feet (15.2 meters) of power cable. K488 SG Control Module - Controls wire speed and gas flow. Provides the required control interface between the GX-271 and the K487-25 Magnum Spool Gun. GX 271 Chopper...
  • Page 29 ACCESSORIES - CONNECTION DIAGRAMS GX 271 Chopper...
  • Page 30 ACCESSORIES - CONNECTION DIAGRAMS GX 271 Chopper...
  • Page 31 ACCESSORIES - CONNECTION DIAGRAMS GX 271 Chopper...
  • Page 32 ACCESSORIES - CONNECTION DIAGRAMS GX 271 Chopper...
  • Page 33 ACCESSORIES - CONNECTION DIAGRAMS GX271 GX 271 Chopper...

  • Page 34: Maintenance

    (Honda Code 2106235) Spark Plugs NGK BPR6ES Nippondenso W20EPR-U .030 in., (.76 mm.) gap * Oil capicity increases from 2.0 Qts. to 2.1 Qts when using this filter. GX 271 Chopper TABLE D.1 Kohler CH 20 Kohler 1205001 Fram PH3614* Kohler 4708303...

  • Page 35: Engine Maintenance Schedule

    • • • (1) Every 2 Years (3) TABLE D.3 Each 5 Hrs. 25 Hrs. First Oil Change Every 2 Years GX 271 Chopper Every Every Year or 100 Hrs. 300 Hours • • or 200 Hours • (2) •...

  • Page 36: Changing The Engine Oil

    Replace the paper ele- ment if it is excessively dirty. Replace the paper element and both gaskets. 5. Reinstall the air cleaner elements. Tighten the wing bolt securely. GX 271 Chopper TABLE D.5 Honda Kohler 16 ft-lb, (22 Nßm) 10 ft-lb, (13.6 Nßm)

  • Page 37: Kohler Engine

    Use only the recommended spark plug or equivalent. A spark plug which has an improper heat range may cause engine damage. ------------------------------------------------------------------------------------------ GX 271 Chopper WARNING TABLE D.6 Kohler .030 in. (.76 mm) 20 ft.

  • Page 38: Fuel Filter Service

    1/4 pound (0.1113 kg) of baking soda and 1 quart (0.946 L) of water. Be sure the battery vent plugs (if equipped) are tight so that none of the solution enters the cells. GX 271 Chopper WARNING...

  • Page 39: Servicing Optional Spark Arrestor

    It is normal for the brushes and slip rings to wear and darken slightly. Inspect the brushes when a generator overhaul is necessary. Do not attempt to polish slip rings while the engine is running. ------------------------------------------------------------------------ GX 271 Chopper WARNING...

  • Page 40: Troubleshooting

    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 throughout this manual.
  • Page 41 1. Faulty battery. 2. Loose connections at battery or alternator. 3. Faulty engine alternator or charg- er module. CAUTION GX 271 Chopper RECOMMENDED COURSE OF ACTION 1. Contact your Local Lincoln Authorized Field Service Facility. 1. Charge Battery. 2. Inspect, clean and tighten.
  • Page 42 1. Fuel filter clogged. 2. Air filter clogged. 3. Fouled spark plugs. 4. Valves out of adjustment. CAUTION GX 271 Chopper RECOMMENDED COURSE OF ACTION 1. Set switch to Auto. 2. Remove all external loads. 3. Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance.
  • Page 43 1. Wire Feeder Power circuit breaker open. 2. Faulty wiring in control cable 3. Faulty wire feeder. CAUTION GX 271 Chopper RECOMMENDED COURSE OF ACTION 1. Place switch in "Always On" position when welding without welding terminal control cable. Refer to Operation chapter for proper switch function.
  • Page 44 DIAGRAMS GX 271 Chopper...
  • Page 45 DIAGRAMS GX 271 Chopper...
  • Page 46 Protégez vos yeux, vos oreilles et inflammable. votre corps. ● ● Entfernen Sie brennbarres Material! Tragen Sie Augen-, Ohren- und Kör- perschutz! ● ● Mantenha inflamáveis bem guarda- Use proteção para a vista, ouvido e dos. corpo. GX 271 Chopper...
  • Page 47 ATTENTION protection enlevés. ● German Anlage nie ohne Schutzgehäuse oder Innenschutzverkleidung in WARNUNG Betrieb setzen! Portuguese ● Mantenha-se afastado das partes moventes. ATENÇÃO ● Não opere com os paineis abertos ou guardas removidas. Japanese Chinese Korean Arabic GX 271 Chopper...

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