Lincoln Electric RED-D-ARC GX 271 Chopper Operator'S Manual Download Page 1

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RED-D-ARC
GX 271 Chopper

IM603

March, 1999

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.

For use with machines having Code Numbers:

10527

North America’s Largest Fleet of Welding Equipment

1-800-245-3660

OPERATOR’S MANUAL

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

Page 1: ...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 For use with machines having Code Numbers 10527 North America s Largest Fleet of Welding Equi...

Page 2: ...ACEMAKER 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...

Page 3: ...d 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 w...

Page 4: ...m 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 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...

Page 5: ...propriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons 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 l on pique le laitier 6...

Page 6: ...n must be followed to avoid minor personal injury or damage to this equipment CAUTION 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 Please reco...

Page 7: ... Section B General Description B 1 Design Features B 1 Other Features B 2 Recommended Applications B 2 Limitations B 2 Additional Safety Precautions B 2 Controls and Settings B 3 Welder Generator Controls B 3 Engine Operation B 4 Before Starting the Engine B 4 Starting the Engine B 4 Stoping the Engine B 5 Fuel Consumption Data B 5 Welding Operation B 6 Welder Controls Function and Operation B 6 S...

Page 8: ... Oil Filter D 3 Air Cleaner Service D 3 Spark Plug Service D 4 Fuel Filter Service D 5 Engine Adjustments D 5 Battery Maintenance D 5 Servicing Optional Spark Arrestor D 6 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...

Page 9: ... 30 3 in 19 1 in 42 0 in 469 lbs 770 mm 485 mm 1067 mm 212 kg OUTPUT GENERATOR Welding Output Volts at Rated Amps Duty Cycle1 Max OCV 3700 RPM CC Stick TIG Pipe and CV Wire Welding 275 Amps 28 volts 100 80 volts DC 300 Amps 25 volts 60 Auxiliary Power 2 8 000 Watts 60 Hz 120 240 Volts 100 Duty Cycle 42 Volt Auxiliary Power for Wire Feeders PHYSICAL DIMENSIONS 1 Duty cycle is based on a 10 minute p...

Page 10: ...A 2 INSTALLATION GX 271 Chopper A 2 TECHNICAL SPECIFICATIONS Red D Arc GX 271 K1623 1 ...

Page 11: ...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 operator s manual WARNING Always operate the GX 271 with the case roof on and all machine components completely assembled This will protect you from the dangers of moving parts hot metal surfaces and live electrical devices STORING 1 Store the ma...

Page 12: ... frame and should always be used when lifting the machine ADDITIONAL SAFETY PRECAUTIONS FALLING EQUIPMENT can cause injury Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting WARNING PRE OPERATION ENGINE SERVICE READ and UNDERSTAND the engine op...

Page 13: ...er Use correct polarity Negative Ground The GX 271 is shipped with the negative battery cable disconnected Before you operate the machine make sure the Engine Switch is in the STOP position and attach the disconnected cable securely to the negative battery terminal Remove the insulating cap from the negative battery terminal Replace and tighten negative battery cable terminal NOTE This machine is ...

Page 14: ...ommended 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 Lincoln Electric offers a welding accessory kit with the properly specified welding cables See the ACCESSORIES section of this manual for more infor mation WARNING Table A 1 CA...

Page 15: ...nerator it can be permanent ly installed as a standby power unit for 240 volt three wire single phase 33 ampere service Only a licensed certified trained electrician should install the machine to a premises or residential elec trical system Be certain that The installation complies with the National Electrical Code and all other applicable electrical codes The premises is isolated and no feedbacki...

Page 16: ...DOUBLE POLE CIRCUIT BREAKER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION 50 AMP 115 230 VOLT PLUG NEMA TYPE 14 50 50 AMP 115 230 VOLT RECEPTACLE Figure A 1 CONNECTION OF GX 271 TO PREMISES WIRING Table A 1 Extension Cord Length Recommendations WARNING Current Voltage Load Maximum Allowable Cord Length in ft m for Conductor Size AW...

Page 17: ...der it provides up to 300 amps of DC current for DC stick welding and DC semiautomatic wire feed welding The GX 271 can also perform DC TIG welding DESIGN FEATURES FOR WELDING DC constant current output for stick and TIG weld ing Two continuous CC output settings of 20 to 300 amps one for general purpose stick and tig welding and one with a fixed controlled slope for out of position and pipe weldi...

Page 18: ...and long life CSA approved RECOMMENDED APPLICATIONS WELDER The GX 271 provides excellent constant current DC welding output for stick SMAW welding and for TIG welding and it offers constant voltage output for DC semiautomatic wire feed welding GENERATOR The GX 271 gives AC power output for medium use demands LIMITATIONS The GX 271 is not recommended for any process es besides those that are normal...

Page 19: ...y circuit if a short develops Engine will not crank if this circuit breaker is open 7 WIRE FEEDER POWER CIRCUIT BREAKER Opens the wire feeder circuit and disables the feeder if a fault is detected in the circuit 8 15 AMP 120 VOLT DUPLEX RECEPTACLES Connection point for supplying 120 volt power to oper ate one or more electrical devices 9 50 AMP 120 240 VOLT RECEPTACLE Connection point for supplyin...

Page 20: ...ns WARNING WARNING STARTING THE ENGINE Be sure all Pre Operation Maintenance has been per formed See the INSTALLATION section Remove all loads connected to the AC power recepta cles and the welder before starting the diesel engine To start the engine set the IDLER switch in the AUTO position Pull the choke control out Place the Engine Switch in the RUN Position Push the Start button and crank the ...

Page 21: ...ons hour 29 Imp gal hr 1 31 liters hour 76 US gallons hour 63 Imp gal hr 2 86 liters hour 1 21 US gallons hour 1 01 Imp gal hr 4 57 liters hour 1 40 US gallons hour 1 17 Imp gal hr 5 30 liters hour 1 53 US gallons hour 1 27 Imp gal hr 5 79 liters hour 1 67 US gallons hour 1 39 Imp gal hr 6 32 liters hour 1 56 US gallons hour 1 30 Imp gal hr 5 89 liters hour K1624 2 GX 271 Kohler Engine 40 US gallo...

Page 22: ...n of Hot or Cold welding terminals With the switch in the WELDING TERMINALS ALWAYS ON position the contactor is closed and the welding terminals are always Hot With the switch in the WELDING TERMINALS 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 ...

Page 23: ...l down techniques on pipe joints using EXX10 type electrodes This slope controlled setting allows the operator to control the welding current by changing the arc length The ARC CONTROL arc force is automatically switched off in this mode TIG WELDING The GX 271 can be used in a wide variety of DC Tungsten Inert Gas TIG welding applications When used with the K930 1 or 2 TIG module ratings are limit...

Page 24: ...zes 4 TIG torch nozzle sizes are in multiples of 1 16ths of an inch 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 1 2 in 12 5 mm 10 5 8 in 16 mm 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 and high duty cycles WIRE WELDING Connect a wire feeder to th...

Page 25: ...71 contactor closes Welding starts immediately and engine goes to high idle Press gun trigger GX 271 contactor closes Welding starts immediately and engine goes to high idle Press gun trigger LN 25 contactor closes Welding starts immediately and engine goes to high idle Press gun trigger GX 271 contactor closes Welding starts immediately and engine goes to high idle Press gun trigger GX 271 contac...

Page 26: ...cles 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 240V receptacle has two circuits each of which measure 120 V to neutral but are of opposite polarities and cannot be paralleled SIMULTANEOUS WELDIN...

Page 27: ... Thirty five feet 10 5 meters of 1 0 AWG elec trode cable Thirty feet 9 1 meters of 1 0 AWG work cable Headshield with No 12 filter GC500 work clamp Cooltong 300 insulated electrode holder K802 R Power Plug Kit Provides four 15 amp 120 volt plugs and one 50 amp dual voltage 120 240V full kVA plug K857 Remote Control Includes a control box with 25 feet 7 5 meters of 4 conductor cable Allows out put...

Page 28: ...ding requires a Magnum Gun Gasless welding requires an Innershield Gun K487 25 Magnum Spool Gun A lightweight semi automatic wire feeder for aluminum welding with argon gas Has built in remote wire speed control in the handle 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 interfac...

Page 29: ...IES CONNECTION DIAGRAMS 01 2 0 3435 6 1 1 27 03 285 38 6 9 0 22 8 89 2 388 2 0 3 4 032 8 0 2 6 27 22 2 8 3885 8 03 0 7 3 9 2 083 0 7 3 9 2 083 01 2 0 3435 6 1 1 27 03 285 38 6 9 0 22 8 89 2 388 2 0 3 4 032 8 0 2 22 6 27 2 8 3885 8 03 ...

Page 30: ...IES CONNECTION DIAGRAMS 0 7 3 9 2 083 01 2 0 3435 6 1 1 27 03 285 38 6 9 0 22 8 89 2 388 2 8 3885 8 03 2 0 3 4 032 8 0 2 22 6 27 2 0 3 4 032 8 0 2 22 6 27 2 8 3885 8 03 0 7 3 9 2 083 0 3435 6 1 1 27 03 285 38 6 9 0 22 8 89 2 388 01 2 ...

Page 31: ... CONNECTION DIAGRAMS 01 2 0 3435 6 1 1 27 03 0 7 3 9 2 083 A 6 27 2 8 3885 8 03 2 0 3 4 032 8 0 2 22 285 38 6 9 0 22 8 89 2 388 22 2 8 3885 8 03 B 6 27 2 0 3 4 032 8 0 2 0 7 3 9 2 083 0 3435 6 1 1 27 03 285 38 6 9 0 22 8 89 2 388 01 2 A ...

Page 32: ...NNECTION DIAGRAMS 0 3435 6 1 1 27 03 C 285 38 6 9 0 22 8 89 2 388 2 8 3885 8 03 2 0 3 4 032 8 0 2 D 22 6 27 0 7 3 9 2 083 01 2 C E 6 27 22 A 01 2 D 0 3435 6 1 1 27 03 2 0 3 4 032 8 0 2 0 7 3 9 2 083 285 38 6 9 0 22 8 89 2 388 2 8 3885 8 03 ...

Page 33: ...GX 271 Chopper C 7 C 7 ACCESSORIES CONNECTION DIAGRAMS 6 27 2 8 3885 8 03 AC 0 7 3 9 2 083 0 3435 6 1 1 27 03 285 38 6 9 0 22 8 89 2 388 01 2 2 0 3 4 032 8 0 2 22 A C GX271 ...

Page 34: ...roblem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop 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 no...

Page 35: ...adjust 3 Fuel Filter Check Replace 3 Fuel Line Check Replaceif necessary Every 2 Years 3 1 Service more frequently when used in dusty areas 2 Replace the paper element only 3 These items should be services by an authorized engine dealer Regular Service Period 3 Each Use 5 Hrs 25 Hrs Every 100 Hrs Every 200 Hours ITEM Perform at every indicated month or operating hour interval whichever comes first...

Page 36: ... TABLE D 5 OIL FILTER TIGHTENING TORQUES 5 Refill the crankcase with the specified amount of the recommended oil Reinstall the oil filler cap 6 Start the engine and check for oil filter leaks 7 Stop the engine and check the oil level If neces sary add oil to the upper limit mark on the dipstick AIR CLEANER SERVICE A dirty air cleaner will restrict air flow to the carburetor To prevent carburetor m...

Page 37: ...ecleaner element cover element cover nut and air cleaner cover Secure cover with the cover retaining knob SPARK PLUG SERVICE To ensure proper engine operation the spark plugs must be properly gapped and free of deposits 1 Remove the spark plug caps 2 Clean any dirt from around the spark plug bases 3 Use a plug wrench to remove the spark plugs The muffler becomes very hot during operation and remai...

Page 38: ... to new battery last CONNECTING A BATTERY CHARGER remove battery from welder by disconnecting nega tive cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USING A BOOSTER connect positive lead to battery first then connect negative lead to negative battery lead at engine foot BATTERY ACID can burn eyes and skin Wear gloves and eye p...

Page 39: ... cable first and the negative cable last Failure to do co can result in damage to the internal charger components Follow the instructions of the battery charger manu facturer for proper charger settings and charging time SERVICING OPTIONAL SPARK ARRESTOR MUFFLER MAY BE HOT ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTOR DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTOR 1 Service ...

Page 40: ...general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION If you have exhausted all of the items in step 2 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 ...

Page 41: ...Engine switch in OFF position 3 Faulty fuel solenoid or faulty PC board or ignition system 1 Low oil level 2 Faulty oil pressure switch or other engine component 1 Faulty battery 2 Loose connections at battery or alternator 3 Faulty engine alternator or charg er module 1 Contact your Local Lincoln Authorized Field Service Facility 1 Charge Battery 2 Inspect clean and tighten 3 Contact authorized e...

Page 42: ...2 Welding Terminals switch is in wrong position 3 Faulty PC board Low idle speed set too low 1 Auxiliary power load is less than 100 watts 2 Faulty PC board 1 Fuel filter clogged 2 Air filter clogged 3 Fouled spark plugs 4 Valves out of adjustment 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: ... tripped 4 Faulty welding alternator or faulty PC board 1 Wire Feeder Power circuit breaker open 2 Faulty wiring in control cable 3 Faulty wire feeder 1 Place switch in Always On position when welding without welding terminal control cable Refer to Operation chapter for proper switch function 2 Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance 1 ...

Page 44: ...ce only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 45: ...F 2 DIAGRAMS F 2 GX 271 Chopper ...

Page 46: ...t touch 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 E...

Page 47: ...Sie für 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 ...

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