RED-D-ARC GX 271 Chopper For use with machines having Code Numbers: IM603 10527 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.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii 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.
iii iii SAFETY WELDING SPARKS can 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. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv iv SAFETY PRÉCAUTIONS 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 suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v 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! 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.
vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Installation Instructions. ........................................................................................................A-3 Location and Ventilation ....................................................
vii TABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine and Periodic Engine Maintenance ...........................................................D-1 Engine Maintenance Parts..............................................................................D-1 Engine Maintenance Schedule ......
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Red-D-Arc GX-271 (K1623-1) INPUT - ENGINE Make/Model Description Speed (RPM) Displacement Starting System Honda GX620 Gas Engine 2 cylinder 20.0 HP @ 3600 RPM Full Load High Idle 3700 Low Idle 2400 Full Load 3400 37.7 cu. in (615 cc) 12VDC battery Fuel: 9.0 gal. (Group 58, 435 34 L cold crank amps) Oil: 1.59 Qts. 20A. Battery 1.5 L Charger Bore x Stroke 3.00” x 2.
A-2 INSTALLATION TECHNICAL SPECIFICATIONS - Red-D-Arc GX-271 (K1623-1) GX 271 Chopper A-2
A-3 INSTALLATION INSTALLATION INSTRUCTIONS SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. -----------------------------------------------------------------------ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing.
A-4 A-4 INSTALLATION HIGH ALTITUDE OPERATION At high altitude, the standard carburetor air-fuel mixture 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 to the carburetor. If you always operate your engine at altitudes above (6,000 feet) 1,800 meters, have a engine dealer perform this carburetor modification.
A-5 FUEL IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN: Fill the fuel tank with clean, fresh regular grade leadfree 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. BATTERY CONNECTIONS WARNING GASES FROM BATTERY can explode. ● Keep sparks, flame and cigarettes away from battery.
A-6 A-6 INSTALLATION ELECTRICAL CONNECTIONS See Figure B.1 in the OPERATION section of this manual for location of the 120 and 240 volt receptacles, weld output terminals, circuit breakers and ground stud. TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Length 0-50 Ft. (0-15 meters) Cable Size for 300 Amps 100% Duty Cycle 1/0 AWG MACHINE GROUNDING Because the GX-271 creates its own power from its engine driven generator, and if the machine is not connected to premises wiring (home, shop, etc.
A-7 A-7 INSTALLATION AUXILIARY POWER RECEPTACLES, PLUGS, AND HAND-HELD EQUIPMENT The control panel of the GX-271 features three auxiliary power receptacles: See Figure B.1. • Two 15 amp, 120 volt duplex (double outlet) receptacles. PREMISES WIRING The GX-271 is suitable for temporary, standby, or emergency power using the engine manufacturer’s recommended maintenance schedule.
A-8 A-8 INSTALLATION Table A.
B-1 OPERATION B-1 OPERATING INSTRUCTIONS GENERAL DESCRIPTION Read and understand this entire section before operating your GX-271. The GX-271 is an engine driven, multi-process DC arc welder and AC power generator for commercial and residential applications. As a generator it can supply up to 8,000 continuous watts of 120/240 volt, 60 Hz, single-phase AC power to operate AC power tools, battery chargers, and lighting; it can also be used to provide standby power.
B-2 OPERATION 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. LIMITATIONS • Welding and AC auxiliary power at the same time (within machine total capacity). • The GX-271 is not recommended for pipe thawing.
B-3 OPERATION CONTROLS 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. B-3 TROLLED” is used to control the operation of the solid state output contactor. With the switch in the “WELDING TERMINALS ALWAYS ON” position, the contactor is closed at low and high idle. 6.
B-4 B-4 OPERATION ENGINE OPERATION STARTING THE ENGINE CAUTION WARNING 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.
B-5 B-5 OPERATION 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 “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. ------------------------------------------------------------------------ TABLE B.
B-6 B-6 OPERATION WELDING OPERATION purposes in each mode. It is not active in the “PIPE” mode. WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. -----------------------------------------------------------------------ELECTRIC SHOCK can kill.
B-7 OPERATION 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. B-7 TIG WELDING The GX-271 can be used in a wide variety of DC Tungsten Inert Gas (TIG) welding applications.
B-8 B-8 OPERATION Table B.2 TYPICAL CURRENT RANGES Tungsten Electrode Diameter in. (mm) DCEN (-) DCEP (+) 1%, 2% Thoriated Tungsten 1%, 2% Thoriated Tungsten (1) FOR TUNGSTEN ELECTRODES (2) Approximate Argon Gas Flow Rate C.F.H. (l/min.) Stainless Steel TIG TORCH Nozzle Size (4), (5) 0 .010 0.020 0.040 (.25) (.50) (1.0) 2-15 5-20 15-80 (3) (3) (3) 3-8 5-10 5-10 (2-4) (3-5) (3-5) #4, #5, #6 1/16 (1.6) 70-150 10-20 9-13 (4-6) #5, #6 3/32 1/8 (2.4) (3.
B-9 B-9 OPERATION TABLE B.
B-10 B-10 OPERATION The 120V duplex auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. AUXILIARY POWER 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.
C-1 ACCESSORIES GENERAL OPTIONS / ACCESSORIES C-1 - GC500 work clamp. - Cooltong® 300 insulated electrode holder. 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 canvas material that is flame retardant, mildew resistant and water repellent. K889-2 Two Wheel Undercarriage - For moving by hand. Two 4.00" x 8" pneumatic tires. Overall width 29" (.74m).
C-2 ACCESSORIES SEMIAUTOMATIC FCAW AND MIG WELDING OPTIONS / ACCESSORIES 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 Innershield Gun. K487-25 Magnum Spool Gun - A lightweight, semiautomatic wire feeder for aluminum welding with argon gas. Has built-in remote wire speed control in the handle.
C-3 C-3 ACCESSORIES - CONNECTION DIAGRAMS # " $ ! " % 2%, %0(&3,( 4*,- 032(8' %0(2 *'+%22(+, < = ((0 7/3&9' *2 083+( ((0 3435 6&%1 1%)*27 03&,' ;(6%&( '(&)*+*27 285 ./38*6*(9 0(&'%22(8 '-%/89 *2',388:/'( %& '(&)*+( ,-*' (.
C-4 C-4 ACCESSORIES - CONNECTION DIAGRAMS % 2%, %0(&3,( 4*,- 032(8' %0(2 *'+%22(+, < = ((0 7/3&9' *2 083+( ((0 3435 6&%1 1%)*27 03&,' ;(6%&( '(&)*+*27 285 ./38*6*(9 0(&'%22(8 '-%/89 *2',388:/'( %& '(&)*+( ,-*' (.
C-5 C-5 ACCESSORIES - CONNECTION DIAGRAMS % 2%, %0(&3,( 4*,- 032(8' %0(2 *'+%22(+, < = ((0 7/3&9' *2 083+( ((0 3435 6&%1 1%)*27 03&,' ;(6%&( '(&)*+*27 285 ./38*6*(9 0(&'%22(8 '-%/89 *2',388:/'( %& '(&)*+( ,-*' (.
C-6 C-6 ACCESSORIES - CONNECTION DIAGRAMS % 2%, %0(&3,( 4*,- 032(8' %0(2 *'+%22(+, < = ((0 7/3&9' *2 083+( ((0 3435 6&%1 1%)*27 03&,' ;(6%&( '(&)*+*27 285 ./38*6*(9 0(&'%22(8 '-%/89 *2',388:/'( %& '(&)*+( ,-*' (.
C-7 C-7 ACCESSORIES - CONNECTION DIAGRAMS #! % 2%, %0(&3,( 4*,- 032(8' %0(2 *'+%22(+, < = ((0 7/3&9' *2 083+( ((0 3435 6&%1 1%)*27 03&,' ;(6%&( '(&)*+*27 285 ./38*6*(9 0(&'%22(8 '-%/89 *2',388:/'( %& '(&)*+( ,-*' (.
D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS 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 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. Do not put your hands near any rotating parts.
D-2 D-2 MAINTENANCE TABLE D.2 HONDA 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 first.
D-3 D-3 MAINTENANCE CHANGING THE ENGINE OIL TABLE D.5 OIL FILTER TIGHTENING TORQUES Drain the oil while the engine is warm to assure rapid and complete draining. OIL FILTER TORQUE: 1. Remove the oil filler cap and drain cap, and drain the oil into a suitable container. Honda Kohler 16 ft-lb, (22 Nßm) 10 ft-lb, (13.6 Nßm) 5. Refill the crankcase with the specified amount of the recommended oil. Reinstall the oil filler cap. 2. Retighten the drain cap securely. 6.
D-4 D-4 MAINTENANCE KOHLER ENGINE SPARK PLUG SERVICE Air Precleaner Service To ensure proper engine operation, the spark plugs must be properly gapped and free of deposits. 1. Loosen the cover retaining knob and remove the cover. 1. Remove the spark plug caps. 2. Remove the precleaner from the paper element. 2. Clean any dirt from around the spark plug bases. 3. Wash the precleaner in warm water with detergent. Rinse the precleaner thoroughly until all traces of detergent are eliminated.
D-5 D-5 MAINTENANCE FUEL FILTER SERVICE BATTERY MAINTENANCE WARNING WARNING When working on the fuel system GASES FROM BATTERY can explode. ● Keep sparks, flame and cigarettes away from battery. • Keep naked lights away, do not smoke ! • Do not spill fuel ! -----------------------------------------------------------------------1. Check the fuel filter for water accumulation or sediment. 2. Replace the fuel filter if it is found with excessive water accumulation or sediment.
D-6 D-6 MAINTENANCE 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 and early battery failure. 4. Lightly tap on arrestor around drain hole to remove particulate. 5.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING 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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) Major Physical or Electrical Damage is Evident. RECOMMENDED COURSE OF ACTION 1. Contact your Local Lincoln Authorized Field Service Facility. Engine will not "crank". 1. Battery is low. 2. Loose battery cable connections. 3. Faulty engine starter motor. 1. Charge Battery. 2. Inspect, clean and tighten. 3. Contact authorized engine Service Shop. 4.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION Engine will not idle down to low 1. Idler switch in High idle position. 1. Set switch to Auto. speed. 2. External load on welder or auxil- 2. Remove all external loads. iary power. 3. Faulty PC board or idler solenoid. 3. Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION No welding power output. 1. "Welding Terminals" switch in 1. Place switch in "Always On" position wrong position. when welding without welding terminal control cable. Refer to Operation chapter for proper switch function. 2. Faulty welding alternator or faulty 2. Contact your Local Lincoln Authorized PC board.
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● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el 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 mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.