IM603
RED-D-ARC March, 1999
GX 271 Chopper
10527
For use with machines having Code Numbers:
RETURN TO MAIN INDEX
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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER 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 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.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
GX 271 Chopper
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
GX 271 Chopper
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
GX 271 Chopper
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
a. Les circuits à l’électrode et à la piéce sont sous tension
la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours
endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue
de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans
age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains.
des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble
produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de
voir le code “Code for safety in welding and cutting� CSA
courant pour soudage semi-automatique, ces precautions
Standard W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie
LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. �93
GX 271 Chopper
v v
for selecting this QUALITY product. We want you to take pride in
Thank You operating this product •â?¢â?? 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.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
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 safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
GX 271 Chopper
vi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications .......................................................................................................A-1
Installation Instructions. ........................................................................................................A-3
Location and Ventilation ................................................................................................A-3
Storing ...........................................................................................................................A-3
Stacking ........................................................................................................................A-3
Angle of Operation ........................................................................................................A-3
High Altitude Operation .................................................................................................A-4
Lifting.............................................................................................................................A-4
Additional Safety Precautions .......................................................................................A-4
Pre-Operation Engine Service..............................................................................................A-4
Oil ..................................................................................................................................A-4
Fuel ...............................................................................................................................A-5
Battery Connections ......................................................................................................A-5
Muffler ...........................................................................................................................A-5
Spark Arrester ...............................................................................................................A-5
Electrical Connections ..........................................................................................................A-6
Machine Grounding .......................................................................................................A-6
Welding Cable Connections ..........................................................................................A-6
Auxiliary Power Receptacles, Plugs, and Hand-Held Equipment ........................................A-7
Circuit Breakers ....................................................................................................................A-7
Premises Wiring ...................................................................................................................A-7
Operation.........................................................................................................................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
Stick Welding ................................................................................................................B-7
Pipe Welding .................................................................................................................B-7
TIG Welding ..................................................................................................................B-7
Wire Welding .................................................................................................................B-8
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
GX 271 Chopper
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 .......................................................................D-2
Changing the Engine Oil .................................................................................D-3
Changing the Engine 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 Print................................................................Section F
Parts Lists ....................................................................................................P325 Series
GX 271 Chopper
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - Red-D-Arc GX-271 (K1623-1)
INPUT - ENGINE
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)
Full Load Bore x Stroke Oil: 1.59 Qts.
20A. Battery 1.5 L
3.00� x 2.60� Charger
(77 mm x 66 mm)
RATED OUTPUT - WELDER
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%
OUTPUT - GENERATOR
Auxiliary Power 2
8,000 Watts, 60 Hz
120/240 Volts
100 % Duty Cycle
42 Volt Auxiliary Power for Wire Feeders
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
30.3 in. 19.1 in. 42.0 in. 469 lbs.
770 mm 485 mm 1067 mm 212 kg.
1. Duty cycle is based on a 10 minute period. This machine can be loaded to 300 amps for 6 minutes out of every 10 minute
period.
2. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to
rated capacity. When welding, available auxiliary power will be reduced.
GX 271 Chopper
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - Red-D-Arc GX-271 (K1623-1)
GX 271 Chopper
A-3 A-3
INSTALLATION
Always operate the GX-271 with the case roof on and
INSTALLATION INSTRUCTIONS
all machine components completely assembled. This
will protect you from the dangers of moving parts, hot
SAFETY PRECAUTIONS metal surfaces, and live electrical devices.
WARNING STORING
Do not attempt to use this equipment until you
1. Store the machine in a cool, dry place when it is
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes not in use. Protect it from dust and dirt. Keep it
important safety precautions, detailed engine where it can’t be accidentally damaged from con-
starting, operating and maintenance instructions, struction activities, moving vehicles, and other
and parts lists.
hazards.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
2. Drain the engine oil and refill with fresh oil. Run
� Do not touch electrically live parts or
the engine for about five minutes to circulate oil to
electrode with skin or wet clothing.
� Insulate yourself from work and all the parts. See the MAINTENANCE section of
ground this manual for details on changing oil.
� Always wear dry insulating gloves.
------------------------------------------------------------------------
3. Remove the battery, recharge it, and adjust the
ENGINE EXHAUST can kill.
electrolyte level. Store the battery in a dry, dark
� Use in open, well ventilated areas or
place.
vent exhaust outside.
------------------------------------------------------------------------ STACKING
MOVING PARTS can injure.
� Do not operate with doors open or
GX-271 machines CANNOT be stacked.
guards off.
� Stop engine before servicing.
� Keep away from moving parts.
------------------------------------------------------------------------ ANGLE OF OPERATION
See additional warning information at Place the machine on a secure, level surface whenev-
front of this operator’s manual. er you use it or store it. Any surfaces you place it on
other than the ground must be firm, non-skid, and
-----------------------------------------------------------
structurally sound.
Only qualified personnel should install,
The engine is designed to run in a level position for
use, or service this equipment.
best performance. It can operate at an angle, but this
should never be more than 15 degrees in any direc-
tion. If you do operate it at a slight angle, be sure to
check the oil regularly and keep the oil level at the
LOCATION AND VENTILATION
FULL mark as it would be in its normal level condition.
Also, fuel capacity will be a little less at an angle.
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 machine away from heat sources. Do not
place the engine end of the machine anywhere near
hot engine exhaust from another machine or closer
than two feet from a wall. And of course, make sure
that engine exhaust is ventilated to an open, outside
area.
The GX-271 may be used outdoors. Do not set the
machine in puddles or otherwise submerge it in water.
Such practices pose safety hazards and cause
improper operation and corrosion of parts.
GX 271 Chopper
A-4 A-4
INSTALLATION
HIGH ALTITUDE OPERATION PRE-OPERATION ENGINE SERVICE
At high altitude, the standard carburetor air-fuel mix-
CAUTION
ture will be too rich. Performance will decrease, and
fuel consumption will increase. A very rich mixture will READ and UNDERSTAND the engine operating and
also foul the spark plug and cause hard starting. maintenance instructions supplied with this machine.
------------------------------------------------------------------------
High altitude performance can be improved by specific
modifications to the carburetor. If you always operate WARNING
your engine at altitudes above (6,000 feet) 1,800
meters, have a engine dealer perform this carburetor
� Keep hands way from the engine muffler or HOT
modification.
engine parts.
Even with carburetor modification, engine horsepower
� Stop the engine when fueling.
will decrease about 3.5% for each 1,000 feet (300
meter) increase in altitude. The effect of altitude on
� Do not smoke when fueling.
horsepower will be greater than this if no carburetor
modification is made. Do not operate a modified
� Do not overfill the fuel tank.
engine below 6,000 feet.
� Wipe up spilled fuel and allow the fumes to clear
LIFTING before starting the engine.
� Keep sparks and flame away from the fuel tank.
The GX-271 weighs approximately 469 lbs/212 kg. A
------------------------------------------------------------------------
lift bail is mounted to the machine frame and should
always be used when lifting the machine.
OIL
ADDITIONAL SAFETY PRECAUTIONS
The GX-271 is shipped with the engine filled with SAE
WARNING 10W-30 oil. CHECK THE OIL LEVEL BEFORE YOU
START THE ENGINE. If it is not full, add enough oil
FALLING EQUIPMENT can cause to fill it to the full mark.
injury.
q Do not lift this machine using lift For more information on oil viscosity and service con-
bale if it is equipped with a heavy ditions, see the MAINTENANCE section of this manu-
accessory such as trailer or gas al and the engine Operator’s Manual.
cylinder.
Lift only with equipment of adequate lifting
q
capacity.
Be sure machine is stable when lifting.
q
GX 271 Chopper
A-5 A-5
INSTALLATION
FUEL IMPORTANT: To prevent ELECTRICAL DAMAGE
WHEN:
Fill the fuel tank with clean, fresh regular grade lead- a) Installing new batteries.
free gasoline. Observe the fuel gauge while filling to b) Using a booster.
prevent overfilling.
Use correct polarity � Negative Ground.
The GX-271 has a 9 U.S. gallon (7.5 Imp. Gal., 34L) The GX-271 is shipped with the negative battery cable
fuel tank mounted below the generator. See the disconnected. Before you operate the machine, make
Engine Owners Manual for more details about the sure the Engine Switch is in the STOP position and
fuel. 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
BATTERY CONNECTIONS terminal. NOTE: This machine is furnished with a wet
charged battery; if unused for several months, the bat-
tery may require a booster charge. Be sure to use the
WARNING correct polarity when charging the battery.
GASES FROM BATTERY can explode. MUFFLER
q Keep sparks, flame and cigarettes
CAUTION
away from battery.
Shut off the machine and allow the muffler to cool
To prevent EXPLOSION when: before touching the muffler.
q INSTALLING A NEW BATTERY � disconnect ------------------------------------------------------------------------
negative cable from old battery first and connect
to new battery last. The GX-271 is shipped with a rain cap that is easily
attached to the top exhaust.
q CONNECTING A BATTERY CHARGER �
remove battery from welder by disconnecting nega-
SPARK ARRESTER
tive cable first, then positive cable and battery
clamp. When reinstalling, connect
Gasoline engine mufflers may emit sparks when the
negative cable last. Keep well ventilated.
engine is running. Some federal, state, or local laws
USING A BOOSTER � connect positive lead to
q require spark arresters in locations where unarrested
battery first then connect negative lead to negative sparks could present a fire hazard.
battery lead at engine foot.
Standard mufflers do not act as spark arresters.
BATTERY ACID can burn eyes and When local laws require it, a spark arrester must be
skin. installed on the machine and properly maintained. An
q Wear gloves and eye protection and optional spark arrester kit is available for your GX-
be careful when working near battery. 271. See the ACCESSORIES section of this manual
for more information.
q Follow instructions printed on battery.
------------------------------------------------------------------------
CAUTION
An incorrect spark arrester may lead to damage to the
engine or reduce performance.
------------------------------------------------------------------------
GX 271 Chopper
A-6 A-6
INSTALLATION
ELECTRICAL CONNECTIONS TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
See Figure B.1 in the OPERATION section of this
Cable Size for
manual for location of the 120 and 240 volt recepta-
Cable Length 300 Amps
cles, weld output terminals, circuit breakers and
100% Duty Cycle
ground stud.
1/0 AWG
0-50 Ft. (0-15 meters)
MACHINE GROUNDING
1/0 AWG
50-100 Ft. (15-39 meters)
Because the GX-271 creates its own power from its
2/0 AWG
100-150 Ft. (30-46 meters)
engine driven generator, and if the machine is not
connected to premises wiring (home, shop, etc.), you
150-200 Ft. (46-61 meters) 2/0 AWG
do not need to connect the machine frame to an earth
ground. However, for best protection against electri-
200-250 Ft. (61-76 meters) 3/0 AWG
cal shock, connect a heavy gauge wire (#8 AWG or
larger) from the ground stud located on the bottom of
Table A.1
the output panel (See Figure B.1) to a suitable earth
ground such as a metal pipe driven into the ground.
CABLE INSTALLATION
WARNING
Install the welding cables to your GX-271 as follows.
See Figure B.1 for location of parts.
Do not ground the machine to a pipe that carries
explosive or combustible material.
1. The engine must be OFF to install welding cables.
------------------------------------------------------------------------
2. Remove the flanged nuts from the output terminals.
When the GX-271 is mounted on a truck or a trailer,
the machine generator ground stud MUST be securely
3. Connect the electrode holder and work cables to
connected to the metal frame of the vehicle. See
the weld �+� and �-� output terminals. The terminals
Figure B.1. The ground stud is marked with the
are identified on the case front. The polarity require-
ground symbol.
ment for the welding process being used deter-
mines which terminal the electrode cable is
If the GX-271 is connected to premises wiring such as
attached to.
a home or shop, it must be properly connected to the
system earth ground.
4. Tighten the flanged nuts securely.
WELDING CABLE CONNECTIONS
5. Be certain that the metal piece you are welding (the
“work�) is properly connected to the work clamp and
CABLE SIZE AND LENGTH
cable.
Be sure to use welding cables that are large enough.
6. Check and tighten the connections periodically.
The correct size and length becomes especially
important when you are welding at a distance from the
CAUTION
welder.
� Loose connections will cause the output terminals to
Table A.1 lists recommended cable sizes and lengths
overheat. The terminals may eventually melt.
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
� Do not cross the welding cables at the output termi-
welder. Cable diameters are increased for long cable
nal connection. Keep the cables isolated and sepa-
lengths to reduce voltage drops.
rate from one another.
------------------------------------------------------------------------
Lincoln Electric offers a welding accessory kit with the
properly specified welding cables. See the
ACCESSORIES section of this manual for more infor-
mation.
GX 271 Chopper
A-7 A-7
INSTALLATION
AUXILIARY POWER RECEPTACLES, PREMISES WIRING
PLUGS, AND HAND-HELD EQUIPMENT
The GX-271 is suitable for temporary, standby, or
emergency power using the engine manufacturer’s
The control panel of the GX-271 features three auxil-
recommended maintenance schedule. With its three-
iary power receptacles: See Figure B.1.
wire grounded neutral generator, it can be permanent-
ly installed as a standby power unit for 240 volt, three
� Two 15 amp, 120 volt duplex (double outlet) recepta-
wire, single phase 33 ampere service.
cles.
WARNING
� One 50 amp 120/240 volt single outlet receptacle.
Only a licensed, certified, trained electrician should
Through these receptacles the machine can supply up
install the machine to a premises or residential elec-
to 8,000 rated continuous watts of single-phase, 60
trical system. Be certain that:
Hz AC power.
� The installation complies with the National Electrical
For further protection against electric shock, any elec-
Code and all other applicable electrical codes.
trical equipment connected to the 120V duplex recep-
tacles must use a three-blade, grounded type plug or
� The premises is isolated and no feedbacking into
an Underwriter’s Laboratories (UL) approved double
the utility system can occur. Certain state and local
insulation system with a two-blade plug. Lincoln
laws require the premises to be isolated before the
offers an accessory plug kit that has the right type of
generator is linked to the premises. Check your
plugs. See the ACCESSORIES section of this manual
state and local requirements.
for more information.
� A double pole, double throw transfer switch in con-
If you need ground fault protection for hand-held
junction with the properly rated double throw circuit
equipment refer to the K896-1 GFCI Receptacle kit in
breaker is connected between the generator power
the ACCESSORIES section of this manual for more
and the utility meter.
information.
------------------------------------------------------------------------
The following information and the connection diagram,
For recommended extension cord lengths and sizes
Figure A.1, can be used as a guide by the electrician
see Table A.1.
for most applications to premises wiring.
1. Install a double pole, double throw switch between
CIRCUIT BREAKERS
the power company meter and the premises dis-
connect. The switch rating must be the same as
or greater than the premises disconnect and
The GX-271 machines are equipped with 50 amp cir-
service overcurrent protection.
cuit breakers on the 120/240 V receptacle and 15 amp
circuit breakers on the 120 receptacles for overload
2. Take the necessary steps to assure that the load is
protection. Under high heat a breaker may tend to trip
limited to the capacity of the GX-271 by installing a
at lower loads than it would normally.
35 amp 240 volt double pole circuit breaker.
Maximum rated load for the 240 volt auxiliary is 33
CAUTION amperes. Loading above 33 amperes will reduce
output voltage below the allowable -10% of rated
Never bypass the circuit breakers. Without overload
voltage. This may damage appliances or other
protection, the GX-271 could overheat and/or cause
motor-driven equipment.
damage to the equipment being used.
------------------------------------------------------------------------
3. Install a 50 amp 120/240 volt plug (NEMA type 14-
50) to a double pole circuit breaker using No. 8 or
larger, 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
A-8 A-8
INSTALLATION
Table A.1
Extension Cord Length Recommendations
Current Voltage Load Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)
(Amps) (Volts) (Watts) 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
15 120 1800 30 (9) 40 (12) 75 (23) 125 (38) 175 (53) 300 (91)
15 240 3600 60 (18) 75 (23) 150 (46) 225 (69) 350 (107) 600 (183)
20 240 4800 60 (18) 100 (30) 175 (53) 275 (84) 450 (137)
25 240 600 90 (27) 150 (46) 225 (69) 250 (76)
30 240 7200 75 (23) 120 (37) 175 (53) 300 (91)
35 240 8400 100 (30) 150 (46) 250 (76)
Figure A.1
CONNECTION OF GX-271 TO PREMISES WIRING
230 VOLT
GROUNDED CONDUCTOR
POWER
230 Volt 115 VOLT
60 Hz.
COMPANY
3-Wire
115 VOLT
Service
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
GROUND OVERCURRENT
35 AMP
PROTECTION
230 VOLT
DOUBLE
POLE
50 AMP, 115/230 CIRCUIT
VOLT PLUG 230 VOLT BREAKER
NEMA TYPE 14-50
GND
N
50 AMP, 115/230 VOLT
NOTE: No. 8 COPPER CONDUCTOR CABLE SEE
RECEPTACLE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
WARNING
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.
GX 271 Chopper
B-1 B-1
OPERATION
OPERATING INSTRUCTIONS GENERAL DESCRIPTION
Read and understand this entire section before oper- The GX-271 is an engine driven, multi-process DC arc
ating your GX-271. welder and AC power generator for commercial and
residential applications. As a generator it can supply
SAFETY INSTRUCTIONS 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. As a welder it provides up to
WARNING
300 amps of DC current for DC stick welding and DC
semiautomatic wire feed welding. The GX-271 can
Do not attempt to use this equipment until you have
also perform DC TIG welding.
thoroughly read all operating and maintenance man-
uals supplied with your machine. They include impor-
DESIGN FEATURES
tant safety precautions, detailed engine starting,
operating and maintenance instructions and parts
FOR WELDING:
lists.
ELECTRIC SHOCK can kill. � DC constant current output for stick and TIG weld-
ing - Two continuous CC output settings of 20 to
•Do not touch electrically live parts such 300 amps, one for general purpose stick and tig
as output terminals or internal wiring. welding and one with a fixed controlled slope for out
of position and pipe welding. The STICK-TIG mode
•Insulate yourself from the work and includes an arc force control.
ground.
� DC constant voltage output for MIG and Flux Cored
•Always wear dry insulating gloves. wire welding - One continuous CV welding range of
------------------------------------------------------------------------ 11 to 32 volts. Excellent MIG welding with CO2 and
blended gas. A pinch control allows the arc to be
ENGINE EXHAUST can kill. fine tuned from “soft � to “crisp�. The recommended
wire feeder is the K446 LN-25 with the K624-1 42
•Use in open, well ventilated areas or Volt Remote Output Control Module or the K449 LN-
vent exhaust outside 25 with an internal contactor.
•Do not stack anything near the engine. � 100% duty cycle at 275 amps output.
------------------------------------------------------------------------
� Remote control capability. Nine pin and fourteen
MOVING PARTS can injure. pin connectors for easy connection of Lincoln wire
feeders and remote control accessories. The 14 pin
•Do not operate with doors open or connector includes power for 42 VAC wire feeders.
guards off.
� Internal “Solid State� contactor allows for the selec-
•Stop engine before servicing. tion of “hot� or “cold� output terminals.
•Keep away from moving parts FOR AUXILIARY POWER
------------------------------------------------------------------------
Only qualified personnel should operate this equip- � 8,000 watts of 240 V AC, 60Hz auxiliary power.
ment.
� Power for tools, 120/240 lights, electric pumps and
for standby emergency power.
� 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
B-2 B-2
OPERATION
� One 50 amp 120/240 V AC, single phase power, LIMITATIONS
dual voltage receptacle with two 35 amp circuit
breakers. Supplies up to 33 amps of 240 V AC and � The GX-271 is not recommended for any process-
up to 66 amps of 120 V AC single phase auxiliary es besides those that are normally performed using
power per side to separate branch circuits (not in stick welding (SMAW), TIG welding (GTAW), MIG
parallel). Allows easy connection to premises wiring. (GMAW) welding and Innershield® (FCAW) welding.
� Welding and AC auxiliary power at the same time � The GX-271 is not recommended for pipe thawing.
(within machine total capacity).
� During welding, generator power is limited and out-
OTHER FEATURES put voltages can drop. Therefore, DO NOT OPER-
ATE ANY SENSITIVE ELECTRICAL EQUIPMENT
� Overhead valve, V-twin, 20 HP gasoline engine. WHILE YOU ARE WELDING. See Table B.4 for
Designed for long life, easy maintenance and excel- permissible simultaneous welding and auxiliary
lent fuel economy. power loads.
� Engine protection system shuts the engine down
with low oil pressure.
� Large maintenance-free battery. Group 58 with 435
ADDITIONAL SAFETY PRECAUTIONS
cold cranking amps.
Always operate the welder with the roof and case
� Battery charging ammeter.
sides in place as this provides maximum protection
from moving parts and assures proper cooling air flow.
� Engine hour meter.
Read and understand all Safety Precautions before
� Extended range 9 U.S. gallon (7.5 Imp. Gal., 34
operating this machine. Always follow these and any
liters) fuel tank.
other safety procedures included in this manual and in
the Engine Owner’s Manual.
� Automatic idler reduces engine speed when not
welding or drawing auxiliary power. This feature
Only qualified personnel should install, use, or service
reduces fuel consumption and extends engine life.
this equipment.
� Compact size fits crosswise in compact size pick-up
truck.
� Copper alternator windings for dependability 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.
GX 271 Chopper
B-3 B-3
OPERATION
CONTROLS AND SETTINGS TROLLED� is used to control the operation of the
solid state output contactor. With the switch in the
“WELDING TERMINALS ALWAYS ON� position, the
All generator/welder controls are located on the
contactor is closed at low and high idle.
Output Control Panel of the machine case front. Idler
control, and start/stop controls are also on the case 6. BATTERY CHARGER CIRCUIT BREAKER: Opens
front. See Figure B.1 and the explanations that follow. the engine battery circuit if a short develops. Engine
will not crank if this circuit breaker is open.
15
4 3
5
7. WIRE FEEDER POWER CIRCUIT BREAKER: Opens
17
the wire feeder circuit and disables the feeder if a fault
is detected in the circuit.
1
18
8. 15 AMP, 120 VOLT DUPLEX RECEPTACLES:
Connection point for supplying 120 volt power to oper-
2
ate one or more electrical devices.
16
9. 50 AMP, 120/240 VOLT RECEPTACLE: Connection
6
8
point for supplying 240 volt power to operate one
electrical device.
19
10. WELD OUTPUT TERMINALS WITH FLANGE NUT:
20
Provides the connection point for the electrode and
work cables.
7
9
11. GROUND STUD: Provides a connection point for
11
connecting the machine case to earth ground for the
safest grounding procedure.
10
12. 6 PIN AMPHENOL: For attaching optional remote
control equipment to the GX-271.
13 14 12
13. 14 PIN AMPHENOL: For attaching wire feeder con-
trol cables to the GX-271 (Includes contactor closure
FIGURE B.1
circuit, remote control circuit, wire feeder 115/42 volt
OUTPUT PANEL CONTROLS power source).
14. WIRE FEEDER VOLTMETER POLARITY SWITCH:
WELDER/GENERATOR CONTROLS
matches polarity of wire feeder voltmeter to polarity
of electrode.
See Figure B.1 for the location of the following features:
15. ENGINE RUN-STOP SWITCH: Energizes engine cir-
1. OUTPUT CONTROL: Allows full range adjustment of
cuit.
welding current or voltage.
16. ENGINE START PUSHBUTTON SWITCH:
2. ARC CONTROL: The “ARC CONTROL� potentiome-
Energizes starter solenoid contactor and fuel sole-
ter is active in two modes: “STICK/TIG� and “WIRE
noid.
WELDING� with different purposes in each mode.
17. ENGINE CHOKE
3. MODE SWITCH: Selects three possible modes of
welding operation, 1.) CC Stick/Tig welding, 2.) Pipe
18. AUTO IDLER SWITCH: In the “AUTO� mode, the
welding, and 3.) CV Wire Welding.
engine goes to low idle speed 12 seconds after a
welding or auxiliary power load is removed. Engine
4. LOCAL/REMOTE CONTROL SWITCH: Allows the
goes to high speed when the load is re-applied.
operator to control welding output at the welding con-
trol panel or at a wire feeder, TIG amptrol, or a K857
19. BATTERY CHARGER AMMETER
remote control.
20. ENGINE HOUR METER
5. WELDING TERMINALS SWITCH: The toggle switch
labeled “WELDING TERMINALS ALWAYS ON� and
“WELDING TERMINALS REMOTELY CON-
GX 271 Chopper
B-4 B-4
OPERATION
ENGINE OPERATION STARTING THE ENGINE
CAUTION
WARNING
DO NOT RUN THE ENGINE AT EXCESSIVE Be sure all Pre-Operation Maintenance has been per-
SPEEDS. The maximum allowable high idle speed formed. See the INSTALLATION section.
for the GX-271 is 3750 RPM, no load. Do NOT adjust
the governor screw on the engine. Severe personal Remove all loads connected to the AC power recepta-
injury and damage to the machine can result if it is cles and the welder before starting the diesel engine.
operated at speeds above the maximum rated speed. ------------------------------------------------------------------------
------------------------------------------------------------------------ To start the engine, set the “IDLER� switch in the
Read and understand all safety instructions included “AUTO� ( / ) position. Pull the choke
in the Engine Owner’s manual that is shipped with control out.
your GX-271.
Place the “Engine� Switch in the “RUN� Position.
BEFORE STARTING THE ENGINE Push the “Start� button and crank the engine until it
starts. Release the button as soon as the engine
starts. After the engine has started, slowly return the
Check the engine oil level:
choke control to the full “in� position (choke open). In
the “AUTO� position, the engine will run at high idle for
10-14 seconds and then go to low idle. Allow the
1. Be sure the machine is on a level surface.
engine to warm up by letting it run at low idle for a few
minutes.
2. Remove the engine oil dipstick and wipe it with a
clean cloth. Reinsert the dipstick and check the
At cold temperatures, it may be necessary to start the
level on the dipstick.
engine in “HIGH� idle and allow it to run for several
minutes before using “AUTO� idle.
3. Add oil (if necessary) to bring the level up to the full
mark. Do not overfill.
When starting a hot engine, it is not necessary to pull
the choke out but the engine will start faster if it is
4. See Engine Owner’s Manual for specific oil recom-
pulled out. Push it in immediately after the engine
mendations.
starts.
Check and fill the engine fuel tank:
CAUTION
WARNING Operating the starter motor for more than 5 seconds
can damage the motor. If the engine fails to start,
GASOLINE can cause fire or release the switch and wait 10 seconds before operat-
ing the starter again. Do not push the “Start� button
explosion.
while the engine is running because this can damage
� Stop engine when fueling.
the ring gear and/or starter motor.
� Do not smoke when fueling.
------------------------------------------------------------------------
� Do not overfill tank.
NOTE: When starting a GX-271 for the first time, after
� Avoid contact with skin or breathing of vapor.
an extended period of not operating, it will take longer
� Keep sparks and flame away from tank.
than normal because the fuel pump has to fill the fuel
------------------------------------------------------------------------
line and carburetor.
1. Remove the fuel tank cap.
2. Fill the tank approximately 4 inches (100 mm) from
the top of the filler neck to allow for fuel expansion
(observe the fuel gauge.) DO NOT FILL THE
TANK TO THE POINT OF OVERFLOW.
3. Replace the fuel tank cap and tighten securely.
4. See Engine Owner’s Manual for fuel recommenda-
tions.
GX 271 Chopper
B-5 B-5
OPERATION
STOPPING THE ENGINE Stop the engine by placing the “Engine� switch in the
“STOP� position.
Remove all welding and auxiliary power loads and
A fuel shut off valve is not required on the GX-271
allow the engine to run at low idle speed for a few
because the fuel tank is mounted below the engine.
minutes to cool the engine.
------------------------------------------------------------------------
TABLE B.1
TYPICAL GX-271 FUEL CONSUMPTION
K1624-1 GX-271 Honda Engine K1624-2 GX-271 Kohler Engine
.35 US gallons/hour .40 US gallons/hour
Low Idle - No Load
(.29 Imp. gal./hr., 1.31 liters/hour) (.34 Imp. gal./hr., 1.53 liters/hour)
2400 RPM
.76 US gallons/hour .87 US gallons/hour
High Idle - No Load
(.63 Imp. gal./hr., 2.86 liters/hour) (.73 Imp. gal./hr., 3.30 liters/hour)
3700 RPM
1.27 US gallons/hour
1.21 US gallons/hour
210 Amps @ 25 Volts
(1.01 Imp. gal./hr., 4.57 liters/hour) (1.06 Imp. gal./hr., 4.82 liters/hour)
DC Weld Output
1.40 US gallons/hour 1.37 US gallons/hour
250 Amps @ 25 Volts
(1.17 Imp. gal./hr., 5.30 liters/hour) (1.14 Imp. gal./hr., 5.17 liters/hour)
DC Weld Output
1.53 US gallons/hour 1.44 US gallons/hour
275 Amps @ 25 Volts
(1.27 Imp. gal./hr., 5.79 liters/hour) (1.20 Imp. gal./hr., 5.45 liters/hour)
DC Weld Output
1.67 US gallons/hour 1.53 US gallons/hour
275 Amps @ 28 Volts
(1.39 Imp. gal./hr., 6.32 liters/hour) (1.28 Imp. gal./hr., 5.80 liters/hour)
DC Weld Output
1.47 US gallons/hour
1.56 US gallons/hour
8,000 kVA
(1.22 Imp. gal./hr., 5.55 liters/hour)
(1.30 Imp. gal./hr., 5.89 liters/hour)
Auxiliary Power
GX 271 Chopper
B-6 B-6
OPERATION
WELDING OPERATION purposes in each mode. It is not active in the “PIPE�
mode.
WARNING
“STICK/TIG� mode: In this mode, the “ARC CON-
Do not attempt to use this equipment until you
TROL� knob sets the short circuit (arc force) current
have thoroughly read the engine manufacturer’s
during stick welding. Increasing the number from 1 to
manual supplied with your welder. It includes
important safety precautions, detailed engine 10 increases the short circuit current. This prevents
starting, operating and maintenance instructions, sticking of the electrode to the plate at low welding
and parts lists. current settings. This also increases spatter. It is rec-
------------------------------------------------------------------------
ommended that the control is set to the minimum
ELECTRIC SHOCK can kill.
number without electrode sticking.
� Do not touch electrically live parts or
electrode with skin or wet clothing.
“WIRE WELDING� mode: In this mode, increasing
� Insulate yourself from work and
ground the number from 1 to 10 changes the arc from soft
� Always wear dry insulating gloves. and washed in to crisp and narrow. It acts as an
------------------------------------------------------------------------ inductance control. The proper setting depends on
FUMES AND GASES can be dangerous.
the application and operator preference. In general,
� Keep your head out of fumes.
Mig welding performs best in the “SOFT� range and
� Use ventilation or exhaust to remove
Innershield in the “CRISP� range.
fumes from breathing zone.
------------------------------------------------------------------------
MOVING PARTS can injure. “LOCAL� / “REMOTE� Switch
� Do not operate with doors open or
guards off.
The toggle switch on the control panel labeled
� Stop engine before servicing.
“LOCAL/REMOTE� gives the operator the option of
� Keep away from moving parts.
controlling the output at the welder control panel or at
------------------------------------------------------------------------
WELDING SPARKS can cause fire or a wire feeder, TIG amptrol, or a K857 Remote Control
explosion. that is connected to either the 6 pin or 14 pin amphe-
� Keep flammable material away. nol connector.
For remote control the toggle switch is set in the
------------------------------------------------------------------------
“REMOTE� position.
ARC RAYS can burn.
� Wear eye, ear and body protection.
For control at the welder control panel, the toggle
switch is set in the “LOCAL� position.
------------------------------------------------------------------------
“WELDING TERMINALS� Switch
See additional warning information
throughout this operator’s manual.
The toggle switch on the control panel labeled
----------------------------------------------------------- “WELDING TERMINALS ALWAYS ON� and “WELD-
ING TERMINALS REMOTELY CONTROLLED�, is
WELDER CONTROLS - FUNCTION used to control the operation of the solid state contac-
AND OPERATION tor which allows for the selection of “Hot� or “Cold�
welding terminals.
See Figure B.1 for control locations.
With the switch in the “WELDING TERMINALS
Output “CONTROL� ALWAYS ON� position, the contactor is closed and
the welding terminals are always “Hot.�
Continuous CC welding current control from 20 amps
With the switch in the “WELDING TERMINALS
to 300 amps in the STICK/TIG and PIPE modes.
REMOTELY CONTROLLED� position, the contactor
Continuous CV welding arc voltage control from 11
operation is controlled by an Amptrol, Arc Start Switch
volts to 32 volts in the WIRE FEED mode.
or some other type of triggering device through the
use of a control cable connected to the 6 pin or 14 pin
“ARC CONTROL�
amphenol.
The “ARC CONTROL� is active in two modes:
“STICK/TIG� and “WIRE WELDING� and has different
GX 271 Chopper
B-7 B-7
OPERATION
When the triggering device is pressed the contactor is TIG WELDING
closed and the welding terminals are “Hot.�
The GX-271 can be used in a wide variety of DC
When the triggering device is released the contactor is Tungsten Inert Gas (TIG) welding applications. When
opened and the welding terminals are “Cold.� used with the K930-1 or -2 TIG module, ratings are
limited to 275A at a 60% duty cycle and 250A at a
“MODE� Switch - Set to the desired process: 80% duty cycle.
STICK/TIG, PIPE, or WIRE FEED.
GX-271 settings when using the K930-1 or -2 Tig
“WIRE FEEDER VOLTMETER� Switch - If Module:
using a wire feeder that has a voltmeter, set this
switch to match the polarity of the electrode. a. Set the “MODE� Switch to the STICK/TIG setting.
STICK WELDING b. Set the “IDLER� Switch to the “AUTO� position.
c. Set the “LOCAL/REMOTE� switch to the
The GX-271 can be used with a broad range of DC
“REMOTE� position.
stick electrodes. The output “CONTROL� adjusts the
full range of 20 to 300 amps. Set the “ARC CON-
d. Set the â€WELDING TERMINALSâ€? switch to the
TROL� to low setting to minimize spatter. If sticking is
“WELDING TERMINALS REMOTELY CON-
a problem, turn this control to a higher setting (clock-
TROLLED� position. This will keep the “Solid
wise). This will increase the short circuit current (arc
State� contactor open and provide a “cold� elec-
force).
trode until the triggering device (Amptrol or Arc
Start Switch) is pressed.
PIPE WELDING
e. Set the “ARC CONTROL� to minimum.
The “PIPE WELDING� mode is recommended for
manual vertical-down techniques on pipe joints using See Table B.2 for Typical Current Ranges for
EXX10 type electrodes. This slope controlled setting Tungsten Electrodes.
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.
GX 271 Chopper
B-8 B-8
OPERATION
(1) (2)
Table B.2 TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES
DCEN (-) DCEP (+) Approximate Argon Gas Flow Rate
C.F.H. (l/min.)
Tungsten
Electrode TIG TORCH
1%, 2% 1%, 2%
Diameter Nozzle
Thoriated Thoriated Stainless Steel
in. (mm) Size (4), (5)
Tungsten Tungsten
0 .010 (.25) 2-15 (3) 3-8 (2-4) #4, #5, #6
0.020 (.50) 5-20 (3) 5-10 (3-5)
0.040 (1.0) 15-80 (3) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 11-15 (5-7) #6, #7, #8
1/8 (3.2) 250-400 25-40 11-15 (5-7)
5/32 (4.0) 400-500 40-55 13-17 (6-8) #8, #10
3/16 (4.8) 500-750 55-80 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 23-27 (11-13)
(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 applications.
(3) DCEP is not commonly used in these sizes.
(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 Some recommended solid wires for MIG welding are:
.035 (0.9 mm) and .045 (1.1 mm) L-50, L-56, and
Blue Max MIG 308 LS.
Connect a wire feeder to the GX-271 and set welder
controls according to the instructions on the appropri-
For any electrodes, including the above recommenda-
ate wire feeder connection diagram.
tions, the procedures should be kept within the rating
of the machine. For additional electrode information,
The GX-271 in the â€WIRE FEEDâ€? position, permits it
see Lincoln publications N-675, GS-100 and GS-210.
to be used with a broad range of flux cored wire
(Innershield and Outershield) electrodes and solid
wires for MIG welding (gas metal arc welding).
Welding can be finely tuned using the “ARC CON-
TROL�.
Some recommended Innershield electrodes are: NR-
311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H.
Recommended Outershield electrodes are: 0S-70,
0S-71M.
GX 271 Chopper
B-9 B-9
OPERATION
TABLE B.3
SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS
CONTROL MODE IDLER OUTPUT WELDING ELECTRODE
TO START WELDING
PROCESS CABLE SWITCH SWITCH CONTROL TERMINALS WHEN NOT
USED SWITCH SWITCH WELDING
Touch electrode to work.
NO AUTO
STICK/TIG Welding starts immediately
LOCAL WELDING HOT
STICK - CC
or PIPE and engine goes to high idle.
ON
Press Amptrol. GX-271
TIG - CC
YES AUTO
STICK/TIG contactor closes. Welding
REMOTE CONTACTOR COLD
K930-1 TIG MODULE /
starts immediately and engine
CONTROLLED
K936-1 CONTROL CABLE
goes to high idle.
(With Amptrol)
Press gun trigger, GX-271
WIRE FEED - CV,
YES AUTO contactor closes. Welding
WIRE FEED REMOTE CONTACTOR COLD
LN-25 WITH 42V
starts immediately and engine
CONTROLLED
REMOTE CON-
goes to high idle.
TROL KIT
Press gun trigger, LN-25
WIRE FEED - CV,
NO AUTO contactor closes. Welding
WIRE FEED LOCAL WELDING COLD
LN-25 WITH
starts immediately and engine
ON
INTERNAL
goes to high idle.
CONTACTOR
Press gun trigger, GX-271
WIRE FEED - CV,
YES contactor closes. Welding
AUTO
WIRE FEED REMOTE CONTACTOR COLD
LN-742
starts immediately and engine
CONTROLLED
goes to high idle.
Press gun trigger, GX-271
COLD
WIRE FEED - CV,
YES contactor closes. Welding
HIGH
WIRE FEED REMOTE CONTACTOR
LN-7
starts immediately.
CONTROLLED
GX 271 Chopper
B-10 B-10
OPERATION
AUXILIARY POWER 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.
Start the engine and set the "IDLER" control switch to
the desired operating mode. Full power is available
The current rating of any plug used with the system
regardless of the welding output settings, if no welding
must be at least equal to the current capacity of the
current is being drawn.
associated receptacle.
The auxiliary power of the GX-271 consists of two 15
NOTE: The 240V receptacle has two circuits, each of
Amp-120VAC (5-15R) duplex receptacles and one 50
which measure 120 V to neutral but are of opposite
Amp 120/240 VAC (14-50R) receptacle.
polarities and cannot be paralleled.
The auxiliary power capacity is 8,000 watts of 60 Hz,
SIMULTANEOUS WELDING AND POWER
single phase power. The auxiliary power capacity rat-
LOADS
ing in watts is equivalent to volt-amperes at unity
power factor. The max permissible current of the 240
VAC output is 33 Amps. The 240 VAC output can be It must be noted that the above auxiliary power ratings
split to provide two separate 120 VAC outputs with a are with no welding load. Simultaneous welding and
max permissible current of 33 Amps per output to two power loads are specified in the following table. The
separate 120 VAC branch circuits. Output voltage is permissible currents shown assume that current is
within Ã… 10% at all loads up to rated capacity. being drawn from either the 120 VAC or 240 VAC
supply (not both at the same time).
TABLE B.4
GX-271 SIMULTANEOUS WELDING AND POWER LOADS
Welding Arc Available Auxiliary Permissible Permissible
Output Voltage Power - Watts Auxiliary Current Auxiliary Current
Amps (Unity Power in Amperes @ in Amperes @
Factor) 120V 240V
0 33
0 8000 66
25 31
50 7400 62
25 26
100 6300 52
25 20
150 4800 40
25 14
200 3400 28
25 7.5
250 1800 15
25 4
275 1000 8
28 0
275 0 0
GX 271 Chopper
C-1 C-1
ACCESSORIES
GENERAL OPTIONS /
- GC500 work clamp.
ACCESSORIES
- Cooltong® 300 insulated electrode holder.
The following options/accessories are available for
your GX-271: K802-R Power Plug Kit - Provides four 15 amp, 120
volt plugs and one 50 amp, dual voltage 120/240V, full
K886-1 Canvas Cover - To protect the GX-271 when kVA plug.
it is not being operated. Made from attractive red can-
vas material that is flame retardant, mildew resistant K857 Remote Control - Includes a control box with
and water repellent. 25 feet (7.5 meters) of 4-conductor cable. Allows out-
put voltage to be controlled remotely.
K889-2 Two Wheel Undercarriage - For moving by
hand. Two 4.00" x 8" pneumatic tires. Overall width K857-1 Remote Control - Includes a control box with
29" (.74m). 100 feet (30.5 meters) of 4-conductor cable. Allows
output voltage to be controlled remotely.
K893-1 Caster for K889-2 Undercarriage - Mounts
to the front of the Two-Wheel undercarriage to allow K896-1 GFCI Receptacle Kit - Includes two UL
easy movement on smooth surfaces. Includes a 6" approved 120 volt ground fault circuit interrupter
diameter hard rubber wheel with a convenient toe-on, receptacles (duplex type) with covers and installation
toe-off locking brake. instructions. Each receptacle is rated 15 amps, but
the maximum total current from each GFCI duplex is
K933-1 Four Wheel Undercarriage - Allows move- limited to 20 amps. The GFCI receptacles replace the
ment of the GX-271 by hand without lifting on smooth two factory installed 120 volt duplex receptacles.
surfaces. Includes two rugged, hard molded wheels
and two durable pneumatic tires. The spring loaded
handle provides convenient, comfortable steering.
TIG WELDING OPTIONS /
The K934-1 Bracket is available for mounting a gas
ACCESSORIES
cylinder on the undercarriage.
K934-1 Bracket for Mounting a Gas Cylinder to a
K933-1 Undercarriage - Easily mounts on the back of K930-1 TIG Module - The TIG Module is an accesso-
the K933-1 Four Wheel Undercarriage to carry a weld- ry that provides high frequency and shielding gas con-
ing gas cylinder. trol for AC and DC GTAW (TIG) welding applications.
It provides contactor control of constant current weld-
K957-1 Two-Wheeled Trailer - For in-plant or yard ing power sources having an internal contactor. The
towing of the GX-271. Suitable for road towing with TIG Module is supplied without accessories, Arc Start
optional Fender and Light Kit. The following options switches, Amptrols, cables, torches and mounting
are available for the K957-1 Two-Wheeled Trailer: brackets must be purchased separately.
K958-1 - Ball Coupler 2" K939-1 Docking Kit - For mounting the K930-1 TIG
K958-2 - Lunette Eye Coupler Module on top of the GX-271.
K959-2 - Fender & Light
K965-1 - Cable Rack K936-1 Control Cable - Control cable for connecting
the K930-1 TIG Module to a GX-271.
K894-1 Spark Arrester Kit - A field installed kit for
the GX-271 engine muffler exhaust pipe. Includes a K814 Arc Start Switch - A remote start switch used
heavy-gauge steel, approved spark arrester, mounting in conjunction with the K930-1 TIG Module to energize
clamp and adapter. the GX-271 output terminals via the TIG module.
K703 Accessory Kit - Includes the following: K963 Hand Amptrol - Remote output control and
contactor control.
- Thirty-five feet (10.5 meters) of # 1/0 AWG elec-
trode cable. K870 Foot Amptrol - Remote output control and con-
tactor control.
- Thirty feet (9.1 meters) of # 1/0 AWG work cable.
- Headshield with No. 12 filter.
GX 271 Chopper
C-2 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, 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 interface
between the GX-271 and the K487-25 Magnum Spool
Gun.
GX 271 Chopper
C-3
C-3 ACCESSORIES - CONNECTION DIAGRAMS
GX-271 / LN-25 ACROSS THE ARC CONNECTION DIAGRAM
WITH OPTIONAL K857 REMOTE CONTROL
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
14 PIN OPTIONAL K857
6 PIN
REMOTE CONTROL
AMPHENOL AMPHENOL
LN-25
WIRE FEEDER
WORK CLIP LEAD
ELECTRODE
TO WORK
TO WORK
TO WORK
ELECTRODE CABLE
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE
AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.
N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER
VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE.
N.C. PLACE THE MODE SWITCH IN THE "WIRE WELDING-CV" POSITION.
N.D. IF REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL REMOTE SWITCH IN "REMOTE" POSITION.
N.E. PLACE THE WELDING TERMINALS SWITCH IN THE "ALWAYS ON" POSITION.
N.F. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED.
A
S24095-1
GX-271 / LN-25 ACROSS THE ARC CONNECTION DIAGRAM
WITH OPTIONAL K444-1 REMOTE CONTROL
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
14 PIN 6 PIN
OPTIONAL K444-1
AMPHENOL AMPHENOL
REMOTE CONTROL
LN-25
WIRE FEEDER
WORK CLIP LEAD
ELECTRODE
TO WORK
TO WORK
TO WORK
ELECTRODE CABLE
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE
AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.
N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER
VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE.
N.C. PLACE THE MODE SWITCH IN THE "WIRE WELDING-CV" POSITION.
N.D. IF REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL REMOTE SWITCH IN "REMOTE" POSITION.
N.E. PLACE THE WELDING TERMINALS SWITCH IN THE "ALWAYS ON" POSITION.
N.F. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED.
A
S24095-2
GX 271 Chopper
C-4 C-4
ACCESSORIES - CONNECTION DIAGRAMS
GX-271 / LN-25 WITH K624-1 42 VOLT REMOTE OUTPUT
CONTROL MODULE CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
TO LN-25 INPUT
CABLE PLUG
14 PIN
AMPHENOL
K626-XX INPUT CABLE ASSEMBLY
ELECTRODE
TO WORK
ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK
CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. PLACE THE MODE SWITCH IN THE "WIRE WELDING-CV" POSITION. PLACE WELDER TERMINALS SWITCH TO "REMOTELY
CONTROLLED" POSITION.
N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO
MATCH THE POLARITY OF THE ELECTRODE CABLE.
N.C. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.D. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITIION.
N.E. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED.
A
S24095-3
GX-271 / LN-7 CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
TO LN-7 INPUT
CABLE PLUG
14 PIN
AMPHENOL
K584 CONTROL CABLE
OPTIONAL K857
REMOTE CONTROL
6 PIN
ELECTRODE
TO WORK
AMPHENOL
ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK
CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH
TO MATCH POLARITY OF THE ELECTRODE CABLE.
N.C. PLACE THE MODE SWITCH IN THE " WIRE WELDING-CV" POSITION.
N.D. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE LOCAL REMOTE SWITCH IN "REMOTE" POSITION.
N.E. PLACE IDLER SWITCH IN "HIGH" POSITION.
A
S24095-4
GX 271 Chopper
C-5 C-5
ACCESSORIES - CONNECTION DIAGRAMS
GX-271 / LN-742 CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
TO LN-742 INPUT
CABLE PLUG
14 PIN
AMPHENOL
K592 CONTROL CABLE
ELECTRODE
TO WORK
ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK
CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO
MATCH THE POLARITY OF THE ELECTRODE CABLE.
N.C. PLACE THE MODE SWITCH IN THE " WIRE WELDING-CV" POSITION.
N.D. PLACE WELDER TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.
N.E. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITIION.
N.F. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED.
A
S24095-5
GX-271 / LN-8 CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
TO LN-8 INPUT
CABLE PLUG
K595 CONTROL CABLE
14 PIN
AMPHENOL
-
+
TO WORK
ELECTRODE CABLE TO WIRE FEED UNIT
CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO
MATCH THE POLARITY OF THE ELECTRODE CABLE.
N.C. PLACE THE MODE SWITCH IN THE "WIRE WELDING-CV" POSITION. PLACE LOCAL / REMOTE SWITCH IN "REMOTE" POSITION.
N.D. PLACE IDLER SWITCH IN "HIGH" POSITION.
A
S24095-6
GX 271 Chopper
C-6 C-6
ACCESSORIES - CONNECTION DIAGRAMS
GX-271 TO K867 CONTROL CABLE ADAPTER CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
14 PIN
N.C.
AMPHENOL
81
82 NOT USED ON RANGER POWER SOURCES
SPARE
2
K867 UNIVERSAL CONNECT TOGETHER FOR
N.D.
4
ADAPTER PLUG
WELDING OUTPUT
41
42 VAC
42
N.E.
31
115 VAC
32
ELECTRODE
TO WORK
GND POWER SOURCE FRAME CONNECTION
21 WIRE FEEDER VOLTMETER CONNECTION
ELECTRODE CABLE CONNECTS TO (WORK TERMINAL) OF POWER SOURCE
77
TO WIRE FEED UNIT 10K
76 REMOTE OUTPUT CONTROL
TO WORK MIN.
75
CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. WELDING CABLES MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER
SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE.
N.C. PLACE THE MODE SWITCH IN THE "WIRE WELDING-CV" POSITION.
2 TO
N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY. TO
WIRE
N.E. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION
K867
RELAY TO CLOSE LEADS 2 & 4. FEEDER
4
N.F. REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY CURRENT DRAW.
A
S24095-7
GX-271 / K691-10 / K488 / K487 SPOOL GUN CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
115V RECEPTACLE
K488 SG
CONTROL MODULE
RANGER
K487-25
SPOOL GUN
14 PIN WIRE FEEDER
6 PIN REMOTE K691-10
RECEPTACLE
RECEPTACLE INPUT CABLE
ELECTRODE
TO WORK
ELECTRODE CABLE
TO CONTROL MODULE
TO WORK
BE SURE THAT CONTROL MODULE MODE SLIDE SWITCH IS IN THE "LINCOLN" (CONTACT CLOSURE) POSITION BEFORE ATTEMPTING TO OPERATE
CAUTION :
CONTROL MODULE. INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND/OR POWER SOURCE.
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. WELDING CABLES MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY.
N.C. PLACE THE MODE SWITCH IN THE "WIRE WELDING-CV" POSITION. PLACE WELDING TERMINALS SWITCH TO "REMOTELY
CONTROLLED" POSITION.
N.D. IF OPTIONAL K857 REMOTE OUTPUT CONTROL IS CONNECTED TO 6 PIN RECEPTACLE,PLACE OUTPUT CONTROL SWITCH IN
"OUTPUT CONTROL REMOTE" POSITION.
N.E. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.
A
S24095-8
GX 271 Chopper
C-7 C-7
ACCESSORIES - CONNECTION DIAGRAMS
GX-271 / K930 TIG MODULE / CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
REGULATOR
FLOWMETER
ARGON GAS
TO GAS
CYLINDER
INPUT
GX271
FITTING
K870 FOOT AMPTROL
K936-1
CONTROL CABLE
-OR-
TO WORK K963-1 HAND AMPTROL
14 PIN -OR-
AMPHENOL
K814 ARC START SWITCH
ELECTRODE
CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.
N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY.
N.C. PLACE THE MODE SWITCH IN THE "STICK/WELD" POSITION.
N.D. PLACE WELDER TERMINALS SWITCH TO " REMOTELY CONTROLLED" POSITION.
N.E. PLACE OUTPUT CONTROL SWITCH IN "REMOTE CONTROL" POSITION.
N.F. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED.
A
S24095-9
GX 271 Chopper
D-1 D-1
MAINTENANCE
SAFETY PRECAUTIONS ROUTINE AND PERIODIC ENGINE
MAINTENANCE
WARNING
Have qualified personnel do the maintenance At the end of each day’s use, refill the fuel tank to min-
work. Turn the engine off before working inside imize moisture condensation in the tank. Running out
the machine. In some cases, it may be of fuel tends to draw dirt into the fuel system. Also,
necessary to remove safety guards to perform check the crankcase oil level and add oil if indicated.
required maintenance. Remove guards only
when necessary and replace them when the
ENGINE MAINTENANCE PARTS
maintenance requiring their removal is
complete. Always use the greatest care when
TABLE D.1
working near moving parts.
HondaGX 620 Kohler CH 20
Do not put your hands near any rotating parts. If Oil Filter Honda15400-PR3-004 Kohler 1205001
a problem cannot be corrected by following the (Honda Code 3179553) Fram PH3614*
Fram PH6811
instructions, take the machine to the nearest
Air Filter Honda 17211-ZJ1-000 Kohler 4708303
Lincoln Field Service Shop. (Honda Code 4209672) Fram CA79
----------------------------------------------------------------------- Air Filter Honda 17218-ZJ1-000 Kohler 2408302
Pre-Cleaner (Honda Code 4209706)
ELECTRIC SHOCK can kill.
Fuel Filter Honda 16910-ZE8-005 Kohler 2505002
� Do not touch electrically live parts or (Honda Code 2106235) Fram G1
electrode with skin or wet clothing.
SparkPlugs NGK BPR6ES Champion RC12YC
� Insulate yourself from work and Nippondenso W20EPR-U .030 in., (.76 mm.) gap
.030 in., (.76 mm.) gap
ground
� Always wear dry insulating gloves.
* Oil capicity increases from 2.0 Qts. to 2.1 Qts when using this filter.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
� Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOVING PARTS can injure.
� Do not operate with enclosure or
guards off.
� Stop engine before servicing.
� Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information
throughout this operator’s manual and
the Engine manual as well.
-----------------------------------------------------------
GX 271 Chopper
D-2 D-2
MAINTENANCE
TABLE D.2
HONDA ENGINE MAINTENANCE SCHEDULE
Regular Service Period (3) Each First Every Every Every
Use Month or 3 Months 6 Months or Year or
20 Hrs. or 50 Hrs. 100 Hrs. 300 Hours
ITEM Perform at every indicated month or operating hour
interval, whichever comes first.
Engine Oil Check Level �
Change � �
Engine Oil Filter Replace � or 200
Hours
Air Cleaner Check �
Clean � (1)
Replace � (2)
Spark Plug Clean adjust �
Replace �
Spark Arrestor Clean �
(Optional Part)
Engine Speed Check-Adjust � (3)
Valve Clearance Check-Readjust � (3)
Fuel Filter Check �
Replace � (3)
Fuel Line Check Every 2 Years (3)
(Replace if necessary)
(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.
TABLE D.3
KOHLER ENGINE MAINTENANCE SCHEDULE
Regular Service Period (3) Each 5 Hrs. 25 Hrs. Every Every
Use 100 Hrs. 200 Hours
ITEM Perform at every indicated month or operating hour
interval, whichever comes first.
Engine Oil (1) Check Level O
Change First Oil O
Change
Engine Oil Filter Replace O
(1)
Air Pre Cleaner Clean O
(1)
Air Cleaner Clean O
Element (1)
Spark Plug Clean adjust O
Spark Arrestor Clean O
(Optional Part)
Fuel Filter Check Visually O
Fuel Line Check Every 2 Years
(Replace if necessary)
(1) Service more frequently when used in dusty areas and or at high ambient temperatures.
GX 271 Chopper
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
Honda Kohler
and complete draining.
OIL FILTER 16 ft-lb, (22 Nßm) 10 ft-lb, (13.6 Nßm)
TORQUE:
1. Remove the oil filler cap and drain cap, and drain
the oil into a suitable container. 5. Refill the crankcase with the specified amount of
the recommended oil. Reinstall the oil filler cap.
2. Retighten the drain cap securely.
6. Start the engine and check for oil filter leaks.
3. Refill to the upper limit mark on the dipstick with
the recommended oil. Tighten the oil filler cap 7. Stop the engine, and check the oil level. If neces-
securely. sary, add oil to the upper limit mark on the dipstick.
TABLE D.4
ENGINE OIL REFILL CAPACITIES AIR CLEANER SERVICE
Honda Kohler
A dirty air cleaner will restrict air flow to the carburetor.
Without oil filter replacement: 1.27 US qt. (1.06 Imp qt., 1.20 1.70 US qt (1.41 Imp qt., 1.60
liter) liter)
To prevent carburetor malfunction, service the air
With oil filter replacement: 1.59 US qt. (1.32 Imp. qt., 1.50 2.0 US qt. (1.66 Imp qt., 1.90
liter) liter)
cleaner regularly. Service more frequently when oper-
Use 4-stroke motor oil that meets or exceeds the ating the engine in extremely dusty areas.
requirements for API service classification SG or SH.
Always check the API SERVICE label on the oil con-
WARNING
tainer to be sure it includes the letters SG or SH.
� Never use gasoline or low flash point solvents for
SAE 10W-30 is recommended for general, all-temper- cleaning the air cleaner element. A fire or explosion
ature use, -5% F to 86%F (-20%C to 30%C). See could result.
Engine Owner’s Manual for more specific information
on oil viscosity recommendations. � Never run the engine without the air cleaner. Rapid
engine wear will result from contaminants, such as
Wash your hands with soap and water after handling dust and dirt being drawn into the engine.
used oil. ------------------------------------------------------------------------
HONDA ENGINE
Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you 1. Remove the wing bolt and remove the air cleaner
take it in a sealed container to your local service sta- cover.
tion or recycling center for reclamation. Do not throw
it in the trash, pour it on the ground or down a drain. 2. Remove the two 5 mm Phillips head screws from
the air cleaner cover and remove the paper ele-
CHANGING THE ENGINE OIL FILTER ment from the cover. Remove the foam element
from the air cleaner body.
1. Drain the engine oil, and retighten the drain cap
3. Foam element: Clean in warm, soapy water, rinse
securely.
and dry thoroughly.
2. Remove the oil filter, and drain the oil into a suit-
4. Paper element: Tap the element lightly several
able container. Discard the used oil filter.
times on a hard surface to remove excess dirt, or
blow compressed (not exceeding 2.1 kg/cm2 (30
3. Clean the filter mounting base, and coat the gasket
psi) air through the filter from the air cleaner cover
of the new oil filter with clean engine oil.
side. Never try to brush the dirt off; brushing will
force dirt into the fibers. Replace the paper ele-
4. Screw on the new oil filter by hand, until the gasket
ment if it is excessively dirty. Replace the paper
contacts the filter mounting base, then use an oil
element and both gaskets.
filter socket tool to tighten the filter an additional
1/2 to 7/8 turn. See Table D.5 for tightening torque
5. Reinstall the air cleaner elements. Tighten the
specifications.
wing bolt securely.
GX 271 Chopper
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. 3. Use a plug wrench to remove the spark plugs.
Rinse the precleaner thoroughly until all traces of
detergent are eliminated. Squeeze out excess
WARNING
water (do not wring). Allow the precleaner to air
dry. The muffler becomes very hot during operation and
remains hot for a while after stopping the engine. Be
4. Saturate the precleaner with new engine oil. careful not to touch the muffler while it is hot.
Squeeze out all excess oil. ------------------------------------------------------------------------
5. Reinstall the precleaner over the paper element. 4. Visually inspect the spark plugs. Discard them if
the insulator is cracked or chipped. Clean the
6. Reinstall the air cleaner cover. Secure cover with spark plugs with a wire brush if they are to be
the cover retaining knob. reused.
Air Filter Paper Element Service 5. Measure the plug gap with a feeler gauge. Correct
as necessary by bending the side electrode.
1. Loosen the cover retaining knob and remove the
cover. 6. Check that the spark plug washer is in good condi-
tion and thread the spark plug in by hand to pre-
2. Remove the precleaner from the paper element. vent cross-threading.
3. Remove the element cover nut, element cover, and 7. After the spark plug is seated, tighten with a spark
paper element. plug wrench to compress the washer.
4. Do not wash the paper element or use pressurized - If installing a new spark plug, tighten 1/2 turn
air, as this will damage the element. Replace a after the spark plug seats to compress the
dirty, bent, or damaged element with a new ele- washer.
ment. Handle new elements carefully; do not use if
the sealing surfaces are bent or damaged. - If reinstalling a used spark plug, tighten 1/8 - 1/4
turn after the spark plug seats to compress the
5. When servicing the air cleaner, check the air clean- washer.
er base. Make sure it is secured and not bent or
damaged. Also check the element cover for dam- TABLE D.6
age or improper fit. Replace all damaged air
SPARK PLUG INSTALLATION SPECIFICATIONS
cleaner components.
Honda Kohler
NOTE: Before air cleaner reassembly make sure rub- Spark Plug Gap .030 in. (.76 mm). .030 in. (.76 mm)
ber seal is in position around stud. Inspect, Spark Plug Torque 13.0 ft. lb. (18 N-m) 20 ft. lb. (27 N-m)
making sure it is not damaged and seals with
the element cover.
CAUTION
6. Reinstall the paper element, precleaner, element
The spark plug must be securely tightened. An improperly tight-
cover, element cover nut, and air cleaner cover.
ened spark plug can become very hot and may cause engine dam-
Secure cover with the cover retaining knob.
age.
Use only the recommended spark plug or equivalent. A spark plug
which has an improper heat range may cause engine damage.
------------------------------------------------------------------------------------------
GX 271 Chopper
D-5 D-5
MAINTENANCE
FUEL FILTER SERVICE BATTERY MAINTENANCE
WARNING WARNING
When working on the fuel system
GASES FROM BATTERY can explode.
q Keep sparks, flame and cigarettes
� Keep naked lights away, do not smoke !
away from battery.
� Do not spill fuel !
To prevent EXPLOSION when:
------------------------------------------------------------------------
q INSTALLING A NEW BATTERY � disconnect
1. Check the fuel filter for water accumulation or sedi- negative cable from old battery first and connect to
ment. new battery last.
q CONNECTING A BATTERY CHARGER �
2. Replace the fuel filter if it is found with excessive remove battery from welder by disconnecting nega-
water accumulation or sediment. tive cable first, then positive cable and battery
clamp. When reinstalling, connect
ENGINE ADJUSTMENTS negative cable last. Keep well ventilated.
USING A BOOSTER � connect positive lead to
q
WARNING battery first then connect negative lead to negative
battery lead at engine foot.
OVERSPEED IS HAZARDOUS
The maximum allowable high idle speed for this
BATTERY ACID can burn eyes and
machine is 3750 RPM, no load. Do NOT tamper with
skin.
governor components or setting or make any other
q Wear gloves and eye protection and
adjustments to increase the maximum speed. Severe
be careful when working near battery.
personal injury and damage to the machine can result
if operated at speeds above maximum. Follow instructions printed on battery.
q
------------------------------------------------------------------------
Adjustments to the engine are to be made only by a
To prevent ELECTRICAL DAMAGE when:
Lincoln Service Center or an authorized Field Service
a) Installing a battery.
Shop.
b) Using a booster.
Use correct polarity - Negative Ground.
To prevent BATTERY DISCHARGE, if you have an
ignition switch, turn it off when engine is not
running.
------------------------------------------------------------------------
The battery is a group 58, with a rating of 435 cold
cranking amps.
CLEANING THE BATTERY
Keep the battery clean by wiping it with a damp cloth
when dirty. If the terminals appear corroded, discon-
nect the battery cables and wash the terminals with an
ammonia solution or a solution of 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
D-6 D-6
MAINTENANCE
After cleaning, flush the outside of the battery, the bat- 4. Lightly tap on arrestor around drain hole to remove
tery compartment, and surrounding areas with clear particulate.
water. Coat the battery terminals lightly with petrole-
um jelly or a non-conductive grease to retard corro- 5. It may be necessary to poke around inside drain
sion. hole with a wire or screwdriver to break up particu-
late.
Keep the battery clean and dry. Moisture accumula-
6. Reinstall clean out plug.
tion on the battery can lead to more rapid discharge
and early battery failure.
WELDER / GENERATOR
CHECKING ELECTROLYTE LEVEL
MAINTENANCE
If battery cells are low, fill them to the neck of the filler
hole with distilled water and recharge. If one cell is STORAGE
low, check for leaks.
Store the GX-271 in clean, dry protected areas.
CHARGING THE BATTERY
When you charge, jump, replace, or otherwise con-
CLEANING
nect battery cables to the battery, be sure the polarity
is correct. Improper polarity can damage the charging
Blow out the generator and controls periodically with
circuit. The GX-271 positive (+) battery terminal has a
low pressure air. Do this at least once a week in par-
red terminal cover.
ticularly dirty areas.
If you need to charge the battery with an external
charger, disconnect the negative cable first, then the
BRUSH REMOVAL AND REPLACEMENT
positive cable before you attach the charger leads.
after the battery is charged, reconnect the positive
It is normal for the brushes and slip rings to wear and
battery cable first and the negative cable last. Failure
darken slightly. Inspect the brushes when a generator
to do co can result in damage to the internal charger
overhaul is necessary.
components.
WARNING
Follow the instructions of the battery charger manu-
facturer for proper charger settings and charging
Do not attempt to polish slip rings while the engine is
time.
running.
------------------------------------------------------------------------
SERVICING OPTIONAL SPARK ARRESTOR
WARNING
� MUFFLER MAY BE HOT!
� ALLOW ENGINE TO COOL BEFORE
INSTALLING THE SPARK ARRESTOR!
� DO NOT OPERATE ENGINE WHILE INSTALLING
THE SPARK ARRESTOR!
------------------------------------------------------------------------
1. Service every 100 hours.
2. Shut off engine and allow muffler to cool.
3. Remove clean out plug on bottom of spark
arrestor.
GX 271 Chopper
E-1 E-1
TROUBLESHOOTING
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.
__________________________________________________________________________
Step 2. PERFORM EXTERNAL TESTS.
This Troubleshooting Guide is provided to
The second column labeled “POSSIBLE
help you locate and repair possible machine
AREAS OF MISADJUSTMENT(S)� lists the
malfunctions. Simply follow the three-step
obvious external possibilities that may con-
procedure listed below.
tribute to the machine symptom. Perform
Step 1. LOCATE PROBLEM (SYMPTOM). these tests/checks in the order listed. In
Look under the column labeled “PROBLEM general, these tests can be conducted with-
(SYMPTOMS)�. This column describes out removing the case wrap-around cover.
possible symptoms that the machine may
exhibit. Find the listing that best describes Step 3. RECOMMENDED COURSE OF
the symptom that the machine is exhibiting. ACTION
Symptoms are grouped into the following
categories: engine problems, function prob- If you have exhausted all of the items in
lems and output problems. step 2. Contact your Local Lincoln
Authorized Field Service Facility.
WARNING
ELECTRIC SHOCK can kill.
� Do not touch electrically live parts such as output
terminals or internal wiring.
ENGINE EXHAUST can kill.
� Use in open, well ventilated areas or vent exhaust
outside.
MOVING PARTS can injure.
� Do not operate with doors open or guards off.
� Stop engine before servicing.
� Keep away from moving parts.
� Remove guards only when necessary and replace when work
requiring removal is complete.
� Only qualified personnel should install, use or service this
equipment.
CAUTION
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.
GX 271 Chopper
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
Major Physical or Electrical Damage 1. Contact your Local Lincoln Authorized
is Evident. Field Service Facility.
Engine will not "crank". 1. Battery is low. 1. Charge Battery.
2. Loose battery cable connections. 2. Inspect, clean and tighten.
3. Faulty engine starter motor. 3. Contact authorized engine Service
Shop.
4. “Battery Circuit� circuit breaker is 4. Re-set. If it continues to trip, contact
tripped. your local Local Lincoln Authorized
Field Service Facility.
Engine will "crank" but not start. 1. Out of fuel. 1. Fill tank and start engine.
2. Engine switch in "OFF" position. 2. Set switch to "ON" position.
3. Faulty fuel solenoid or faulty PC 3. Contact your Local Lincoln Authorized
board or ignition system. Field Service Facility or authorized
engine service shop.
Engine shuts down shortly after 1. Low oil level. 1. Change oil and oil filter and fill to prop-
starting. er level. Start engine and look for
leaks.
2. Faulty oil pressure switch or other 2. Contact your Local Lincoln Authorized
engine component. Field Service Facility or authorized
engine service shop.
Battery does not stay charged. 1. Faulty battery. 1. Replace
2. Loose connections at battery or 2. Clean and tighten connections.
alternator.
3. Faulty engine alternator or charg- 3. Consult authorized engine service
er module. shop.
CAUTION
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.
GX 271 Chopper
E-3 E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) 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.
Engine will not go to high idle when 1. Poor work lead connection to 1. Make sure work clamp is tightly con-
attempting to weld. work. nected to clean base metal.
2. "Welding Terminals" switch is in 2. Set to "Always On" when welding with-
wrong position. out a welding terminal control cable.
Refer to Operations chapter for proper
use of this switch.
3. Faulty PC board. Low idle speed 3. Contact your Local Lincoln Authorized
set too low. Field Service Facility for technical
troubleshooting assistance.
Engine will not go to high idle when 1. Auxiliary power load is less than 1. Idler may not respond with less than a
using auxiliary power. 100 watts. 100 watt load. Set idler to "High".
2. Faulty PC board. 2. Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
Engine does not develop full power. 1. Fuel filter clogged. 1. Replace.
2. Air filter clogged. 2. Clean or replace.
3. Fouled spark plugs. 3. Clean or replace.
4. Valves out of adjustment. 4. Contact authorized engine service
shop.
CAUTION
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.
GX 271 Chopper
E-4 E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) 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. Field Service Facility for technical
troubleshooting assistance.
Welder has output but no control. 1. "Local/Remote" switch is in wrong 1. Place switch in "Control at Welder"
position. position to control output at welder.
Place switch in "Remote" position to
control output remotely. Refer to
Operation chapter for proper switch
function.
2. Poor remote kit connection. 2. Check connections.
3. Faulty remote kit. 3. Replace if necessary.
4. Faulty control potentiometer or 4. Contact your Local Lincoln Authorized
faulty PC board. Field Service Facility for technical
troubleshooting assistance.
No auxiliary power. 1. Open circuit breakers. 1. Reset breakers. If breakers keep trip-
ping, reduce power draw.
2. Faulty connections to auxiliary 2. Check connections.
receptacles.
3. GFCI tripped. 3. Clear any ground fault and reset GFCI
circuit by pressing "Reset" button on
the 120 V receptacle.
4. Faulty welding alternator or faulty 4. Contact your Local Lincoln Authorized
PC board. Field Service Facility for technical
troubleshooting assistance.
Wire feeder does not work when 1. Wire Feeder Power circuit breaker 1. Reset
connected to welder 14 pin amphe- open.
nol. 2. Faulty wiring in control cable 2. Repair or replace cable
3. Faulty wire feeder. 3. Replace with known good one.
CAUTION
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.
GX 271 Chopper
WIRING DIAGRAM
F-1
OUTPUT CONT. POT
67
CCW
D2 - D7
75 R1
W4 W4 STATOR 75A 77B PINCH POT
W6 WELD
REMOTE/LOCAL
50K
WINDINGS SWITCH 76B
TWISTED PAIR J15 P15
RIGHT 68 W3
251
FROM PCB3
J12 15A 1
SIDE 15 277
278
75D
6
3
16A 2 16 S6
+ PCB1
W1
67C R2
13 76 77
13A 3
25A
200 AMP
CAP
MODULE 23A
4
1
14
14A 4
-
15A
25 watts
250 ohms
SHOWN IN
CHOKE 16A 76D 77D
D11
HEATSINK S5
LOCAL POS.
L1
MODE SWITCH
W5 W5
POS. (VIEWED FROM REAR WITH
LOCKING TAB DOWN)
W6 251A
W7
HEATSINK TWISTED PAIR
FROM PCB3
J13 3 6
6
WRAP 2 TURNS #3 & #6 LEADS
3
220
+
260 PCB2 CC
IN DIRECTION SHOWN 16
12 6G
14 W2 2
200 AMP
6A 25
D10
261 CAP
67A 11 15 5G
13 222 223
MODULE 23 W3
4
1
-
3
1 4
67B 214
LEFT
P16
3 13A CV
SIDE 14A 1 4 5 6 7 8
2 3
6A
218
PIPE
J16
69 Y BR
R
PCB3
Y
W7 IDLER/CONTROL P.C.
BRBLK
R
BLK
SHUNT
50MV=400AMPS
NEG.
W8
21D
1
22 22 IDLER CONTROL
2
21A 21 CONTROL PCB
CONTROL
STATOR AUX. WINDING 250
220 214 277 77 75 218
222 5L
RED
6G BROWN YELLOW 12 11 69 23A
23 250 248 211A 260 215 261
P14
J14
21 22
20VAC 67
278 76
40VAC 68
20VAC 25 25A
2B 213 5F 200
212 210 213
5G 215 S4
3 6
21A SHOWN IN
GND-E 1 8 1
5
1 6
"AUTO" POSITION
5 PRIMARY
42
115VAC
BLK
BLK WELDING TERMINALS
SOL.
16 IDLE
9 7 12
6 10 CONTROL
J3
67A J1 J2
248
6A 6A
+
-
5L
3 3
S3 5K
POLARITY SWITCH SHOWN IN
'ALWAYS ON'
21C S7 STATOR FIELD WINDING
42 6
POSITION
6G
CB7
5F
7 9
15A
2B
2D
42A
200
6A 6A
WHITE
5 200
31A 6A
6
WHITE
6G
31 200B
31A
J 31
32
115AC 32
A 32 31
5G
D 4A INSULATED STUD
RF BYPASS NEUTRAL STUD
5
CONTACTOR IN CONTOL BOX
C PCB 4 IN CONTROL BOX
2A + -
9 209A
3
75C 1
H
GREEN
21C
WORK AM1
WHITE D8
2
76C
E 3
77C 77C AUX. POWER 5H 7 C1 208C
GND-E
2A 4 WHITE
REMOTE F GND. SCREW IN
76C 800uf
J4 5C
5 5A
CONTROL CONTROL BOX 32 150vdc
G 75C 21D 6 25A
67B 7
I 5B 201A
5H
FRAME GND.
31A 6A CB8
4C 8
42VAC 15A
K 42A 212
GND-F 208A
B GND-A 200A
76B 1
GROUND 5E
GREEN
3C
77B 2 FRAME GND. "S1" SHOWN
3B
2C CB3
3
AMPHENOL 1 IN "RUN"
J5 GND-G 201
4B POSITION
4
15A
5
WHITE
3C
75B 6 BLACK
DIAGRAMS
S3
A 77B S2
GREEN
J12 3D 3A
START
221
CB1
REMOTE B 75D 1
76B BUTTON
CONTROL BRUSH
76D 2 BRUSH
C 75B GND-D
J6 211A
77D SILVER
3
5A
2D 15A
4
BLACK
D 2C
GREEN
5J 211
3A
CONTACTOR BLACK
E 4B 6B
6E
CND-C
4A
CB2
GND-B 211B
GROUND F 5C 208B
J11 6C
15A
AMPHENOL 2 ROTOR
3 210
4C
WHITE
CB4
SILVER
GREEN
5B
+
GROUND SCREW ABOVE 6D HOUR METER
GND-F 50A POSITIVE BRUSH CONNECTED
210A
AMPHENOL HOLE CB5 3A
TO SLIP RING NEAREST
BLACK 6B
5E
5D
3E 5J
3
TO THE LAMINATION
J10 OIL D9
GX 271 Chopper
115/230V 50A 4 AMP
PRESSURE N.O.
3E IN LINE
CB6 SWITCH
BLACK
DIODE
BLACK 221 209
6F 6A 208
225A 12 VOLT
6B 209A +
BATTERY
WHITE
WHITE
5C 225
TERM.
1 2 3 4 6
5 - 5N
211
CONNECTOR CAVITY NUMBERING SEQUENCE
FOR CONNECTORS ON PCB1, PCB2, PCB3 & PCB4 RECTIFIER/REGULATOR 5P
MODULE
GND-H
CR1
STARTER FRAME GROUND
SOLENOID
FRAME IGNITION
GROUNDED AT MODULE ENGINE GROUND
5P
STATOR HOUSING
225
STARTER
FUEL
SHUTOFF
20 AMP
SOLENOID
CHARGE COIL
5E BLOWER BAFFLE
ELECTRICAL SYMBOLS PER E1537
GROUND SCREW
5E
LEAD COLOR CODE:
CONNECTORS VIEWED FROM INSERTION END
B = BLACK
R = RED ENGINE COMPONENTS
N.A. GROUNDING THIS TERMINAL STOPS THE ENGINE. 5F
5K
W = WHITE
5D
5N
U = BLUE
FRAME GND.
V = VIOLET
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
B-RW
L10791
NOTE: This diagram is for reference 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..
F-1
F-2
C OF SHAFT
L
CENTER OF GRAVITY WITH OIL IN
ENGINE AND FULL FUEL TANK.
9.31 9.29
21.21
20.51
30.28
26.59
2.75
FOR OIL FILTER
REMOVAL
10.32
DIAGRAMS
17.00
9.09 9.09
8.80 30.00
GX 271 Chopper
42.00
UNDERCARRIAGE MOUNTING HOLES
12-16-93
M17216
F-2
q Do not touch electrically live parts or q Keep flammable materials away. q Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
q Insulate yourself from work and
ground.
Spanish
q No toque las partes o los electrodos q Mantenga el material combustible q Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION q Aislese del trabajo y de la tierra.
French q Ne laissez ni la peau ni des vête- q Gardez à l’écart de tout matériel q Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
q Isolez-vous du travail et de la terre.
German q Berühren Sie keine stromführenden q Entfernen Sie brennbarres Material! q Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
q Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
q Não toque partes elétricas e elec- q Mantenha inflamáveis bem guarda- q Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
q Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
GX 271 Chopper
q Keep your head out of fumes. q Turn power off before servicing. q Do not operate with panel open or
WARNING
q Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
Spanish
q Los humos fuera de la zona de res- q Desconectar el cable de ali- q No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
q Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
q Débranchez le courant avant l’entre- q N’opérez pas avec les panneaux
q Gardez la tête à l’écart des fumées.
tien. ouverts ou avec les dispositifs de
q Utilisez un ventilateur ou un aspira-
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
q Strom vor Wartungsarbeiten q Anlage nie ohne Schutzgehäuse
q Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
nen; Maschine anhalten!) Betrieb setzen!
q Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Portuguese
q Não opere com as tampas removidas. q Mantenha-se afastado das partes
q Mantenha seu rosto da fumaça.
q Desligue a corrente antes de fazer moventes.
q Use ventilação e exhaustão para
ATENÇÃO
serviço. q Não opere com os paineis abertos
remover fumo da zona respiratória.
q Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
GX 271 Chopper
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