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IM603
March, 1999
RED-D-ARC
GX 271 Chopper
For use with machines having Code Numbers:
10527
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 REA
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 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. Us
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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 hos
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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 provo
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v v for selecting this QUALITY product. We want you to take pride in operating this product ��� as much pride as we have in bringing Thank You 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
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vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Installation Instructions.........................................................................................................A-3 Location and Ventilation............................................
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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 Sche
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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 1 Welding Output Volts at Ra
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - Red-D-Arc GX-271 (K1623-1) GX 271 Chopper
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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. Prot
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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 performanc
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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 machin
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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 dri
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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)
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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
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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 up to 8,000 continuous watts of 120/240 volt, 60 Hz, SAFETY INSTRUCTIONS single-phase AC power to operate AC power tools, battery chargers, and lighting; it can also be used to provide standby power. As a wel
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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 Inne
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B-3 B-3 OPERATION TROLLED” is used to control the operation of the CONTROLS AND SETTINGS 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 ba
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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 e
