Lincoln Electric IM635 User Manual
IM635
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RED-D-ARC
GX 271Chopper LPG
For use with machines having Code Numbers:
10579
October, 2000
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
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
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.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered equipment.
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.
____________________________________________________
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
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ’95
GX 271 Chopper LPG
ii
SAFETY
ii
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95
vapors
to
GX 271 Chopper LPG
iii
SAFETY
iii
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
GX 271 Chopper LPG
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
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
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
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
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
GX 271 Chopper LPG
for selecting this QUALITY product. We want you to take pride in
Thank You
operating this product ••• as much pride as we have in bringing
this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
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.
vv
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 LPG
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
Lifting.............................................................................................................................A-3
Additional Safety Precautions .......................................................................................A-3
Pre-Operation Engine Service..............................................................................................A-4
Fuel ...............................................................................................................................A-4
Oil..................................................................................................................................A-4
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
vi
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 LPG
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 List ......................................................................................................P325 Series
GX 271 Chopper LPG
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - Red-D-Arc GX-271 LPG (K1680-1)
INPUT - ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
A-1
Kohler 2 cylinder High Idle 3700 38.1 cu. in
CH20S 20.0 HP @ Low Idle 2400 (624 cc) (Group 58, 435
Command® w/LP 3600 RPM Full Load 3500 cold crank amps)
Full Load Bore x Stroke Oil: 2.0 Qts.
4 Cycle 25A. Alternator 1.9 L
Air Cooled 3.03” x 2.64”
LPG Engine
Overhead Valves
(77 mm x 67 mm)
12VDC battery
RATED OUTPUT - WELDER
Welding Output Volts at Rated Amps Duty Cycle
CC Stick/TIG, Pipe and CV Wire Welding
275 Amps 28 volts 100%
300 Amps 25 volts 60%
1
Max. OCV @ 3700 RPM
80 volts DC
OUTPUT - GENERATOR
Auxiliary Power
8,000 Watts, 60 Hz
120/240 Volts
100 % Duty Cycle
42 Volt Auxiliary Power for Wire Feeders
2
Fuel: LPG cyl.
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
30.3 in. 19.1 in. 43.8 in. 469 lbs.
770 mm 485 mm 1113 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 LPG
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - Red-D-Arc GX-271 (K1680-1)
A-2
GX 271 Chopper LPG
A-3
INSTALLATION
A-3
INSTALLATION INSTRUCTIONS
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
front of this operator’s manual.
-----------------------------------------------------------
Only qualified personnel should install,
use, or service this equipment.
STORING
1. Store the machine in a cool, dry place when it is
not in use. Protect it from dust and dirt. Keep it
where it can’t be accidentally damaged from construction activities, moving vehicles, and other
hazards.
2. Drain the engine oil and refill with fresh oil. Run
the engine for about five minutes to circulate oil to
all the parts. See the MAINTENANCE section of
this manual for details on changing oil.
3. Remove the battery, recharge it, and adjust the
electrolyte level. Store the battery in a dry, dark
place.
STACKING
GX-271 machines CANNOT be stacked.
ANGLE OF OPERATION
Place the machine on a secure, level surface whenever you use it or store it. Any surfaces you place it on
other than the ground must be firm, non-skid, and
structurally sound.
The engine is designed to run in a level position for
best performance. It can operate at an angle, but this
should never be more than 15 degrees in any direction. If you do operate it at a slight angle, be sure to
check the oil regularly and keep the oil level at the
FULL mark as it would be in its normal level condition.
LOCATION AND VENTILATION
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.
Always operate the GX-271 with the case roof on and
all machine components completely assembled. This
will protect you from the dangers of moving parts, hot
metal surfaces, and live electrical devices.
LIFTING
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.
ADDITIONAL SAFETY PRECAUTIONS
WARNING
FALLING EQUIPMENT can cause
injury.
● Do not lift this machine using lift
bale if it is equipped with a heavy
accessory such as trailer or gas
cylinder.
● Lift only with equipment of adequate lifting
capacity.
● Be sure machine is stable when lifting.
GX 271 Chopper LPG
A-4
INSTALLATION
PRE-OPERATION ENGINE SERVICE
CAUTION
A-4
If growing bubbles appear, there is a leak. Re-tighten
connection or replace defective component. Retest to
make sure that there is no leak.
READ the engine operating and maintenance instructions supplied with this machine.
WARNING
fuel can cause fire or explosion.
LPG
-
• All leak testing must be done in a well
ventilated area free from all potential
ignition sources.
• Keep sparks and flame away from machine and
LPG supply cylinder.
• Do not expose the LPG supply cylinder to temperatures exceeding 120°F (49°C).
• Do not weld on or near the LPG supply cylinder.
• Do not smoke or allow any potential ignition sources
near the LPG supply cylinder.
•
Always be certain that the LPG supply cylinder is NOT
in the welding circuit. Do not allow either welding
cable to come in contact with the supply cylinder.
• Replace the fuel supply hose if there is excessive
abrasion, cracks or wear or if the hose is cut.
------------------------------------------------------------------------
Leak test must be performed each time the fuel cylinder is replaced.
Always close the cylinder valve when the machine is
not being used.
The specification for aluminum lift truck cylinders are
shown below:
FUEL
A lift truck type coupler is provided on the supplied
fuel line for easy hand attachment to a lift truck type
LPG fuel cylinder. The fuel cylinder must meet D.O.T.
Specification 4E-240. The valve on the fuel cylinder
must
be installed on the outlet marked “LIQUID”.
The engine will not develop full power if connected to
the vapor outlet.
Be certain that the cylinder valve is CLOSED before
attempting to attach the fuel supply hose coupler to the
cylinder. Connect the coupler to the fuel cylinder and
tighten by hand.
CAUTION
___________________________________________
After connecting the fuel supply to the supply cylinder,
open the valve on the fuel cylinder and leak test by
brushing a 50/50 soap and water solution on to the following connections:
• Both ends of the fuel hose where it enters the metal connector.
• The threaded fitting on the end of fuel hose attached to the GX
271 LPG fuel shut off solenoid.
• The fuel hose coupler and the connection to the cylinder valve.
• The stem of the cylinder valve and where the valve is attached
to the top of the cylinder.
• All other fittings on top of the fuel cylinder.
Note: The GX 271 LPG cannot
OIL
The GX 271 is shipped with the engine crankcase filled
with SAE 10W-30 oil. Check the oil level before starting
the engine. If it is not up to the full mark on the dip stick,
add oil as required. Make certain that the oil filler cap is
tightened securely. Refer to the engine Owner’s Manual
for specific oil recommendations.
Capacity Cylinder Weight Footring
LP-Gas Volume Empty Outside
(LBS.) (Cu. In.) (LBS.) Diameter
33.5 2219 22.5 9 3/8”
43.5 2873 25.5 9 3/8”
be used with vapor draw
LP gas cylinders such as those used for recreation
vehicles, trailers, grilles, and boats.
LUBRICATION SYSTEM CAPACITY
(INCLUDING FILTER)
Kohler CH20S - 2.0 Quarts (1.9 Liters)
GX 271 Chopper LPG
A-5
INSTALLATION
A-5
BATTERY CONNECTIONS
WARNING
GASES FROM BATTERY can explode.
● Keep sparks, flame and cigarettes
away from battery.
To prevent EXPLOSION when:
● INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and connect
to new battery last.
● CONNECTING A BATTERY CHARGER —
remove battery from welder by disconnecting negative cable first, then positive cable and battery
clamp. When reinstalling, connect
negative cable last. Keep well ventilated.
● USING A BOOSTER — connect positive lead to
battery first then connect negative lead to negative
battery lead at engine foot.
BATTERY ACID can burn eyes and
skin.
● Wear gloves and eye protection and
be careful when working near battery.
● Follow instructions printed on battery.
------------------------------------------------------------------------
IMPORTANT: To prevent ELECTRICAL DAMAGE
WHEN:
a) Installing new batteries.
b) Using a booster.
Use correct polarity — Negative Ground.
The GX 271 is shipped with the negative battery cable
disconnected. Before you operate the machine, make
sure the Engine Switch is in the STOP position and
attach the disconnected cable securely to the negative
(-) battery terminal.
Remove the insulating cap from the negative battery
terminal. Replace and tighten negative battery cable
terminal. NOTE: This machine is furnished with a wet
charged battery; if unused for several months, the battery may require a booster charge. Be sure to use the
correct polarity when charging the battery.
MUFFLER
CAUTION
Shut off the machine and allow the muffler to cool
before touching the muffler.
------------------------------------------------------------------------
SPARK ARRESTER
Engine mufflers may emit sparks when the engine is
running. Some federal, state, or local laws require
spark arresters in locations where unarrested sparks
could present a fire hazard.
Standard mufflers do not act as spark arresters.
When local laws require it, a spark arrester must be
installed on the machine and properly maintained.
CAUTION
An incorrect spark arrester may lead to damage to the
engine or reduce performance.
------------------------------------------------------------------------
GX 271 Chopper LPG
A-6
INSTALLATION
A-6
ELECTRICAL CONNECTIONS
See Figure B.1 in the OPERATION section of this
manual for location of the 120 and 240 volt receptacles, weld output terminals, circuit breakers and
ground stud.
MACHINE GROUNDING
Because the GX 271 creates its own power from its
engine driven generator, and if the machine is not
connected to premises wiring (home, shop, etc.), you
do not need to connect the machine frame to an earth
ground. However, for best protection against electrical shock, connect a heavy gauge wire (#8 AWG or
larger) from the ground stud located on the bottom of
the output panel (See Figure B.1) to a suitable earth
ground such as a metal pipe driven into the ground.
WARNING
Do not ground the machine to a pipe that carries
explosive or combustible material.
------------------------------------------------------------------------
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable Length
0-50 Ft. (0-15 meters)
50-100 Ft. (15-39 meters)
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
200-250 Ft. (61-76 meters)
Cable Size for
300 Amps
100% Duty Cycle
1/0 AWG
1/0 AWG
2/0 AWG
2/0 AWG
3/0 AWG
Table A.1
CABLE INSTALLATION
Install the welding cables to your GX 271 as follows.
See Figure B.1 for location of parts.
1. The engine must be OFF to install welding cables.
When the GX 271 is mounted on a truck or a trailer,
the machine generator ground stud MUST be securely
connected to the metal frame of the vehicle. See
Figure B.1. The ground stud is marked with the
ground symbol.
If the GX 271 is connected to premises wiring such as
a home or shop, it must be properly connected to the
system earth ground.
WELDING CABLE CONNECTIONS
CABLE SIZE AND LENGTH
Be sure to use welding cables that are large enough.
The correct size and length becomes especially
important when you are welding at a distance from the
welder.
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
Lincoln Electric offers a welding accessory kit with the
properly specified welding cables. See the
ACCESSORIES section of this manual for more information.
2. Remove the flanged nuts from the output terminals.
3. Connect the electrode holder and work cables to
the weld “+” and “-” output terminals. The terminals
are identified on the case front. The polarity requirement for the welding process being used determines which terminal the electrode cable is
attached to.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding (the
“work”) is properly connected to the work clamp and
cable.
6. Check and tighten the connections periodically.
CAUTION
• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.
• Do not cross the welding cables at the output termi-
nal connection. Keep the cables isolated and separate from one another.
------------------------------------------------------------------------
GX 271 Chopper LPG
A-7
INSTALLATION
A-7
AUXILIARY POWER RECEPTACLES,
PLUGS, AND HAND-HELD EQUIPMENT
The control panel of the GX 271 features three auxiliary power receptacles: See Figure B.1.
• Two 15 amp, 120 volt duplex (double outlet) receptacles.
• One 50 amp 120/240 volt single outlet receptacle.
Through these receptacles the machine can supply up
to 8,000 rated continuous watts of single-phase, 60
Hz AC power.
For further protection against electric shock, any electrical equipment connected to the 120V duplex receptacles must use a three-blade, grounded type plug or
an Underwriter’s Laboratories (UL) approved double
insulation system with a two-blade plug. Lincoln
offers an accessory plug kit that has the right type of
plugs. See the ACCESSORIES section of this manual
for more information.
If you need ground fault protection for hand-held
equipment refer to the K896-1 GFCI Receptacle kit in
the ACCESSORIES section of this manual for more
information.
For recommended extension cord lengths and sizes
see Table A.1.
PREMISES WIRING
The GX 271 is suitable for temporary, standby, or
emergency power using the engine manufacturer’s
recommended maintenance schedule. With its threewire grounded neutral generator, it can be permanently installed as a standby power unit for 240 volt, three
wire, single phase 33 ampere service.
WARNING
Only a licensed, certified, trained electrician should
install the machine to a premises or residential electrical system. Be certain that:
• The installation complies with the National Electrical
Code and all other applicable electrical codes.
• The premises is isolated and no feedbacking into
the utility system can occur. Certain state and local
laws require the premises to be isolated before the
generator is linked to the premises. Check your
state and local requirements.
• A double pole, double throw transfer switch in conjunction with the properly rated double throw circuit
breaker is connected between the generator power
and the utility meter.
------------------------------------------------------------------------
The following information and the connection diagram,
Figure A.1, can be used as a guide by the electrician
for most applications to premises wiring.
CIRCUIT BREAKERS
The GX 271 machines are equipped with 50 amp circuit breakers on the 120/240 V receptacle and 15 amp
circuit breakers on the 120 receptacles for overload
protection. Under high heat a breaker may tend to trip
at lower loads than it would normally.
CAUTION
Never bypass the circuit breakers. Without overload
protection, the GX 271 could overheat and/or cause
damage to the equipment being used.
------------------------------------------------------------------------
1. Install a double pole, double throw switch between
the power company meter and the premises disconnect. The switch rating must be the same as
or greater than the premises disconnect and
service overcurrent protection.
2. Take the necessary steps to assure that the load is
limited to the capacity of the GX 271 by installing a
35 amp 240 volt double pole circuit breaker.
Maximum rated load for the 240 volt auxiliary is 33
amperes. Loading above 33 amperes will reduce
output voltage below the allowable -10% of rated
voltage. This may damage appliances or other
motor-driven equipment.
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 receptacle on the GX 271 case front.
GX 271 Chopper LPG
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