Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
GX 271 Chopper FOR ENGINEpowered 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 ...
Page 5 - PRÉCAUTIONS DE SÛRETÉ
GX 271 Chopper 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
GX 271 Chopper Thank You for selecting this QUALITY product. We want you to take pride in operating this product ••• as much pride as we have in bringingthis product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick re...
Page 7 - TABLE OF CONTENTS
GX 271 Chopper vi TABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications ...............................................................................................
Page 8 - vii
GX 271 Chopper vii TABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1Routine and Period...
Page 9 - INSTALLATION; RATED OUTPUT - WELDER
A-1 INSTALLATION GX 271 Chopper A-1 TECHNICAL SPECIFICATIONS - Red-D-Arc GX-271 (K1623-1) 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...
Page 11 - INSTALLATION INSTRUCTIONS
A-3 INSTALLATION GX 271 Chopper A-3 INSTALLATION INSTRUCTIONS SAFETY PRECAUTIONS Only qualified personnel should install,use, or service this equipment. LOCATION AND VENTILATION Whenever you use the GX-271, be sure that cleancooling air can flow through the machine’s engine andthe machine case. Avoi...
Page 12 - HIGH ALTITUDE OPERATION; OIL
A-4 INSTALLATION GX 271 Chopper A-4 HIGH ALTITUDE OPERATION At high altitude, the standard carburetor air-fuel mix-ture will be too rich. Performance will decrease, andfuel consumption will increase. A very rich mixture willalso foul the spark plug and cause hard starting. High altitude performance ...
Page 13 - FUEL; MUFFLER; CAUTION
A-5 INSTALLATION GX 271 Chopper A-5 FUEL Fill the fuel tank with clean, fresh regular grade lead-free gasoline. Observe the fuel gauge while filling toprevent overfilling. The GX-271 has a 9 U.S. gallon (7.5 Imp. Gal., 34L)fuel tank mounted below the generator. See theEngine Owners Manual for more d...
Page 14 - ELECTRICAL CONNECTIONS; MACHINE GROUNDING; TOTAL COMBINED LENGTH OF
A-6 INSTALLATION GX 271 Chopper A-6 ELECTRICAL CONNECTIONS See Figure B.1 in the OPERATION section of thismanual for location of the 120 and 240 volt recepta-c l e s , w e l d o u t p u t t e r m i n a l s , c i r c u i t b r e a k e r s a n dground stud. MACHINE GROUNDING Because the GX-271 creates...
Page 15 - CIRCUIT BREAKERS; PREMISES WIRING
A-7 INSTALLATION GX 271 Chopper A-7 AU X I L I A RY P OW E R R E C E P TAC L E S ,PLUGS, AND HAND-HELD EQUIPMENT The control panel of the GX-271 features three auxil-iary power receptacles: See Figure B.1. • Two 15 amp, 120 volt duplex (double outlet) recepta- cles. • One 50 amp 120/240 volt single ...
Page 16 - CONNECTION OF GX-271 TO PREMISES WIRING
A-8 INSTALLATION GX 271 Chopper A-8 Connection of GX-271 to premises wiring must be done by a licensed electrician and must comply withthe National Electrical Code and all other applicable electrical codes. 230 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 230 VOLT 115 VOLT 115 VOLT LOAD N NEUTRALB...
Page 17 - OPERATION; OPERATING INSTRUCTIONS; GENERAL DESCRIPTION; FOR AUXILIARY POWER
B-1 OPERATION GX 271 Chopper B-1 OPERATING INSTRUCTIONS Read and understand this entire section before oper-ating your GX-271. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you havethoroughly read all operating and maintenance man-uals supplied with your machine. They include impor-...
Page 18 - OTHER FEATURES; RECOMMENDED APPLICATIONS; WELDER; LIMITATIONS; ADDITIONAL SAFETY PRECAUTIONS
GX 271 Chopper B-2 OPERATION B-2 • One 50 amp 120/240 V AC, single phase power, dual voltage receptacle with two 35 amp circuitbreakers. Supplies up to 33 amps of 240 V AC andup to 66 amps of 120 V AC single phase auxiliarypower per side to separate branch circuits (not inparallel). Allows easy conn...
Page 19 - CONTROLS AND SETTINGS; OUTPUT PANEL CONTROLS
GX 271 Chopper B-3 OPERATION B-3 CONTROLS AND SETTINGS A l l g e n e r a t o r / w e l d e r c o n t r o l s a r e l o c a t e d o n t h eOutput Control Panel of the machine case front. Idlercontrol, and start/stop controls are also on the casefront. See Figure B.1 and the explanations that follow. ...
Page 20 - ENGINE OPERATION
GX 271 Chopper B-4 OPERATION B-4 ENGINE OPERATION D O N O T R U N T H E E N G I N E A T E X C E S S I V ESPEEDS. The maximum allowable high idle speedfor the GX-271 is 3750 RPM, no load. Do NOT adjustthe governor screw on the engine. Severe personalinjury and damage to the machine can result if it i...
Page 21 - STOPPING THE ENGINE
B-5 OPERATION B-5 STOPPING THE ENGINE Remove all welding and auxiliary power loads andallow the engine to run at low idle speed for a fewminutes to cool the engine. Stop the engine by placing the “Engine” switch in the“STOP” position. A fuel shut off valve is not required on the GX-271because the fu...
Page 22 - WELDING OPERATION
GX 271 Chopper B-6 OPERATION B-6 purposes in each mode. It is not active in the “PIPE”mode. “STICK/TIG” mode: In this mode, the “ARC CON- TROL” knob sets the short circuit (arc force) currentduring stick welding. Increasing the number from 1 to10 increases the short circuit current. This preventssti...
Page 23 - “MODE” Switch; STICK WELDING
B-7 OPERATION B-7 When the triggering device is pressed the contactor isclosed and the welding terminals are “Hot.” When the triggering device is released the contactor isopened and the welding terminals are “Cold.” “MODE” Switch - Set to the desired process: STICK/TIG, PIPE, or WIRE FEED. “WIRE FEE...
Page 24 - WIRE WELDING
GX 271 Chopper B-8 OPERATION B-8 Tungsten Electrode Diameter in. (mm) 2-155-20 15-80 70-150 150-250250-400 400-500500-750 750-1000 (3)(3)(3) 10-20 15-3025-40 40-5555-80 80-125 3-8 (2-4) 5-10 (3-5) 5-10 (3-5) 9-13 (4-6) 11-15 (5-7) 11-15 (5-7) 13-17 (6-8) 18-22 (8-10) 23-27 (11-13) TIG TORCH Nozzle S...
Page 25 - SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS
GX 271 Chopper B-9 OPERATION B-9 TABLE B.3 SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS CONTROL CABLE USED MODE SWITCH IDLER SWITCH OUTPUT CONTROL SWITCH WELDING TERMINALS SWITCH ELECTRODE WHEN NOT WELDING TO START WELDING PROCESS STICK - CC TIG - CCK930-1 TIG MODULE /K936-1 CONTROL CABLE(With ...
Page 26 - AUXILIARY POWER; GX-271 SIMULTANEOUS WELDING AND POWER LOADS
GX 271 Chopper B-10 OPERATION B-10 AUXILIARY POWER Start the engine and set the "IDLER" control switch tothe desired operating mode. Full power is availableregardless of the welding output settings, if no weldingcurrent is being drawn. The auxiliary power of the GX-271 consists of two 15Amp-...
Page 27 - ACCESSORIES
C-1 ACCESSORIES C-1 GENERAL OPTIONS / ACCESSORIES The following options/accessories are available foryour GX-271: K886-1 Canvas Cover - To protect the GX-271 when it is not being operated. Made from attractive red can-vas material that is flame retardant, mildew resistantand water repellent. K889-2 ...
Page 29 - ACCESSORIES - CONNECTION DIAGRAMS
GX 271 Chopper C-3 C-3 ACCESSORIES - CONNECTION DIAGRAMS !" #"$ %&'(&)*+(,-*'(./*01(2, ((034356&%11%)*2703&,' !" 285./38*6*(90(&'%22(8'-%/89*2',388:/'( : %2%,%0(&3,(4*,-032(8'%0(2 ;(6%&('(&)*+*27 *'+%22(+,<= %2%,,%/+-(8(+,&*+38858*)(03&,' ((07/3...
Page 34 - MAINTENANCE; ENGINE MAINTENANCE PARTS; SAFETY PRECAUTIONS; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n
GX 271 Chopper D-1 MAINTENANCE D-1 ROUTINE AND PERIODIC ENGINEMAINTENANCE At the end of each day’s use, refill the fuel tank to min-imize moisture condensation in the tank. Running outof fuel tends to draw dirt into the fuel system. Also,check the crankcase oil level and add oil if indicated. ENGINE...
Page 35 - HONDA ENGINE MAINTENANCE SCHEDULE
GX 271 Chopper D-2 MAINTENANCE D-2 TABLE D.2 HONDA ENGINE MAINTENANCE SCHEDULE TABLE D.3 KOHLER ENGINE MAINTENANCE SCHEDULE Regular Service Period (3) Each Use First Month or 20 Hrs. Every 3 Months or 50 Hrs. Every 6 Months or 100 Hrs. Every Year or 300 Hours ITEM Perform at every indicated month or...
Page 36 - CHANGING THE ENGINE OIL
D-3 MAINTENANCE D-3 CHANGING THE ENGINE OIL Drain the oil while the engine is warm to assure rapidand complete draining. 1. Remove the oil filler cap and drain cap, and drain the oil into a suitable container. 2. Retighten the drain cap securely. 3. Refill to the upper limit mark on the dipstick wit...
Page 37 - SPARK PLUG SERVICE
D-4 MAINTENANCE D-4 KOHLER ENGINE Air Precleaner Service 1. Loosen the cover retaining knob and remove the cover. 2. Remove the precleaner from the paper element. 3. Wash the precleaner in warm water with detergent. Rinse the precleaner thoroughly until all traces ofdetergent are eliminated. Squeeze...
Page 38 - FUEL FILTER SERVICE; BATTERY MAINTENANCE
GX 271 Chopper D-5 MAINTENANCE D-5 FUEL FILTER SERVICE 1. Check the fuel filter for water accumulation or sedi- ment. 2. Replace the fuel filter if it is found with excessive water accumulation or sediment. ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS T h e m a x i m u m a l l o w a b l e h i g h i d l...
Page 39 - SERVICING OPTIONAL SPARK ARRESTOR; STORAGE
D-6 MAINTENANCE D-6 After cleaning, flush the outside of the battery, the bat-tery compartment, and surrounding areas with clearwater. Coat the battery terminals lightly with petrole-um jelly or a non-conductive grease to retard corro-sion. Keep the battery clean and dry. Moisture accumula-tion on t...
Page 40 - TROUBLESHOOTING
GX 271 Chopper E-1 TROUBLESHOOTING E-1 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. CAUTION This Troubleshooting...
Page 41 - PROBLEMS
GX 271 Chopper E-2 TROUBLESHOOTING E-2 Observe all Safety Guidelines detailed throughout this manual 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 troubleshooti...
Page 44 - DIAGRAMS
F-1 DIAGRAMS F-1 GX 271 Chopper !" # # # ! $ # % " % % % ! % % % % &$& % % % $'(' )*) ! % % !" !" %+ $$ ! $ *$!%,$ *!% %-%-%(% ! ./01 23441 * * % % # # % !* $$ %+ $+" " %+ %* % $+" # % % % % % % !" % 56 789 % %$ ! %$ %$ # # # " % % % % % ! ! % % # $ !:! ! ...
