Lincoln Electric IM856 User's Manual
Contents
1. Section D Safety Precautions iii D 1 Routine Engine Maintenance nennen nnne nnne D 1 D2 Engine D 3 Slip ipfc E D 3 Battery D 3 Engine Maintenance Parts D 3 aegnpme Section E How to Use Troubleshooting Guide E 1 Troubleshooting UE E 2 E 3 Wiring Diagrams amp Dimension Print sens Section F Wiring and Connection F 1 F 2 Dimension Cm F3 Parts NY EE P505 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS Ranger GXT 2382 1 INPUT GASOLINE ENGINE Make Model Description Horsepower Operating Displacement Starting Capacities Speed RPM cu in System cu cm 2 cylinder 4 Cycle High Idle 3700 12VDC Air Cooled Battery Fuel Gasoline Electric Start 12 Gal 45 4 L Engine 20HP Full Load 3500 Group 58 Lubricating Oil Aluminum Alloy 3600 RPM Battery 2 0 1 9 L with Cast Iron 435 cold Liners Low Idle 2200 Cranking Electronic Amps Ignition RATED OUTPUT BE WELDER EE Constant Current 2504 25V 100 DC Constant Current 250A 25V 10096 DC Constant Voltage 250A 25V 100 RATED OUTPUT 104 F 40 C GENERATOR Auxiliary Power 10 000 Watts Continuous 60 Hz AC 11 000 Watts Peak 60 Hz AC 120 240 Volts PHYSI2. o Wr o o dX o 8 1NONJ3SVO 1331 voz 5728 gt 3GISNI NO M3H2S j WOLLOS t vez cr e er ds NS H L49d 2272 1 2902 az oez LINOHIO Liz SSVdA8 I 44 VSL VoL VLL 0802 dloNa10s o IOHINOO 4 070 X ev D inano XXL x 8VIS SERE 092 X X 92 136 XXX E NOLLISOd JALLVO3N 30012313 9d NI NMOHS S HOLMS AINOA HOLIMS OHLNOO 3NION3 3onvo SNOILOSYIG 3LISOddO NYNL L ez NI GIONOL NYHL SNYNLZ 9 ANY savant 1X9 HJONVH RANGER GXT LINCOLN E DIAGRAMS F 2 F 2 16502 7002 02 80 NOILISOd ALOWSY 3HL HOLIMS ALOWSY 1V901 SHL 39V Id 381 SI TOMINOO 310 33 TYNOILdO 41 ON NOILISOd A9 Q334 3HIM OL HOLIMS YOLOATAS LAdLNO AHL NOILISOd ALIHV10d 300419313 0341530 401 LAS OL HOLIMS ALIYV10d ISN aN 30 31949 ALNG LN388609 803 03215 38 LSNW 318V9 ON DM VN 1872 300812313 OL 4751 HOM 20331 JOHLNOO SLOWSY OL Eoo TREIE SL N180 SCNT1 7 9 3NION3 NHOLO3NNOO Nid 9 jueuudinbe siy eoiAJes 10 sued jou oq e esn jejsui pjnoys jeuuosjed payrjenb e Buroi es sued Aeme dasy e peaj Kiegeg JALLVO3N 1290002517 e opd ui
3. y JO euo uo eui LL peised s epoo siy Aq je 104 eq jou 10 51 SIUL 310 trtOcIN 9 AT8W3SSV Od NHOSS3Hddns SJOLOSNNOS JONSHJNV 3 LORS 42913 SIOEGWAS T1VOIHLO3 T3 9 8 A HOLO3NNOO ANION3 sr vas Wows NMOHS SLN3NOdWOO 1 3SVO TIV 28 ALIHM M Se RN m BECK 130A HO Gay i it ALIAVO
4. ud AA Sal lala L LINCOLN 8 World s Leader in Welding and Cutting P roducts Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
5. TRANSFORMATEUR Un coup d arc peut tre plus qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier LINCOLN 8 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s
6. Blow outthe machine with low pressure air period ically In particularly dirty locations this may be required once a week Output Ranger Selector and Polarity Switches S witch contacts should not be greased To keep contacts clean rotate the switch through its entire range frequently Good practice is to turn the han dle from maximum to minimum setting twice each morning before starting to weld RANGER GXT LINCOLN 8 D 3 ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS A WARNING The maximum allowable high idle speed for this machine is 3750 RPM no load Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed Severe personal injury and damage to the machine can result if operated at speeds above maximum Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop SLIP RINGS A slight amount of darkening and wear of the slip rings and brushes is normal Brushes should be inspected when a general overhaul is necessary If brushes to be replaced clean slip rings with a fine emery paper CAUTION Do not attempt to polish slip rings while engine is running MAINTENANCE D 3 A WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery Chi prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and conne
7. 3 C 1 OPTIONAL EQUIPMENT K957 1 HEAVY DUTY TWO WHEEL TRAILER FOR SMALL WELDERS For road off road and in plant and yard towing For highway use consult applicable federal state and local laws regarding requirements for brakes lights fenders etc Order 957 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 2 Fender amp Light Kit K965 1 Cable Storage Rack Field Installed K1737 1 FOUR WHEEL ALL TERRAIN UNDER CARRIAGE For moving by hand at construction sites Heavy duty puncture resistant pneumatic tires K1770 1 UNDERCARRIAGE FACTORY For mov ing by hand on a smooth surface One or two gas cylinders can be mounted on the rear of the undercar riage with the installation of K1745 1 Cylinder Holder s Heavy duty puncture resistant pneumatic tires and front caster K1745 1 GAS CYLINDER HOLDER Holds Welding Gas Cylinder for use on K1770 1 Undercarriage One or two may be installed on an undercarriage K1788 1 ROLL CAGE Gives added damage protection Attaches to K1737 1 K1770 1 and K957 1 K886 2 Canvas Cover To protect the RANGER GXT when not in use Made from attractive red canvas material which is flame retardant mildew resistant and water repellent K802R Power Plug Kit provides four 120V plugs rated at 15 amps each and one dual voltage Full KVA plug rated at 120 240V 50 amps K802N Power Plug Kit Provides four 120V plugs rated at 20 amps each and one dual voltage
8. la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret 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 prot ger PR CAUTIONS DE S RET POUR contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER
9. IM856 RANGER GXT oe For Machines with Code Number 11154 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful 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 4 OPERATOR S MANUAL E o ISO 9001 gt PNE SER Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 LI COLN Copyright 2005 Lincoln Global Inc World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com l A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A 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 Eng
10. Load Amps Volts Maximum Allowable Cord Length in ft m for Conductor Size 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 20 _ 120 2400 30 9 50 15 88 27 138 42 225 69 15 240 3600 60 18 75 23 150 46 225 69 350 107 600 183 20 240 4800 60 42 240 10000 275 84 450 137 150 46 225 69 Conductor size is based on maximum 2 0 voltage drop RANGER GXT LINCOLN INSTALLATION TABLE Ill ELECTRICAL DEVICE USE WITH THE RANGER GXT Type Common Electrical Devices Possible Concerns Resistive Heaters toasters incandescent light bulbs electric range hot pan skillet coffee maker NONE Capacitive TV sets radios microwaves appliances with electrical control Voltage spikes or high voltage regulation can cause the capac itative elements to fail Surge protection transient protection and additional loading is recom mended for 100 fail safe operation DO NOT RUN THESE DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS Inductive Single phase induction motors drills well pumps grinders small refrigerators weed and hedge trimmers These devices require large current inrush for starting Some synchronous motors may be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency i
11. Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER GXT LINCOLN 8 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Engine will not go to high idle when 1 No voltage signal from the using auxiliary power current sensor Auxiliary power load less than 100 to 150 watts Faulty P C Board Engine will not crank or is hard to Battery will not hold a charge crank Faulty Battery If all recommended possible areas of misadjustment have been checked No or insufficient charging and the problem persists Contact current your local Lincoln Authorized Field Service Facility Loose battery cable connection s Engine shuts down Out of fuel Low oil level Engine does not develop full power 1 Fuel filter clogged Air filter clogged Engine is hard to start Spark plugs do not have specified gap Spark plugs are fouled 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 RANGER GXT LINCOLN 8 YT Jequunu epoo 1ueuudinbe y e jueunredeg eui 914A e qiGej s eui j sjeued
12. Zz 9 Lz gir Lu NX 00 0 0 oo 5506 ania MOVIE 8 94r gt E ALIAVD iz o o o o o o j oooo 895 avaT EI 8 8 E A e LAN S 2890 190 SV SHAMVSNE 310d TIONIS SHASNNN 310 SYIAWNN OML SVM 199 69211 M0739 53800 NO EN an Y ANS ONS OVA ANIDNA JHL 58015 TWNINYAL SIHL 894 D 36 2 S3HIM 3LIHM TEE EE E SIN3NOdMOO 3NION3 NO LON Nas 11 T33HMA 1d 1913 NOI s 55 21419919 WS 9 GION310S LU m SNA ml 4401NHS 1 i 6 aynssaud SECH gt so H0 vais 9 ov a ov wei SL 3 sd AOVZINOZL ONnouo HOI eg anaon i VOL VLL 49 ir 1uoddns NOILINOI 4 dor 1 h 39 SO T n HALHVLS ys y HOLIMS voor 622 Tm Se 3 LOWSY 5 RO ao 185 5405 AOL 9 LE n et D y A xg Q M 3NION3 tc ae SE 339 9 AN9 s 4 ra 32018 icd Oo FOND Ayauya et 5 V6oc enz LLZ Velez 9 al e SN 30ND 1NONJ3SVO LHOIH 3QISNI VELZ siz 09 AS 22 vec H voa ayya g 9 4 1an4 012 l H H 9 3d0 193713 ns
13. e uedo sjaued ejejedo jou e eunfui S SNIAOIN 7 III Ueo MDOHS 91419113 ONINHVM 7 NOLLO3NNOO JHL 5509 61 1 SCNT1 1X9 H39NVMH RANGER GXT LINCOLN E Jl 219020 SATOH ONILNNOW 0017 m T ac eee asa 09096 gt lt gt CD 5 DIAGRAMS 1304 ALdW3 ON NI HLIM ALIAVHO 40 H31N39 70 On TL 810 820 F 3 RANGER GXT LINCOLN E 5 RANGER GXT LINCOLN 8 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO 5 SI Chinese Korean Do nottouch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a e Aislese del trabajo y de la tierra Ne laissez ni la peau ni des ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sic
14. requirements for use on public highways VEHICLE MOUNTING A WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on serviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for compo nents such as suspension axles and tires Mount equipment base to metal bed or frame of vehicle Follow vehicle manufacturer s instructions PRE OPERATION SERVICE A CAUTION READ the engine operating and maintenance instructions supplied with this machine WARNING Stop engine while fueling Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling Wipe up spilled fuel and allow GASOLINE fumes to clear before starting can cause fire engine or explosion Do not overfill tank fuel expan sion may cause overflow GASOLINE FUEL ONLY INSTALLATION FUEL mn Fill the fuel tank with clean fresh lead free gasoline Observe fuel gauge while filling to prevent overfilling WARNING Damage to the fuel tank may cause fire or explosion Do not drill holes in the RANGER GXT base or weld to the RANGER GXT base LUBRICATION SYSTEM CAPACITY INCLUDING FILTER Kohler 205 2 0 Quarts 1 9 Liters
15. DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION gt PREMISES DISCONNECT AND SERVICE GROUND OVERCURRENT 240 VOLT PROTECTION DOUBLE 50 120 240 POLE CIRCUIT VOLT PLUG 240 VOLT BREAKER NEMA TYPE 14 50 1 50 120 240 VOLT Le a NOTE No 6 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS A WARNING Connection of RANGER GXT to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes RANGER GXT LINCOLN 8 B 1 OPERATION B 1 SAFETY PRECAUTIONS 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 9 not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves Always operate the welder with the hinged door closed and the side panels in place Read carefully the Safety Precautions page before operating this machine Always follow these and any other safety procedures included in this manual and in the Engine Instruction Manual GENERAL D
16. Volts DC CC Weld Output 250 Amps 9 25 Volts Auxiliary Power 10 000 Watts KOHLER 20 H P COMMAND 2400 RPM 1 50 Liters Hour High Idle No Load 77 Gallons Hour 1 27 Gallons Hour DC CV Weld Output 250 Amps 9 25 Volts 1 50 Gallons Hour 5 09 Liters Hour 1 41 Gallons Hour 5 33 Liters Hour 1 48 Gallons Hour 5 62 Liters Hour RANGER GXT LINCOLN 3 STARTING SHUTDOWN INSTRUCTIONS STARTING THE ENGINE A WARNING T Do not touch electrically live parts of electrode with skin or wet clothing Keep flammable material away Insulate yourself from work and ground Wear eye ear and body protection Keep your head out of the fumes Use ventilation or exhaust to remove fumes from breathing zone Re Be sure all Pre Operation Maintenance has been per formed Also read the Engine Owner s Manual before starting for the first time Remove all loads connected to the AC power recepta cles Use the choke control as follows KOHLER ENGINE Always pull the choke control out when starting the engine cold warm or hot Turn the engine switch to the start CH position and crank the engine until it starts Release the switch as soon as the engine starts slowly return the choke control to the full position choke open and turn the switch to the Auto Idle 3 position Do not turn the switch to the start position while the engine is running
17. and 035 L 50 and L 56 They must be used with a blended shielding gas such as C25 75 Argon 25 The welding ranges that can be used with the RANGER GXT are shown in the following table Diameter Wire Speed in Range In Min 75 300 50A to 130A 035 100 250 80A to 175A 045 125 200 145A to 200A ARC GOUGING Approximate Current Range The RANGER GXT can be used for limited arc goug ing Set the Range switch to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following table ELECTRODE SETTING CURRENT RANGE DC electrode positive 1 8 30 60 Amps 5 32 90 150 Amps 316 150 250 Amps RANGER GXT LINCOLN P B 5 OPERATION B 5 SUMMARY OF WELDING PROCESSES ELECTRODE WHEN NOT TO START PROCESS WIRE FEED LN 25 WITH INTERNAL CONTACTOR TIG TIG MODULE WITH WITH CONTACTOR KIT CONTROL CABLE amp AMPTROL WIRE FEED LN 15 ACROSS the ARC has internal contactor RANGER GXT LINCOLN WELDING WELDING Touch electrode to work Welding starts immediately and engine goes to high idle Press gun trigger LN 25 contactor closes Welding starts immediately and engine goes to high idle NOTE Output Control must be set above 3 Press Amptrol contactor closes welding starts immediately Press gun trigger LN 15 contactor closes Welding starts immediately Note Output Control must be set above
18. attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 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 X Connect the work cable to the workpiece as close as possible to the area being welded 1 0 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 Do not work next to welding power source Mar 95 LINCOLN 8 ELECTRIC SHOCK 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 w
19. because this will cause damage to the ring gear and or starter motor After running at high engine speed for 10 14 seconds the engine will go to low idle Allow the engine to warm up by letting it run at low idle for a few minutes OPERATION STOPPING THE ENGINE Remove all welding and auxiliary power loads and allow engine to run at low idle speed for a few minutes to cool the engine Stop the engine by placing the Engine switch in the OFF position A fuel shut off valve is not required on the Ranger GXT because the fuel tank is mounted below the engine BREAK IN PERIOD It is normal for any engine to use a greater amount of oil until the break in is accomplished Check the oil level twice a day during the break in period approxi mately 50 running hours IN ORDER TO ACCOMPLISH THIS BREAK IN THE UNIT SHOULD BE SUBJECTED TO MODERATE LOADS WITHIN THE RATING OF THE MACHINE AVOID LONG IDLE RUNNING PERIODS REMOVE LOADS AND ALLOW ENGINE TO COOL BEFORE SHUTDOWN IMPORTANT The engine manufacturer s recommendation for the running time until the first oil change is as follows KOHLER 205 5 HRS The oil filter is to be changed at the second oil change Refer to the Engine Owner s Manual for more information RANGER GXT LINCOLN P BA WELDING PROCESS For any electrodes the procedures should be kept within the rating of the machine For electrode infor mation see the appropriate Lincoln publ
20. full KVA plug rated at 120 240V 50 amps K857 25 ft 7 5m or K857 1 100 ft 30 4m Remote Control Portable control provides same dial range as the output control on the welder Has a convenient 6 pin plug for easy connection to the welder K704 Accessory Kit Includes 35 ft 10 7m 2 0 AWG elec trode cable 30 ft 9 1m 2 0 AWG work cable headshield with No 12 filter GC300 work clamp and Cooltong 300 electrode holder Cables are rated at 300 amps 100 duty cycle K875 Accessory Kit ACCESSORIES C 1 K1898 1 Spark Arrester Kit Mounts inside exhaust pipe K1690 1 GFCI RECEPTACLE KIT Includes one UL approved120V ground fault circuit interrupter duplex type receptacle with cover and installation instructions Replaces the factory installed 120V duplex receptacle Each receptacle of the GFCI Duplex is rated at 20 Amps the maximum total current from the GFCI Duplex is limit ed to the 20 Amps Two kits are required K1816 1 FULL KVA ADAPTER KIT Plugs into the 120 240V NEMA 14 50R receptacle on the case front which accepts 4 prong plugs and converts itto a NEMA 6 50R receptacle which accepts 3 prong plugs T12153 9 Full KVA Power Plug One dual voltage plug rated at 120 240V 50 amps RANGER GXT LINCOLN 8 C 2 RECOMMENDED EQUIPMENT STICK K704 Accessory Kit which includes Electrode Holder amp Cable Work Clamp amp Cable Headshield WIRE FEED K449 LN 25 Includes interna
21. not operate machine while suspended from lift bail FALLING EQUIPMENT can cause injury HIGH ALTITUDE OPERATION If the RANGER GXT will be consistently operated at altitudes above 5000 ft 1524m a carburetor jet designed for high altitudes should be installed This will result in better fuel economy cleaner exhaust and longer spark plug life It will not give increased power which is decreased at higher altitudes Engine horse power is reduced by 3 5 per 1000 ft 305m for alti tudes above 377 ft 115m CAUTION Do not operate a RANGER GXT with a high alti tude jet installed at altitudes below 5000 ft 1524m This will result in the engine running too lean and result in higher engine operating temper atures which can shorten engine life Contact your local Kohler Authorized Dealer for high altitude jet kits that are available from the engine man ufacturer MUFFLER OUTLET PIPE Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired direction Tighten using a 9 16 socket or wrench RANGER GXT LINCOLN 8 5 LOCATION VENTILATION The welder should be located to provide an unrestrict ed flow of clean cool air to the cooling air inlets and to avoid heated air coming out of the welder recirculating back to the cooling air inlet Also locate the welder so that engine exhaust fumes are properly vented to an outs
22. of four amperage ranges with generous overlap for Stick TIG welding or one Wire Feed welding range Range Setting Current Range 80 Max 50 to 80 Amps 130 Max 70 to 130 Amps 180 Max 110 to 180 Amps 250 Max 160 to 250 Amps Process STICK TIG constant current 4 range settings WIRE FEED constant voltage 2 range setting A CAUTION Never change the RANGE Switch setting while welding This will damage the switch CONTROL DIAL 14 to 22V 18 to 25V Up to 250 Amps Provides a fine welding current adjustment within the Range Switch settings in the STICK mode and weld ing voltage control with the Range switch set in the wire feed mode POLARITY SWITCH Provides three selectable welding polarities AC DC amp DC CAUTION Never change the Polarity switch setting while welding This will damage the switch OPERATION 6 PIN CONNECTOR For attaching optional remote control equipment LOCAL REMOTE CONTROL SWITCH See Accessory Section For numbers The toggle switch on the control panel labeled LOCAL and REMOTE provides the option of con trolling the welding output at the control panel or remotely Remote connections are made at the 6 pin connector For control at the control panel set the switch in the LOCAL position For remote control set the switch in the REMOTE position RANGER GXT APPROXIMATE FUEL CONSUMPTION AC CC Weld Output 250 Amps 9 25
23. ret leur place V V for selecting a QUALITY product by Lincoln Electric We want you Thank You io take pride in operating this Lincoln Electric Company product eee 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 Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please comp
24. when they are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations the K1898 1 spark arrester must be installed and properly maintained CAUTION An incorrect arrester may lead to damage to the engine or adversely affect performance TOWING The recommended trailer for use with this equipment for road in plant and yard towing by a vehiclelt is Lincoln s K957 1 If the user adapts a non Lincoln trailer he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework RANGER GXT LINCOLN 8 3 3 Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself while being operated or serviced 4 Typical conditions of use i e travel speed rough ness of surface on which the trailer will be operated environmental conditions 5 Conformance with federal state and local laws 1 1 Consult applicable federal state and local laws regarding specific
25. 42 amps of 240 volt power to a two wire circuit up to 42 amps of 120 volts power from each side of a three wire cir cuit up to 84 amps total Do not connect the 120 volt circuits in parallel Current sensing for the automatic idle feature is only in one leg of the three wire circuit as shown in the following column GND 7 Le i i 120V 240 V 120 V Y Current Sensing for Automatic Idle Receptacle viewed from front of Machine 120 V DUPLEX RECEPTACLES The 120V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current load through the associated receptacle MOTOR STARTING Most 1 5 hp AC single phase motors can be started if there is no load on the motor or other load connected to the machine since the full load current rating of a 1 5 hp motor is approximately 20 amperes 10 amperes for 240 volt motors The motor may be run at full load when plugged into only one side of the duplex receptacle Larger motors through 2 hp can be run provided the receptacle rating as previously stated is not exceeded This may necessitate 240V operation only RANGER GXT Extension Cord Length Recommendations Use the shortest length extension cord possible sized per the following table Current Voltage
26. CAL DIMENSIONS WEIGHT 602 Ibs 273kg 1073 mm 1 Output rating in watts is equivalent to volt amperes at unity factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced Top of enclosure add 6 00 152mm for exhaust RANGER GXT LINCOLN 8 2 INSTALLATION A 2 SAFETY PRECAUTIONS A 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 e 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 E Ko vent exhaust outside MOVING PARTS can injure Do not operate with doors open guards off MTM Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual MACHINE GROUNDING Because this portable engine driven welder or genera tor creates it s own power it is not necessary to con nect it s frame to an earth ground unless the machine is connected to premises wiring your home shop etc A WARNING To prevent dangerous electric sh
27. E 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 UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o exhaust o para remover fumo da zona respirat ria eta A 59tEM d 257 Feu CORAVHELTIBELTFEL e manm e c EUR E e 2475 HAMAL 877 8 amp HHPI Ash 2414214 37 amp Q all oe dui aul e f AU jul jaa yi aach Jaial e J uu call us e Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier se
28. ESCRIPTION Ranger GXT is a twin cylinder gasoline driven multiprocess arc welder and AC power generator It is built in a heavy gauge steel case for durability on the job site WELDER CONTROLS FUNCTION AND OPERATION ENGINE SWITCH The engine switch is used to Start the Engine Select High Idle or Auto Idle while the engine is running and stop the Engine When placed in the OFF position the ignition circuit is de energized to shut down the engine When held in the START CH position the engine starter motor is energized When in HIGH IDLE position the engine will run continuously at high idle When in AUTO IDLE e position the engine will run continuously and the idler operates as follows Welding When the electrode touches the work the welding arc is initiated and the engine accelerates to full speed After welding ceases and no auxiliary power is being drawn the engine will return to low idle after approximately 10 to 14 seconds e Auxiliary Power With the engine running at low idle and auxiliary power for lights or tools is drawn approximately 100 150 watts or greater from the receptacles the engine will accelerate to high speed If no power is being drawn from the receptacles and not welding for 10 14 seconds the idler reduces the engine speed to low idle RANGER GXT LINCOLN 8 2 Gp RANGE SWITCH The Range switch is used to select one
29. Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 8 CYLINDER may explode 22238 sr 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oyl
30. The RANGER GxXT 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 cer tain that the oil filler cap is tightened securely Refer to the engine Owner s Manual for specific oil recommen dations BATTERY CONNECTIONS CAUTION Use caution as the electrolyte is a strong acid that can burn skin and damage eyes This welder is shipped with the negative battery cable disconnected Make sure that the Engine Switch is in the STOP position and attach the disconnected cable securely to the negative battery terminal before attempting to operate the machine If the battery is discharged and does not have enough power to start the engine see the battery charging instructions in the Battery section NOTE This machine is furnished with a wet charged battery if unused for several months the battery may require a booster charge Be careful to charge the bat tery with the correct polarity RANGER GXT LINCOLN 8 4 WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the studs provided These connections should be checked periodically and tightened if neces sary Loose connections will result in overheating of the output studs When welding at a considerable distance from the welder be sure you use ample size welding cables Listed below are copper cable sizes recom
31. arraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de
32. ct to new battery last CONNECTING A BATTERY CHARGER Remove bat tery from welder by disconnecting negative cable first then positive cable and battery clamp When rein stalling connect negative cable last Keep well venti lated USING A BOOSTER connect positive lead to battery first then connect negative lead to engine foot battery BATTERY ACID CAN BURN EYES AND SKIN Wear gloves and eye protection and be careful when working near battery Follow instructions printed 1 When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed Failure to observe the proper polarity could result in damage to the charging circuit The positive battery cable has a red terminal cover If the battery requires charging from an external charger disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads Failure to do so can result in damage to the internal charger components When reconnecting the cables connect the positive cable first and the negative cable last HARDWARE Both English and Metric fasteners are used in this welder ENGINE MAINTENANCE PARTS KOHLER C20S KOHLER 1205001 FRAM PH3614 Air Filter KOHLER 4708303 Element FRAM CA79 r Air Filte KOHLER 2408302 Pre Cleaner Fuel Filter KOHLER 2505002 FRAM G1 CHAMPION RC12YC 030 GAP Oil capacity increases f
33. ct 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 2 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 Exposure to EMF fields in welding may have other health effects which are now not known 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 fields from the welding circuit 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 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 1 f Do not put your hands near the engine fan Do not
34. e 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 7 WELDING SPARKS gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 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 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 though they have been cleaned For information purchase Recommended
35. e to the WORK termi nal of the welder e Position the welder Polarity switch to the desired polarity either DC or DC INSTALLATION A 5 Position the RANGE switch to the WIRE FEED CV position e Attach the single lead from the LN 25 control box to the work using the spring clip on the end of the lead it carries no welding current Place the engine switch in the AUTO IDLE posi tion e Adjust wire feed speed at the LN 25 and adjust the welding voltage with the output CONTROL at the welder NOTE The welding electrode is energized at all times unless an LN 25 with built in contactor is used If the output CONTROL is set below 3 the LN 25 contactor may not pull in CONNECTION OF K930 2 TIG MODULE TO THE RANGER GXT The TIG Module is an accessory that provides high frequency and shielding gas control for AC and DC GTAW TIG welding See 528 supplied with the TIG Module for installation instructions Note The TIG Module does not require the use of a high frequency bypass capacitor However if the RANGER GxXT is used with any other high frequency equipment the bypass capacitor must be installed order kit T12246 INSTRUCTIONS ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the roof and case sides in place as this provides maximum protection from moving parts and assures proper cooling air flow Read and understand all Safety Precautions before
36. es A 5 Te lu EE 5 Connection of Wire Feeders is A 5 Connection OF H De EE 5 Additional Safety Precautions Welding Operation Output A 5 Auxiliary Power Receptacles and Plugs m ee A 6 Motor Starting and Extension Cord Length Table A 6 Electrical Device Used with the Ranger 10 000 A 7 Auxiliary Power While Welding Standby Power Connections A 8 e nere X ne A 9 ecu T Safety Precautions General Description Welder Controls Function and Operation B 1 Polarity Range and Control Switch B 2 Start in Shutdown Instructions B 3 Starting N Engille uocis er ro etate B 3 ses esse dtes ttem ne B 3 Stopping the m B 3 Break In Period ee ecu elus eege B 3 Welding PROCESS RELIER B 4 Stick Constant Current Weldmg nnne B 4 TIG Constant Current Welding ss B 4 Wire Feed Welding Processes Constant B 4 AC GOUGNO WE B 4 Summary of Welding Processes B 5 1 5 m Section C Optional 1 Recommended Equipment 2
37. h von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra eoo SS MARHE FRANEACRHEUCE ATUBSHELTFEL e ER DEMBEBER amp ORAS RMI HR e 3544 gHEg He 8 AU PHA e 2749 Su ASAI OMAR Yt gw Gall oye daa dea d Ai AA Gadi JS aua ile woe Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos e KAPTU SODMTOBEEER EVA fbi I els Hc AIX uie Jus ALIM Aal e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo ERU B1SICRBRELUCF EU ARAOBFHRBAR ei 712 Sol Soares y due de Lily us cl di en READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO 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 QU
38. ication STICK CONSTANT CURRENT WELDING Connect welding cables to the TO WORK and ELECTRODE studs Start the engine Set the Polarity switch to the desired polarity The RANGE switch markings indicate the maximum current for that range as well as the typical electrode size for that range The OUTPUT Control provides fine adjust ment of the welding current within the select range For maximum output within a selected range set the OUTPUT Control at 10 For minimum output within a selected range set the OUTPUT Control at 5 OUT Control settings below 5 may reduce arc stabili ty For best overall welding performance set the RANGE Switch to the lowest setting and the OUT PUT Control near the maximum to achieve the desired welding current RANGE SETTING TYPICAL CURRENT RANGE ELECTRODE SIZE 80 MAX 3 32 50 TO 80 AMPS 130 MAX 1 8 70 TO 130 AMPS 180 MAX The RANGER GXT can be used with a broad range of AC and DC stick electrodes See Welding Tips 1 included with the RANGER GXT for electrodes within the rating of this unit and recommended welding cur rents of each 110 TO 180 AMPS 250 MAX 160 TO 250 AMPS TIG CONSTANT CURRENT WELDING The Ranger GXT can be used in a wide variety of AC and DC Tungsten Inert Gas TIG welding applications for AC TIG Welding up to 200 amps and DC TIG welding up to 250 amps The K930 TIG Module installed on a Ranger GXT provides high frequenc
39. ide area STACKING RANGER GXT machines cannot be stacked CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS A WARNING Shut off welder before making any electrical connections WIRE FEED CONSTANT VOLTAGE CONNECTION OF LN 15 ACROSS THE ARC WIRE FEEDER The LN 15 has an internal contactor and the electrode is not energized until the gun trigger is closed When the gun trigger is closed the wire will begin to feed and the welding process is started Shut the welder off Connect the electrode cable from the LN 25 to the ELECTRODE terminal of the welder Connect the work cable to the TO WORK terminal of the welder Set the Polarity switch to the desired polarity either DC or DC Attach the single lead from the front of the LN 15 to work using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current Set the RANGE switch to the WIRE FEED CV position Place the Engine switch in the High Idle position Adjust the wire feed speed at the LN 15 and adjust the welding voltage with the output CONTROL at the welder Output CONTROL must set above 3 Note LN 15 Control Cable model will not work with the RANGER GXT CONNECTION OF THE LN 25 TO THE RANGER GXT e Shut the welder off e Connect the electrode cable from the LN 25 to the ELECTRODE terminal of the welder Connect the work cabl
40. inders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and publication 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY PR CAUTIONS DE S RET 6 Eloigner les mat riaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui p
41. ines The Above For Gasoline 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 amp Cutting ANSI Standard 249 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 mm MAGNETIC FIELDS may 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 refueling to prevent spilled fuel from vaporiz ing on conta
42. inside of TIG Module K963 2 Hand Amptrol K870 FootAmptrol REMOTE OUTPUT CONTROL See Operations Section for reference The Ranger GXT is equipped with a 6 pin connector The 6 pin connector is for connecting the K857 or K857 1 Remote Control optional or for TIG welding the K870 Foot Amptrol or the K963 2 Hand Amptrol When remote con trol is used set the LOCAL REMOTE switch in the REMOTE position Plasma K1580 1 Pro Cut 55 Requires Full KVA Adapter K1816 1 RANGER GXT LINCOLN 8 D 1 MAINTENANCE 1 SAFETY PRECAUTIONS WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the machine In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the mainte nance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill K Do not touch electrically live parts or electrode with skin or wet clothing e 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 X MOVING PARTS injure Do not
43. l contactor for across the arc operation no control cable Provides cold electrode until gun trigger is pressed Includes gas solenoid Magnum Gun and Magnum Gun Connector Kit are required for gas shielded welding Innershield Gun is required for gasless welding K126 2 Magnum 350 Innershield Gun K1802 1 Magnum 300 MIG Gun for LN 25 K470 2 Magnum 300 MIG Gun for LN 15 K466 10 Connector Kit for LN 15 K470 2 K1500 1 Gun Receiver Bushing for LN 15 amp K126 2 K1870 1 LN 15 Across the Arc Model TIG Magnum TIG Torch K1783 9 TIG Torch Magnum Parts Kit and Argon Gas K930 2 TIG Module Provides high frequency and shield ing gas control for AC and DC GTAW TIG welding applica tions Its compact case is designed foe easy carrying com plete with a handle High frequency bypass is built in Requires K938 1 Contactor Kit K936 3 Control Cable and K814 Arc Start Switch K938 1 Contactor Kit For use with TIG Module Provides a cold electrode until the triggering device Arc Start S witch is pressed K936 3 Control Cable Connects TIG Module to RANGER GXT ACCESSORIES 2 Optional TIG Equipment K939 1 Docking Kit For Mounting the K930 2 TIG Module on top of the RANGER K937 45 Control Cable Extension Allows TIG Module to be operated at distances up to 200ft from the power source Available in 45ft 13 7m K844 1 Water Valve For use with water cooled TIG torch Installs
44. lete the form and submit your registration 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 loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE 5 Iu aclEupnr m Section A TECHNICAL SPECICATION mem A 1 Safety Precautions alas Een tenia aid A 2 Machine ue WE 2 Spark Arrester 2 Towing Vehicle 2 2 Pre Operation Engine Service sin 3 3 3 Welding Cable Connections ss Angle of Operation A 4 Lifting Additional Safety Precautions A 4 High Altitude Operation nnne nnne nnne nent 4 Murftler Outlet PIPE EE A 4 Location and oneri eor reme i iad ie e
45. mended for the rated current and duty cycle Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES 250 Amps 100 Duty Cycle 0 100 Ft 0 31m 100 150 Ft 31 46m 150 200 Ft 46 61m 1 0 AWG ANGLE OF OPERATION Internal combustion engines are designed to run in a level condition which is where the optimum perfor mance is achieved The maximum angle of operation for the engine is 15 degrees from horizontal in any direction If the engine is to be operated at an angle provisions must be made for checking and maintain ing the oil at the normal FULL oil capacity in the crankcase in a level condition When operating at an angle the effective fuel capacity will be slightly less than the specified 12 Gal 45 L LIFTING The RANGER weighs approximately 685lbs 411kg with a full tank of gasoline A lift bail is mounted to the machine and should always be used when lifting the machine INSTALLATION ADDITIONAL SAFETY PRECAUTIONS WARNING Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trail er or gas cylinder Do not lift machine if lift bail is damaged Do
46. nderstand 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 RANGER GXT LINCOLN 8 2 TROUBLESHOOTING 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION No welder output power or Open in miscellaneous leads AuxiliaryP ower Open lead in flashing or field circuit Faulty rotor Faulty otentiometer R 1 Faulty stator Field winding Faulty Field rectifier On P CB If all recommended possible areas of Faulty P C Board misadjustment have been checked and the problem persists Contact Idler switch on High Idle your local Lincoln Authorized Engine will not idle down to low Field Service Facility speed Insufficient voltage present between terminals 213 and Voltage should be 12V DC External load on welder or auxiliary power Faulty wiring in solenoid circuit Faulty idler solenoid Faulty P C Board Poor work lead connection to Engine will not go to high idle when work attempting to weld No voltage signal from the current sensor No open circuit voltage on output studs Faulty P C Board Printed Circuit Board P CB CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your
47. nduced failures Capacitive Inductive Computers high resolution TV sets complicated electrical equipment An inductive type line condition er along with transient and surge protection is required and liabilities still exist DO NOT USE THESE DEVICES WITH A RANGER GXT The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect ed to the RANGER GXT RANGER GXT LINCOLN 8 INSTALLATION A 8 AUXILIARY POWER WHILE WELDING Simultaneous welding and power loads are permitted by following Table The permissible currents shown assume that current is being drawn from either the 120V or 240V supply not both at the same time Also the Output Control is set at 10 for maximum auxiliary power TABLE SIMULTANEOUS WELDING AND POWER Output Selector Permissible Power Permissible Auxiliary Setting Watts Unity Power Current in Amperes Factor 120V or 240V RH Feed Setting None No Welding 10 000 Each duplex receptacle is limited to 20 amps Not to exceed 50A per 120VAC branch circuit when splitting the 240 VAC output STANDBY POWER CONNECTIONS The RANGER GXT is suitable for temporary standby or emergency power using the engine manufacturer s recommended maintenance schedule The RANGER GXT can be permanently installed as a standby power unit for 240V 3 wire single phase 42 ampere service A WARNING Connections mus
48. ock other equip ment to which this engine driven welder supplies power must be grounded to the frame of the welder using a grounded type plug or be double insulated Do not ground the machine to a pipe that carries explosive or combustible material When this welder is mounted on a truck or trailer it s frame must be electrically bonded to the metal frame of the vehicle Use a 8 or larger copper wire connect ed between the machine grounding stud and the frame of the vehicle Where this engine driven welder is connected to premises wiring such as that in your home or shop it s frame must be connected to the system earth ground See further connection instructions in the section enti tled Standby Power Connections as well as the arti cle on grounding in the latest National Electrical Code and the local code In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulat ed joints or to the metal framework of a building which has been effectively grounded The National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol is provided on the front of the welder SPARK ARRESTER Some federal state or local laws may require that gasoline engines be equipped with exhaust spark arresters
49. oil and oil filter are not changed according to the manufacturer s recommendation ENGINE OIL CHANGE ES Drain the oil while the engine is warm to assure rapid and complete draining e Remove the oil filler cap and dipstick Remove the yellow cap from the oil drain valve and attach the flexible drain tube supplied with the machine Push in and twist the drain valve counterclockwise Pull the valve out and drain the oil into a suitable contain er Close the drain valve by pushing in and twisting clockwise Replace the yellow cap Refill to the upper limit mark on the dipstick with the recommended oil Tighten the oil filler cap securely ENGINE OIL REFILL CAPACITIES Without oil filter replacement 1 7 US qt 1 4 Imp qt 1 6 liter Kohler With oil filter replacement e 2 0 US qt 1 7 Imp qt 1 9 liter Kohler RANGER GXT LINCOLN 8 D 2 Use 4 stroke motor oil that meets or exceeds the requirements for API service classification SG or SH Always check the API SERVICE label on the oil con tainer to be sure it includes the letters SG or SH SAE 10W 30 is recommended for general all tempera ture use 5 F to 104 F 20 C to 40 C See Engine Owner s Manual for more specific informa tion on oil viscosity recommendations Wash your hands with soap and water after handling used oil Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take itin a sealed containe
50. operate with doors open 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 Read the Safety Precautions in the front of this manual and the engine instruction manual before working on this machine Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair cloth ing and tools away from gears fans and all other moving parts when starting operating or repairing the equipment Routine Maintenance e Atthe end of each day s use refill the fuel tank to minimize moisture condensation in the tank Running out of fuel tends to draw dirt into the fuel system Also check the crankcase oil level and add oil if indicated A CAUTION Make certain that the oil filler cap is securely tight ened after checking or adding oil If the cap is not tight oil consumption can increase significantly which may be evidenced by white smoke coming from the exhaust OIL Maintenance schedule for changing the oil and Kohler CH205 oil filter after break in Oil Filter 200 Hrs The above schedule is for normal operating condi tions More frequent oil changes are required with dusty high temperature and other severe operating conditions Refer to the maintenance section of the Engine Owner s Manual for more information NOTE Engine life will be reduced if the
51. operating this machine Always follow these and any other safety procedures included in this manual and in the Engine Owner s Manual WELDER OPERATION WELDER OUTPUT Maximum Open Circuit Voltage at 3700 RPM is 80 Volts RMS Duty Cycle is the percentage of time the load is being applied in a 10 minute period For example a 60 duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minute period Duty Cycle for the RANGER GXT is 100 RANGER GXT Constant Current 250 Amps 25 Volts 250 Amps DC 25 Volts Constant Voltage 250 Amps DC 25 Volts RANGER GXT LINCOLN 8 6 INSTALLATION A 6 AUXILIARY POWER The RANGER GXT can provide up to 10 000 watts of 120 240 volts AC single phase 60Hz power for con tinuous use and up to 11 000 watts of 120 240 volts AC single phase 60Hz power peak use The front of the machine includes three receptacles for connecting the AC power plugs one 50 amp 120 240 volt NEMA 14 50R receptacle and two 20 amp 120 volt NEMA 5 20R receptacles Output voltage is within 10 at all loads up to rated capacity A CAUTION Do not connect any plugs that connect to the power receptacles in parallel Start the engine and set the IDLER control switch to the desired operating mode Set the CONTROL to 10 Voltage is now correct at the receptacles for auxil iary power 120 240 VOLT DUAL VOLTAGE RECEPTACLE The 120 240 volt receptacle can supply up to
52. orkpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4 b Use suitable clothing made from durable flame resistant material to protec
53. r to your local service station or recycling center for reclamation Do not throw it in the trash pour it on the ground or down a drain OIL FILTER CHANGE LA Drain the engine oil Remove the oil filter and drain the oil into a suitable container Discard the used oil filter Clean the filter mounting base and coat the gasket of the new oil filter with clean engine oil Screw on the new oil filter by hand until the gasket contacts the filter mounting base then use an oil fil ter socket tool to tighten the filter an additional 1 2 to 7 8 turn Refill the crankcase with the specified amount of the recommended oil Reinstall the oil filler cap Start the engine and check for oil filter leaks Stop the engine and check the oil level If neces sary add oil to the upper limit mark on the dipstick MAINTENANCE D 2 AIR CLEANER AND OTHER MAINTENANCE Air Cleaner With normal operating conditions the maintenance schedule for cleaning and re oiling the foam pre filter is every 25 hours and replace ment of the air cleaner filter every 100 hours More frequent servicing is required with dusty operating conditions Refer to the maintenance section of the Engine Owner s Manual for more information Refer to the maintenance section of the Engine Owner s Manual for the maintenance schedule spark plug servicing cooling system servicing and fuel filter replacement
54. rom 2 0 Qts to 2 1 Qts when using this filter RANGER GXT LINCOLN 1 TROUBLESHOOTING 1 HOW USE TROUBLESHOOTING GUIDE A 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not u
55. rvicio e D branchez le courant avant l entretien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico toque as partes el tricas nuas e X7TTLZA KR UAURBUD FTF e HENKE SHA AHS Aj SUA a Jil alil e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas e ID 0 8 CHERTMRAARS MRK e do Gel tee Asal OMAR jlgall l a Ja y e el S i di Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO ES BIR Chinese LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR 185 MM BHON A OHERBEEK BA 3890 CL TRHOKRASME HTP SU ARAM MBA AU SERRA A9 BR EL SIAD HAY Sigi Af gl
56. t be made by a licensed electri cian who can determine how the 120 240V power can be adapted to the particular installation and comply with all applicable electrical codes The following information can be used as a guide by the electrician for most applications refer also to the connection diagram shown in Figure 1 Install a double pole double throw switch between the power company meter and the premises disconnect Switch rating must be the same or greater than the customer s premises disconnect and service overcurrent protection Take necessary steps to assure load is limited to the capacity of the RANGER GXT by installing a 50 amp 240V double pole circuit breaker Maximum rated load for the 240V auxiliary is 42 amperes Loading above 42 amperes will reduce output voltage below the allowable 10 of rated voltage which may damage appliances or other motor driven equipment Install a 50 amp 120 240V plug NEMA type 14 50 to the Double Pole Circuit Breaker using No 8 4 conductor cable of the desired length The 50 amp 120 240V plug is available in the optional plug kit Plug this cable into the 50 amp 120 240V receptacle on the RANGER GXT case front RANGER GXT LINCOLN 8 9 INSTALLATION A 9 Figure 1 CONNECTION OF RANGER GXT TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR 240 Volt POWER 120 VOLT 2 60 Hz 3 Wire COMPANY Service METER NEUTRAL BUS LOAD DOUBLE POLE
57. t your skin and that of your helpers from the arc rays 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 2 FUMES AND GASES can be dangerous 5 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 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 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 saf
58. y and shielding gas control for AC and DC GTAW TIG welding processes The TIG Module allows full range out put control When using the Ranger GXT for AC TIG welding of aluminum the following settings and electrodes are recommended For AC TIG Welding the maximum TIG Welding out SETTINGS FOR PURE TUNGSTEN APPROXIMATE CURRENT RANGE 1 8 80 or 130 100 300 Amps 3 32 45 140 Amps 1 16 45 100 Amps TUNGSTEN DIAMETER in RANGE SWITCH SETTINGS OPERATION TUNGSTEN DIAMETER in RANGE SWITCH SETTINGS APPROXIMATE CURRENT RANGE 80 1 8 80 130 or 180 225 Amps 3 32 80 or 130 50 180 Amps 1 16 80 45 120 Amps put currents on each range setting will be approxi mately 50 higher than those marked on the name plate This is due to the special nature of the AC TIG welding arc Do not AC TIG weld on the 250 Amp set ting The output may exceed the rating of the Ranger GXT WIRE FEED WELDING PROCESSES CONSTANT VOLTAGE The Innershield electrode recommended for use with the RANGER GXT is NR 211 MP The electrode sizes and welding ranges that can be used with the RANGER GXT are shown in the following table Diameter Wire Speed Approximate in Range In Min Current Range 80 110 75A to 120A 70 130 120A to 170A 40 90 125A to 210A 50 75 180A to 235A The RANGER GXT is recommended for limited welding GMAW gas metal arc welding The recom mended electrodes are 030
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