Lincoln Electric RANGER GXT IM856 manual

RANGER ™ GX T OPERA TOR’S MANUAL For Machines with Code Number 11154 IM856 May, 2005 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 E[...]

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. ________________________________________________[...]

ii SAFETY ii ARC RA YS 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[...]

FOR ELECTRICALL Y 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 C[...]

Mar. ‘93 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 contre la secousse électrique: a. Les[...]

v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications .......................................................................................................A-1 Safety Precautions .............................[...]

A-1 INST ALLA TION RANGER GXT A-1 TECHNICAL SPECIFICA TIONS - Ranger GXT (K2382-1 ) INPUT - GASOLINE ENGINE RA TED OUTPUT @ 104°F (40°C)- WELDER HEIGHT WIDTH DEPTH WEIGHT 30 in.** 21.5 in. 42.25 in. 762 mm 546 mm 1073 mm RA TED OUTPUT @ 104°F (40°C)- GENERA TOR Welding Output AC Constant Current 250A / 25V / 100% DC Constant Current 250A / 25V [...]

A-2 INST ALLA TION RANGER GXT A-2 SAFETY PRECAUTIONS 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.). To prevent dangerous electric shock, other equip- men[...]

FUEL Fill the fuel tank with clean, fresh, lead-free gasoline. Observe fuel gauge while filling to prevent overfilling. OIL The RANGER GXT 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 oi[...]

A-4 INST ALLA TION RANGER GXT A-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 yo[...]

A-5 INST ALLA TION RANGER GXT A-5 LOCA TION / VENTILA TION 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 outside ar[...]

A-6 INST ALLA TION RANGER GXT A-6 120 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 STARTI[...]

A-7 INST ALLA TION RANGER GXT A-7 TABLE lll ELECTRICAL DEVICE USE WITH THE RANGER GXT. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker. Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage appliances with electrical control.[...]

A-8 INST ALLA TION RANGER GXT A-8 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. (Connections must be made by a li[...]

240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS. 240 VOLT GROUNDED CONDUCTOR 50 AMP 240 VOLT DOUBLE POLE CIRCUIT BREAKER DOUBLE P[...]

WELDER CONTROLS - FUNCTION AND OPERA TION 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 ” position, the engine starter moto[...]

“ RANGE ” SWITCH The “ Range ” switch is used to select one of four amperage ranges with generous overlap for Stick/TIG welding, or one Wire Feed welding range. Never change the “ RANGE ” Switch setting while welding. This will damage the switch. ------------------------------------------------------------------------ “ CONTROL ” DI[...]

B-3 OPERA TION B-3 ST ARTING/SHUTDOWN INSTRUCTIONS STARTING THE ENGINE 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 [...]

B-4 OPERA TION B-4 WELDING PROCESS For any electrodes the procedures should be kept within the rating of the machine. For electrode infor- mation see the appropriate Lincoln publication. STICK (CONSTANT CURRENT) WELDING Connect welding cables to the "TO WORK ” and "ELECTRODE ” studs. Start the engine. Set the "Polarity ” switch[...]

B-5 OPERA TION B-5 RANGER GXT SUMMARY OF WELDING PROCESSES CONTROL ELECTRODE CABLE IDLE WHEN NOT TO START PROCESS USED MODE WELDING WELDING STICK No AUTO Hot Touch electrode to work. Welding starts immediately and engine goes to high idle. WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger, LN-25 INTERNAL CONTACTOR contactor closes. Welding start[...]

C-1 ACCESSORIES C-1 RANGER GXT OPTIONAL EQUIPMENT (Field Installed) 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 K957-1 Trailer K958-1 Ball Hitch K958-2 Lunet[...]

C-2 ACCESSORIES C-2 RANGER GXT RECOMMENDED EQUIPMENT STICK K704 Accessory Kit which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield WIRE FEED K449 LN-25 - Includes internal contactor for across the arc operation (no control cable). Provides “ cold ” electrode until gun trigger is pressed. Includes gas soleno[...]

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 [...]

D-2 MAINTENANCE 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 f[...]

D-3 MAINTENANCE D-3 ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS 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. ---[...]

E-1 TROUBLESHOOTING E-1 RANGER GXT 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 Guide is provided to help you locate and repair possi[...]

E-2 TROUBLESHOOTING E-2 RANGER GXT 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 troubleshooting assistance before you proceed. CAUTION PROBLEMS (SY[...]

E-3 TROUBLESHOOTING E-3 RANGER GXT 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 troubleshooting assistance before you proceed. CAUTION PROBLEMS (SY[...]

F-1 DIAGRAMS F-1 RANGER GXT NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.[...]

F-2 DIAGRAMS F-2 RANGER GXT RANGER GXT / L N-25 OR LN- 15 ACROSS THE ARC CONNECTI ON DI AGRAM TO WORK ELECTROD E TO W ORK LN-25 OR LN-15 WI RE FEEDE R ELECT RODE CABL E W ORK CLIP LE AD N.A. WELDING CABLE MU ST BE SIZ ED FOR CURR ENT AND DUTY CYCL E OF APPLI CATION. N.B. USE POL ARITY SW ITCH TO SE T FOR DESI RED ELECT RODE POL ARITY. POSITIO N THE[...]

F-3 DIAGRAMS F-3 RANGER GXT M20512 A.01. 41.2 0 17.5 0 19.5 0 42.1 0 20.8 0 21.0 0 14.7 5 33.6 2 36.2 4 TRUC K/U ND ERC ARR IAG E MOU NTING HOLE S 24.8 6 2.6 7.22 10.2 8 10.7 8 29.8 8 CE NTER OF GR AVITY WITH OIL IN E NGIN E A ND EM PTY FUEL TA NK.[...]

NOTES RANGER GXT[...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE PARA E[...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]

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